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SAM Configuration Manual

1. 20 Producing Trate cics odi dai aee tree der Rae edt pce ovde e dee 20 Interpreting and utilizing the Trace 22 Trace Markers i cae eere e eret bentes 23 Come PEE 24 Trace Zoom Feature nb dede tee der eds 24 Test Device LARGO ee dene tee e EE ES 25 SAM Operating eene 26 Introduction 26 BIA We TU c 27 Commands Managers ined re een ERE 27 Motion Generator cete eire n cre oper een en 27 Position Controller retra eed pi re Eee rir 27 Position Measurement eseeeesessessssessse essaie nena nani aaa sana nana 28 Current Controller ea tree eee edat RET 28 Status Reglsters 2o ize d e naan 28 SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 3 SAM CONFIGURATION MANUAL TABLE OF CONTENTS Operatirig States xi ipe o RERO E NI MES 29 InitialiZatiori s ete A met em RC RIA 30 IRurieMOde Ru etae tacite te 30 SAM Position Controller Its Tuning seeen me 31 ta g PAPE E EET 31 SAM Position Controller 31 Short Descriptio s o de ce d e 31 Software Object
2. 16 List of ACC Standard Traces 20 Most interesting variables to trace it represents the pipe position of metae menn edant uM cst 22 Short listing of Controller 32 Short listing of Controller Fields Measured position and velocity values Mf POS MES and Mf VEL MES are Main Sensor fields and not Controller fields Their prefix is thus 33 Position Controller 4 8 sirener rreraren aena EEEE eee 43 SAM Default action mask valid only for System 2 0_2 53 oe PRO ER IHR 62 Brake Object parameters sssssssseeeene enne 62 Brake Object behavior 63 Resolver Feedback and Motor Windings Wiring Verification Procedure CLOS tl aed 66 POS RES Values for 67 Page 6 SAM Configuration Manual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL INTRODUCTION Introduction Scope of this Manual This SAM Configuration Manual presents procedures and guidelines for start up of a SAM Drive in a PAM and SAM environment Related Documents The PAM and SAM System User s Handboo
3. menu 2 Select from the MES menu 3 Using the Object Browser locate and select the field or parameter to insert into the control panel Press 4 In the Choose Control Type list box select a display box SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 19 SAM CONFIGURATION MANUAL SAM Toors Trace One of the most useful features of SAM Tools is its trace capability The behavior of up to up to four SAM variables as a function of time may be captured displayed printed or saved for reference purposes Trace setup information including trigger point specifications sampling rate and trace variables are defined in a Trace Command file created using SAM Tools Trace data is captured and saved in a reserved segment of SAM RAM memory then uploaded on command to the Service PC where it may be displayed or saved and displayed at a later time The trace trigger point is defined by an expression which may be a combination of numerical and logical values and operators As with most digital storage oscilloscopes the trace tool may be configured to display data before and after the trigger point The sampling rate is adjustable over a wide range of values from processor cycle rate 8 kHz to 1 one Hz ACC Standard Trace Setups The ProMotion includes a number of standard Trace command files for creating the Trace setups referenced in this manual A description of these ACC standard trace setups in found in Tab
4. the control panel Motor shaft rotates into stable e Set CurReg TETA 16384 Position in alignment with current vector at constant angle designated by CurReg TETA On the control panel refresh POS RES falls within one of the If POS RES is outside one of panel then read ranges of values listed in Table the ranges of values listed in MainSensor POS RES 15 for the motor type Table 15 by just a few degrees increase PosReg I FLOW to 2000 This provides additional current to overcome motor friction If after increasing the value of FLOW POS RES is still outside one of the ranges listed in Table 15 multiply the deviation by the number of pole pairs for the motor model see Table 15 Then if the result is close to 90 or 180 look for a wiring error in the resolver feedback interconnections A result close to 120 strongly suggests a wiring error in the motor winding interconnections Verify SAM Drive to motor interconnections or isolate the error by systematic substitution of known good feedback cable motor windings cable and motor of the same model and type Restore the SAM Drive to its normal operating configuration by removing 24 VDC power Wait a few seconds then re apply power The SAM drive restores the normal configuration saved in flash memory during initialization Table 14 Resolver Feedback and Motor Windings Wiring Verification Procedure SAM Configuration Manual Page 66 P n 9
5. 63 Brake canasta cia omiies 63 Page 4 SAM Configuration Manual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL List OF FIGURES Checking SAM to Motor Wiring eene 64 Motor and Feedback Wiring Errors sesee een 64 Checking Procedur saras reshape ainai raaa ien AEEA a eed athens th nnne nhanh 64 List of Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Multi version 1 9 SAM Tools Top Level 11 Control Panel with Component types 17 Now Dialog BOX 19 Trace Commands Dialog 21 Trace Control P n l 1 eire bt Ri ete ib e elg 22 Trace WIDdOW u obi petere Ult ient dads 23 Test Device Analog panel 25 SAM Drive Software Functions sssssssssssseeeeen 26 Position Controller Functiona
