Mitsubishi Electric Automation Inc.

Technical Solution Reference Guide

An Application Tech Note for

Rotary Knife

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Table of Contents

1. Overview ................................................................................................3
2. Application Example ..............................................................................3
3. Product Solutions...................................................................................4
4. Mechanical Information.......................................................................5
4.1 Mechanical settings for slave (SERVO) axis:.................................................... 5
4.2 Mechanical settings for master (ENCODER) axis:............................................ 5
5. Hardware/Software Configuration..........................................................6
5.1 System Structure .............................................................................................. 6
5.2 Servo Data ........................................................................................................ 7
5.3 Mechanical Editor ............................................................................................. 7
5.3.1 Overview.................................................................................................... 7
5.3.2 Drive module (external encoder)................................................................ 8
5.3.3 Spindle Gear.............................................................................................. 8
5.3.4 Transmission Module (Clutch) ................................................................... 8
5.3.5 Output Module (CAM) ................................................................................ 9
5.3.6 Virtual Auxiliary Servomotor..................................................................... 10
5.4 CAM data ........................................................................................................ 10
6. Variables Used.....................................................................................11
7. SFC Program Details ...........................................................................12
7.1 Overview ......................................................................................................... 12
7.2 Registration Parameters ................................................................................. 12
7.2.1 Registration codes ................................................................................... 12
7.2.2 Mark detection function settings .............................................................. 12
7.3 Gear Ratio....................................................................................................... 13
7.4 Belt Speed ...................................................................................................... 13
7.5 Zero Return..................................................................................................... 14
7.6 Control SFC .................................................................................................... 15
7.7 Rotary (No registration)................................................................................... 16
7.7.1 Establishing variable settings................................................................... 16
7.7.2 Calculating and performing compensation without registration................ 17
7.7.3 Monitoring for the next compensation ...................................................... 19
7.8 Rotary (Registration)....................................................................................... 20
7.8.1 Establishing variable settings................................................................... 20
7.8.2 Calculating and performing compensation with registration..................... 22
7.9 Error Check..................................................................................................... 25
7.10 Stop Compensation ........................................................................................ 25
8. GOT Screen Information......................................................................26

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Application Tech Note for
Rotary Knife
1. Overview
Rotary knife applications involve an axis of servo motion to continually or intermittently
perform a cut, labeling procedure, or stamping process where the servo axis aligns itself
to move at the same speed as a feed axis that drives a material to be
cut/stamped/labeled. The servo axis (or slave axis) moves according to the feedback
pulses from an encoder connected to the feed motor axis (master axis) so that it can
coordinate its movement with speed changes. In this type of application, the cut length,
label or stamp location may change and it is possible that the feed material may slip,
stretch, or bind up, causing the operation’s accuracy to change. The addition of a mark
sensor before the servo axis can help to compensate for these fluctuations.

2. Application Example
In Figure 1 below, a rotary knife example for a cutting application is shown. The servo
axis (slave axis) is positioned to perform a cut at the same speed as the conveyor
(master) through the use of an electronic gear ratio. A feed cam profile is defined so
that the rotary knife axis cuts the material during the angle defined as θ0, also known as
the cut area. A sensor is positioned before the cutter to detect registration marks and
provide compensation readjustment when necessary. Some of the variables that can
be defined by the user for a rotary knife application are shown in the drawing.

Figure 1: Rotary knife application diagram

L0 Product length (mm or inch)

Pm Rotary cutter resolution (PLS/rev)
Dm Rotary cutter diameter (mm or inch)
Pe Encoder resolution (PLS/rev)
De Encoder diameter (mm or inch)
θ0 Cut area (degree)

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3. Product Solutions
The MR-MQ100 provides a simple solution for a single axis rotary knife application.
With high speed registration capability, camming, and electronic pulse compensation
functionality during non-cut regions, the MR-MQ100 can accurately respond to input
pulses from an external encoder. Along with the MR-MQ100 1.5 axis motion controller,
all of Mitsubishi Electric’s Q motion controllers can be configured to control rotary knife
applications.