6. Channel Graphical Area Portion of the channel in which trace data is plotted The areas at the left and right extremes of each channel graph are outside the graphical area Trace Markers Two trace markers M1 amp M2 are available for making precise measurements from graphical trace data The value of each variable at it s point of intersection with the marker is displayed along with the position it time of each marker In addition the delta t and delta values for each channel are displayed on the trace SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 23 SAM CONFIGURATION MANUAL SAM Toors To position a trace marker on a displayed trace position the mouse pointer over the desired point hold down the SHIFT key then click on the left or right mouse button left button to position M1 or right button for M2 Markers are not saved when a trace file is closed Markers may be alternately hidden or shown by selecting from the VIEW menu Grid A grid may be alternately applied or removed from the graphical display area of a trace by selecting from the menu Trace Zoom Feature The zoom feature may be used to magnify a portion of a trace Two zoom modes time zoom and area zoom are available Time zoom takes a selected portion of the trace and expands it horizontally to fill the trace display area Area zoom expands the selected area of a single channel to fill the display area When a trace is e
7. essere eens heen ecient iet ee e 9 Preliminary Remark iid ELEC AM gU LER ant 9 Installing SAM TOGE a ent pete e mede nme 9 PC Hardware Platform sese saa sa sese sa sacer 9 Installation for multi version use eeeeesesesesssessesseeee nnne 9 Getting Started with SAM Tools 11 Top Level MIDdOW iih te tetto ibat t eco oer ant be aote dd 11 SAM Tools Subdirectories and File 12 Parameters doct met n ue tite NH ei wee 13 Downloading eren 13 Uploading Parameters tinte einen tens 14 Upgrading 14 Replacing a SAM QriVG 15 Control Panels eR Ret s ede 15 ONVGIVIGW eie eee eit ne totos Coen de eel eue edendo de a a cea TRY EUR 15 ACC Standard Control Panels 16 Control Panel Components and their Operation 16 Activating a Control Panel sse 18 Creating a New Control Panel sssseeee eene 18 en baee Pestis a 20 ACC Standard Trace
8. 20 TR349 t s 01 20 05 005 01 015 02 026 03 035 300 Figure 22 PID Axis Response without Feed forward Compensation Figure 23 shown the axis response to the same move following introduction of feed forward compensation in the Controller In this example the Controller is configured as a proportional plus derivative controller with the same proportional and derivative gain settings as for Figure 21 Static friction viscous friction and inertia compensation parameters which were previously zero have been adjusted to the correct values for the motor and its load Due to the auto scaling feature of the SAM Tools Trace function the position lag appears larger than previous examples but peak to peak position lag is now approximately 110 an 80 reduction and average position lag is nearly zero Speed Reference 1750 150 1250 4 1000 4 350 4 500 4 280 4 Position Lag 15 0 05 o 005 1 0 15 02 025 03 0 35 Figure 23 PD Axis Respond with Feed forward Compensation SAM Configuration Manual Page 40 P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM POSITION CONTROLLER ITS TUNING Converting SAM Controller Parameters to usual units Listed below are the SAM system specific equations and relationships corresponding to those listed in this general discussion of tuning principles M K cp paame D O
9. e g R PGain Controller fields prefix is Rf R DGain sets derivative gain of controller R_ExtTorg R IGain R Inertia R MaxPosLag sets threshold value for position lag error R MaxTorq sets upper torque limit R MaxVelLag sets threshold value for velocity lag error R PGain sets proportional gain of controller RStatFriqTorq sets static friction torque feed forward compensation value RViscFricTorq Sets viscous friction torque feed forward compensation gain Ri RegMode sets Controller working mode Table 7 Short listing of Controller Parameters Page 32 SAM Configuration Manual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM POSITION CONTROLLER ITS TUNING Rf POS REF position command from TMP Generator Rf TORQ FEEDF torque feed forward command Table 8 Short listing of Controller Fields Measured position and velocity values Mf POS MES and Mf VEL MES are Main Sensor fields and not Controller fields Their prefix is thus Mf Some Theory regarding PD Position Control Referring to the block diagram of a proportional plus derivative control system shown in Figure 12 let us first define the following terms Kp speed loop gain Kp position loop gain speed speed feedback the measured speed of the axis position position feedback the measured position of the axis speed lag difference between commanded and measured speed position lag difference between commanded and measured position posit