Figure 2: Product configuration with Mitsubishi Electric products

MR-J3-B Induction
motor
MR-MQ100

FX3U
FX3U- FX3U-
485ADP 232ADP

External
encoder

GT15 HF-JP

E700

In a typical rotary knife application, the servo motor continually moves. If the distance
between cuts is small (smaller than the circumference of the cutter), the motor speed
during the non-cut compensation region (360º - θ0) is faster than the conveyor speed.
This is shown below with a 45º cut angle. A servo gearbox combined with a short
product length and fast line speed requires faster movement from the servo. In this
situation, it’s common to configure the cutter axis with 2 to 4 knives instead of 1.

Figure 3: Rotary knife operation with Short product length

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If the product length is large, the compensation speed decreases. For product lengths
that are longer than the circumference of the cutter, the cutter speed is slower than the
conveyor as shown in Figure 4 below.

Figure 4: Rotary knife operation with Long product length

4. Mechanical Information
For setting the mechanical information in the rotary knife motion application, it’s
necessary to configure settings for the servo motor’s pulse resolution and travel amount
per rotation. Other variables such as the speeds and distances are configured
separately in the SFC program. The settings below are used as an example.

4.1 Mechanical settings for slave (SERVO) axis:

Cutter diameter, Dm: 1.96850 inches
Cutter circumference: Dm * π = 6.18423 inches/rev
Servo resolution, Pm: 262,144 pulses/rev
Servo Travel/Rev: (6.18423 inches/rev)/(Gear Ratio)

Note: The diameter, Dm, must be defined precisely to match the speed of the conveyor
and also includes the length of the cutter. Setting this value requires some trial and
error for the machine to work correctly.

4.2 Mechanical settings for master (ENCODER) axis:

Encoder diameter, De: 2.00510 inches
Wheel circumference: De * π = 6.29921 inches/rev
Encoder resolution, Pe: 2000 * 4 = 8000 pulses/rev
Note: Mitsubishi Electric’s motion controllers count
all four edges of an external encoder’s pulses.

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5. Hardware/Software Configuration
Hardware:
1* MR-MQ100
1* MR-J3-( )B with MR-J3 motor
1* External incremental encoder (Open collector/Differential line driver)
1* External sensor 24V for mark detection

Software:
MT Developer2 for MR-MQ100 version 1.04E or higher
MR Configurator SETUP221E version C1 or higher

5.1 System Structure

Figure 5: System structure diagram

An external encoder is
set for the servo to
follow the line speed.

One MR-J3-( )B can be

connected. The axis no.
rotary switch on the
servo must be set to 0.

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5.2 Servo Data
Fixed parameters along with information for defining the home position return data must
be established within the ‘Servo data’ section of MT Developer2 as shown in Figure 6.

Figure 6: Servo data settings

These settings define the servo

settings for the program.

*Note: The [Travel Value/Rev.]

setting must account for the gear
box setting! Here it is 1:1.

The Home Position Return

method can be set according to
the type needed.

*Note: Homing is machine

specific and is not covered in
detail in this document.

5.3 Mechanical Editor

5.3.1 Overview
One of the most beneficial tools for configuring a system with the MR-MQ100 is the
mechanical system editor as shown below. This is also referred to as the “virtual
mode.” Each component is set up individually to use specific variables.

Figure 7: Mechanical system editor

The spindle gear must be
Drive Module:
set corresponding to the
Synchronous encoder
encoder resolution and
connected to the line shaft.
motor movement.

Transmission Module:
A direct ON/OFF mode
clutch is used. When
engaging at high speeds, a
smoothing clutch is
An auxiliary virtual recommended.
servomotor is used for the
compensation travel in
non-cut regions. Output Module:
CAM output module is
directly linked to the servo.

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5.3.2 Drive module (external encoder)
The drive module settings are very straight forward as shown in Figure 8.

Figure 8: Drive module settings

5.3.3 Spindle Gear

Since the rotary knife (servo) axis matches the speed of the material (external encoder)
while cutting, it’s necessary to establish an electronic gear ratio that allows the knife to
follow the encoder 1-to-1 while the clutch is directly engaged. This ratio is defined in the
mechanical editor directly or indirectly through the “Spindle Gear” mechanical parameter
setting. Figure 9 shows the spindle gear ratio being set indirectly through devices
#6000 and #6002.

Figure 9: Spindle gear settings

The encoder (drive module) in the mechanical editor transfers pulses through the
spindle gear to the servo motor (output module).

Servo( PLS / inch)

EncoderPLS   ServoPLS
Encoder ( PLS / inch)
Electronic #6000
Gear Ratio = #6002

The electronic gear ratio is defined as a ratio of the servo’s pulse count per inch divided
by the external encoder’s pulse count per inch.
The values for the motion registers #6000 and #6002 must be 16-bit unsigned values,
which means that each value cannot exceed 65535.

From Sections 4.1 and 4.2, the gear ratio is calculated as follows:

Pm Pe
#6000 L  #6002 L 
  Dm   De

For more information on the gear ratio setting, refer to Chapter 7 - SFC Program Details.
5.3.4 Transmission Module (Clutch)

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The transmission module is defined as a direct ON/OFF mode clutch. When the clutch
is enabled and the auxiliary virtual servomotor isn’t running, the servo follows the
external encoder 1-to-1 for a direct follow. The clutch is turned ON with bit M100 and
the clutch status bit is set to M2160 as shown below.

Figure 10: Clutch settings

The clutch remains on
(closed) during cut and
non-cut regions.

5.3.5 Output Module (CAM)

The output module for this application example is represented as a CAM module as it
provides additional flexibility for more advanced configurations.

Figure 11: Cam module settings

The ‘Number of
Pulses/Rev.(PLS)’ is set to
[262144*(Motor gear box
ratio)] pulses/rev.

The ‘Stroke Setting

Device’ is defined by
#6016L and is equal to the
travel distance for one
revolution of the cutter:
618423” x 10-5 inches.

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5.3.6 Virtual Auxiliary Servomotor
The virtual auxiliary servo motor is a key component in the system setup for performing
compensation moves in non-cut regions. For more information on how the speed and
target distance are defined for this component, refer to Section 7.4, Section 7.7, and
Section 7.8.

Figure 12: Auxiliary virtual servomotor settings

The upper stroke limit and

lower stroke limit are set to
‘0’ indicating that the
auxiliary servomotor does
not have any boundaries.

5.4 CAM data

In some rotary knife applications, the cam profile data is calculated on the fly using a
sine curve and then written to the controller to perform the compensation move. This
includes additional calculations and CPU processing. To keep things simple, a constant
speed feed cam profile is used to run continuously while the clutch is closed, providing a
layer of pulses to which the auxiliary virtual servomotor can add to for performing
compensation. Settings for the cam profile are shown below:

Figure 13: CAM data settings

Start of the CAM profile. End of the CAM profile.

The profile repeats itself The profile starts over.
continuously.

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6. Variables Used
All of the variables used in the program are listed in the table below. For information on
how the variables interact with each other, please refer to the SFC program code and
the Excel file [rotary_knife_variables.xls].

Table 1: Variables used within the program

Address Description Address Description
M100 Clutch ON/OFF command #5028L Old encoder latch value (pls)
M101 Cancel compensation move #5032F Difference between “rotary cutter
circumference” and “product length” (pls)
M110 Home return SFC operation #5036F Error amount (pls)
M111 Registration SFC operation #5040L Auxiliary virtual servomotor compensation
value (pls)
M112 No Registration SFC operation #5042F Cut area (inch)
M120 Operate ‘Error Check’ SFC #5046F Compensation time (sec)
M121 Error detection bit #5050L Auxiliary virtual servomotor speed (pls/sec)
M122 Operate ‘Stop Comp’ SFC #5060F Encoder speed (pls/sec)
M140 Cut area for Knife #1 #5068L Compensation start window range
M141 Cut area for Knife #2 #5070L Compensation lower limit for Knife #1 (pls)
M142 Cut area for Knife #3 #5072L Compensation lower limit for Knife #2 (pls)
M143 Cut area for Knife #4 #5074L Compensation lower limit for Knife #3 (pls)
M130 Start compensation after Knife #1 #5076L Compensation lower limit for Knife #4 (pls)
M131 Start compensation after Knife #2 #5080L Compensation upper limit for Knife #1 (pls)
M132 Start compensation after Knife #3 #5082L Compensation upper limit for Knife #2 (pls)
M133 Start compensation after Knife #4 #5084L Compensation upper limit for Knife #3 (pls)
M2160 Clutch status #5086L Compensation upper limit for Knife #4 (pls)
D2000L Product length (inch) #5100L Encoder current value (pls)
D2002 Cut angle (deg) #5106L Modulus of actual position (inch)
D2004L Manual adjustment (inch) #5108L Nearest next home position (inch)
D2006 Number of knives #5270L Cut area lower limit for Knife #1 (pls)
D2008 Number of times entered cut area #5272L Cut area lower limit for Knife #2 (pls)
during compensation
D2010L Product count #5274L Cut area lower limit for Knife #3 (pls)
D2012L Encoder speed (pls/sec) #5276L Cut area lower limit for Knife #4 (pls)
#5000L Servo resolution (pls/rev) #5280L Cut area upper limit for Knife #1 (pls)
#5002L Cutter diameter (inch) #5282L Cut area upper limit for Knife #2 (pls)
#5004L Encoder resolution (pls/rev) #5284L Cut area upper limit for Knife #3 (pls)
#5006L Encoder diameter (inch) #5286L Cut area upper limit for Knife #4 (pls)
#5008L Cam resolution (pls/rev) #6000L Gear ratio (numerator)
#5010F Servo ratio (pls/inch) #6002L Gear ratio (denominator)
#5014F Encoder ratio (pls/inch) #6014 Cam No. setting device
#5018L Gear ratio x 100 #6016L Stroke setting device
#5020L Motor gear box ratio #6018L Lower stroke limit device
#5022L Encoder gear box ratio #6020L Main shaft side (for CAM)
#5024L Cutter circumference (inch) #6022L Auxiliary input axis side (for CAM)
#5026L Latest encoder latch value (pls)

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7. SFC Program Details
7.1 Overview
The rotary knife application uses 8 different SFC programs with separate ‘Automatic
Start’ settings as shown below.

Table 2: SFC program descriptions

SFC Automatic
No. Name Start Description
Parameter settings to define mark sensor registration for
1 Reg Param No
the encoder value with input PX0.
2 Gear Ratio No Code to define the electronic gear ratio.
Code to monitor the speed of the encoder and to write its
3 Belt Speed Yes value to a data device in order to define the compensation
speed.
4 Zero Return No Homing routine to return the servo axis to the start position.
Selection code for running various modes (Zero Return,
5 Control SFC Yes
Rotary (No Reg), and Rotary (No Reg))
6 Rotary (No Reg) No Cuts material without using registration marks.
Cuts material with registration marks, accounting for error
7 Rotary (Reg) No
between marks.
Disable servo motor on error, reset the error(s), and clear
8 Error Check Yes
all SFC programs.
Stop compensation when compensating during cut area.
9 Stop Comp Yes
Controlled during machine setup (as needed) by operator.

7.2 Registration Parameters

Registration parameters are necessary for the [Rotary (Reg)] SFC program to operate
and allow for the input PX0 to assume a 30µs mark detection time for latching the
current value of the encoder. Using registration allows for the controller to process error
between multiple cuts so the controller can correct itself automatically to cut with better
accuracy. Motion registers for registration are not listed in “Chapter 6 – Variables Used”
since they are not user variables and can be found in Chapter 13 of the MR-MQ100
User’s Manual (Details). A summary of these settings is described below. For further
information on how a registered address is used, please refer to Section 7.8 – Rotary
(Registration).

7.2.1 Registration codes

#7912L, #7914L, #7916L and #7918L must be defined with registration codes to enable
the mark detection functionality.

7.2.2 Mark detection function settings

Registers #7920 to #9215 are dedicated devices for defining which inputs to use for
registration, upper/lower limit information, latch data types, and for monitoring the status
of registration addresses. The most important settings include defining PX0 as the input
for registration and assigning the synchronous encoder pulse data as the latch data for
the input. Motion register #8898 is used for monitoring mark data while #8912L
provides information on which address is latched.

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7.3 Gear Ratio
This program is executed once and is called by the Control SFC program. The gear
ratio depends on the mechanical setup of the hardware and does not change very often.
In some situations, the user may choose to manually configure these settings with a
GOT. The block “G0” below checks to make sure the gear ratio value does not exceed
65535 as indicated in Section 5.2.3 above.

Figure 14: Gear ratio program details

7.4 Belt Speed

This SFC program is needed to define the speed of the auxiliary virtual servo motor for
the compensation move and runs continuously to update the speed of the external
encoder. The block “G10” includes a 100ms timer and D1120L tracks the position of
the encoder. The averaging time for tracking the speed may require some adjustment.
For more information on how this value is used to set the auxiliary virtual servomotor
speed, please refer to Sections 7.7 and 7.8.

Figure 15: Belt speed program details

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7.5 Zero Return
Performing a zero return (home position return) operation on a
machine depends on the actual setup of the machine regarding
the position of the home switches and the actual physical
starting point desired. For this application, the starting position
is set to the beginning of the compensation area, which is
positioned just after the cut region. The code in this SFC should
be modified by the user depending on their machine setup.

Figure 16: Zero return program details

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7.6 Control SFC
This program plays a key role in how the other SFC programs are called and runs
continuously. There are three branches in the program shown below as “G4”, “G5”, and
“G6.” The first branch, “G4” calls the [Zero Return] program when M110 turns ON. The
second branch, “G5” calls the [Rotary (Reg)] SFC program when M111 is active, and
the third branch, “G6”, calls the [Rotary (No Reg)] program when M112 is active.
The code listed above the “P5” jump loop establishes the registration parameters, sets
the gear ratio, enables the servo (sets ‘Servo ON’), and defines variables such as the
cut length, cut angle and number of knives.

Figure 17: Control SFC program details

As shown in block “F6” above, variables are assigned with default values. A GOT can
be used to change the number of knives, set the manual adjustment value, or to change
the product length.

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7.7 Rotary (No registration)
7.7.1 Establishing variable settings
Figure 18 illustrates the SFC layout for performing cuts without registration. “F70” is
used to turn on the clutch and to define the compensation comparison limit values.

Figure 18: ‘Rotary knife without registration’ program details

Block “F70” defines the CAM No. as

‘1’, turns on the clutch with M100
and switches to virtual mode with
M2043. Comparison ranges are also
established for beginning
compensation.

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7.7.2 Calculating and performing compensation without registration
The program code in Figure 19 for “F80” is crucial to understanding how the rotary knife
application operates. “F80” provides values for controlling the auxiliary virtual
servomotor with “K100.”

Figure 19: Calculating the distance and speed for the auxiliary virtual servomotor

The code above is used to define the distance and speed settings for “K100.”
With the product length and cut area known, the compensation area is determined. The
compensation time (#5046F) is then calculated as shown:

Compensation _ Area
Compensation _ Time 
Belt _ Speed

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The compensation amount (#5040L) depends on the number of knives that are being
used and is calculated as follows:

 Cutter _ Circumference 
Compensation _ Amount     Pr oduct _ Length
 Number _ Of _ Knives 

Therefore, the compensation speed (#5050L) is known:

Compensation _ Amount
Compensation _ Speed 
Compensation _ Time

The following figure shows the compensation move “K100” for the auxiliary virtual
servomotor. The distance is defined with #5040L (Compensation_Amount), and the
speed with #5050L (Compensation_Speed).

Figure 20: Compensation movement with auxiliary virtual servomotor

A manual adjustment variable and a multiplier value are also included to provide extra
flexibility. The multiplier (1.25) increases the compensation speed, which essentially
widens the cut angle, guaranteeing that the knife reaches a safe speed before the cut
takes place. When setting up the system for the first time, a few adjustments may be
necessary to establish a safe value for the multiplier. SFC#9 (Stop Comp) is used to
stop ‘K100’ from compensating within the cut region and should be used to avoid
moving the servo at non-synchronous speeds during the cut.

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7.7.3 Monitoring for the next compensation
Without registration, in order for the controller to know when to begin compensating
again, the servo’s current value is monitored. With the “Limit Output Data” setting in MT
Developer2, limits can be set to provide windows (distance ranges) to trigger
compensation moves. Figure 21 shows how these limits are set up in the program.
Figure 22 illustrates how the limits are used in “G82” to start compensation.

Figure 21: Compensation range settings

Figure 22: Compensation range comparison

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7.8 Rotary (Registration)
7.8.1 Establishing variable settings
With the registration SFC, the position of the encoder is captured with #8912L and used
to compare with the previous registration mark to obtain a difference that is then
compared with the product length ‘D2000L.’ If the registered value is smaller or larger
than the cut length, the difference is calculated so that it can be added or subtracted to
the next compensation move. This difference is called the ‘Error’ and is described in
more detail in Figure 24.

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Figure 23: ‘Rotary knife with registration’ program details

Block “F70” defines the CAM No. as

‘1’, turns on the clutch with M100
and switches to virtual mode with
M2043. Comparison ranges are also
established for beginning
compensation.

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7.8.2 Calculating and performing compensation with registration
Figure 24: Calculating the distance and speed for the auxiliary virtual servomotor

 #5032F: Difference between “Cutter circumference” and “Product length” (pls)

Ex: One blade Ex: Two blades

#5002L*π #5002L*π / 2

ENC D2000L ENC D2000L

#5032F= #5002L*π – D2000L #5032F= #5002L*π / 2 – D2000L
(Note: Units must be adjusted depending on the machine.)

 #5036F: The error amount to be compensated (pls)

“[Latest encoder latch value – Old encoder latch value]”
should be equal to the Product length. ENC
If the value is different, the error must also be compensated.
#5036F = (#5026L - #5028L) – D2000L #5026L
(Note: Units must be adjusted depending on the machine.) #5028L
D2000L

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 #5040L: Compensation value (pls)
The compensation value, #5040L, is similar to the distance described for #5040L in
Section 7.7.2 “F80”, except for the error amount (#5036F) that is included.

 #5042F: Cut area (inches)

The knife (cutter) speed and the encoder speed must be the same in the cut area.

 #5046F: Compensation time (sec)

Since the encoder speed is constant, the compensation time can be calculated with
(Product length – Cut area) / ENC speed

 #5050L: Compensation speed (pls/sec)

The compensation speed = [(Compensation value) / (Compensation time)] * 1.25
The 1.25 multiplier provides a margin of safety so that the compensation can finish
before the cut. This protects the machine in case the cut angle is incorrect.
(Note: If the motor speed exceeds the maximum speed, the multiplier value should be considered.)

#5040L and #5050L are then used to perform the virtual auxiliary servomotor
compensation move as shown in Figure 25.

Figure 25: Compensation movement with auxiliary virtual servomotor

Figure 26 explains all of the settings above in a visual format to understand how these
variables are set up relative to speed plotted over time.

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Figure 26: Compensation mechanism

D2002L [degree]
#5002L*π

#5042F = #5002L*π *(D2002L /360º)

Compensation Cut
Area Area
Mark Sensor
Compensation speed
= (Compensation value
/Compensation time) *1.25 Compensation
Value
Knife speed
= Difference
+ Error
ENC speed
+ Manual adjustment
0

Cut Compensation time Cut Area

time = (Product length Product length
- Cut Area)
/ ENC speed

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7.9 Error Check
The error check SFC runs continuously and checks for servo errors. If there is an error,
all servo operations are stopped and all SFC blocks are cleared. Figure 27 displays the
layout for this program where ‘CLR’ blocks are used to stop all of the SFC programs.

Figure 27: Error check program details

7.10 Stop Compensation

This SFC program is set up to stop the auxiliary virtual servomotor from operating
during the cut angle region with a rapid stop. It should only be used during initial setup
and is helpful in preventing knives from crashing into the conveyer belt at different
speeds. Ranges are set up with the limit output data and monitored with this SFC
program. Additional code can be added to this program to activate the “Error Check”
SFC code to stop all operations when the compensation movement enters the cut area
a certain number of times (D2008L).

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8. GOT Screen Information
GOTs provide an interface for the customer to define variables, perform home operation,
and to start the machine operation, eliminating extra effort for the programmer and the
operator. With an HMI on the machine, it is no longer necessary to manually turn bits
on/off with a personal computer connected. Additionally, monitoring becomes easier
with the built-in diagnostic screens for the motion controllers and servo amplifiers.

The following screens are examples of the data that can be changed with a GOT for
rotary knife applications. The application program data included for this program does
not require a GOT for operation. Screen project data is not included.

Figure 28: Setting of rotary knife variables

Figure 29: Monitoring screen with options for manual adjustment

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