10. Buttons for active functions appear in high contrast colors on non active buttons are subdued Table 1 Description of Components of SAM Tools Main Window Components SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 11 SAM CONFIGURATION MANUAL SAM Toors Tool Bar When the mouse cursor is placed on an icon a brief description of the buttons is displayed in a box SAM Tools Subdirectories and File Extensions During installation SAM Tools creates a number of subdirectories at the directory specified by the user at the beginning of the installation procedure Different types of files as described in Table 2 are deposited into each of the subdirectories ACC recommends retaining this structure as well as the file extension defined for each file type because software upgrades and revisions rely on this file structure oa a SAM Drive firmware files SAM Drive bootware files SAM Drive and motor parameter files Creation files for ACC standard panels cmds ACC standard trace commands files 5 commands files up to version 1 3 support conversion utility and C example programs symbols dictionary help files temp temporary workspace for files created during SAM Tools execution Table 2 SAM Tools Subdirectory and file extension conventions We recommend that users create separate directories utilizing the same subdirectory and file extension structure for st
11. PAN If the desired control panel is listed on the SAM Tools recall list it may be accessed as follows 1 From the menu select RECALL 8 then select from the submenu 2 From the pop down list select the desired panel More than one control panel may be open at a time but only one panel may be active and only the active panel is responsive The user may change the active panel by clicking in the panel to be activated The display boxes on a panel are updated automatically when the panel is opened or activated Creating a New Control Panel Creating a new control panel is a straightforward process which requires performing the following steps 1 Determine the functions required of the panel N Open a new panel document 3 Create buttons displays and numeric entry boxes and specify their operation 4 Add any custom labeling or nomenclature desired Determine the Functions Required Panels are usually created for performing a specific task and include only those controls required for the task This approach simplifies creation and use of the panel The ProMotion Help SAM Parameters amp Fields topic provides a listing and description of all SAM Drive fields and parameters accessible by panel Page 18 SAM Configuration Manual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM Toors A Although functions to stop motion and disable a SAM Drive output may be included on a panel th
12. 5 is now displayed in the Trace Commands dialog box It defines for each channel the label and the type the address and the size of the variable to display Table 6 shows the type and the size of the most interesting variables to trace For addresses as they are related to the firmware version please use the browser for the DSP variables or refer to the ProMotion hlp help file for the i960 variable A Trace control panel see Figure 6 is also displayed In the Trace Commands dialog box press to setup the SAM Drive for capturing the trace data The message Execution Successful appearing in the Trace Commands dialog box indicates successful setup of the SAM Drive Press to close the Trace Commands dialog box In the Trace control panel press to initiate the trigger When the Trace control panel displays TRIGGERED and STOPPED the trace data gathering operation is complete On the Trace control panel press to upload the trace data to the Service PC for display The trace data is also saved to a file in the TEMP subdirectory SAM Tools assigns the name TRACExxx TRC where xxx is the next number in sequence to the trace file To initiate another trace operation utilizing the same trace setup first press E on the SAM Tools toolbar to recall the Trace control panel then press to initiate another trace operation 7 Displays velocity and position error 7 Firmwar
13. Forced Mask to initiate a STOP 0 becomes true A status condition pre defined by the application STOPO Action Mask to initiate a STOP 0 becomes true 64 Latched STOPO first StopO cause latched for diagnosis QP L lt 62 all except User Stop 0 input and Stop 0 command Fatal Error Figure 30 STOPO Activation STOPO User Mask STOPO Forced Mask User StopO StopO Input Cmd 64 64 9 Status S z ABCD 64 f 64 Reset StopO actions SAS018 D CDR Page 54 SAM Configuration Manual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL EMERGENCY STOP FuNCTIONS Execution STOPO causes the following actions see Figure 31 within the affected axis e output transistors of power stage are disabled removing drive current to the axis motor Brake Control Option turns off current flow to motor brake The STOPO EXECUTED status bit in SAM Drive Main Status is set Speed reference internal TMP is decreased to zero The STOP2 EXECUTED status bit in SAM Drive Main Status is set If the STOP 0 was activated internally by the SAM Drive firmware due to an error condition the FATAL ERROR contact opens PAM or SAM Tools or from an internal sequence does not open the FATAL ERROR A STOPO due to activation of the USER STOP 0 input or a STOPO command from the o contact
14. StopO W Power Stage i Speed Ref 4 Ki TmpStopDecel Brake Output of Fatal open Fatal Error does not open if STOPO Error closed is due to an external activation STOPO Executed 0 STOP2 1 Executed Figure 31 Execution SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 55 SAM CONFIGURATION MANUAL STOP 1 Activation EMERGENCY STOP FUNCTIONS A STOP1 error response see Figure 32 can be activated by conditions internal and external to the SAM Drive including USER STOP 1 input is set to low state STOP1 command from the PAM or from SAM Tools via the service port A status condition pre defined by Drive firmware STOP1 Forced Mask to initiate a STOP1 becomes true A status condition pre defined by the application STOP1 Action Mask to initiate a STOP1 becomes true STOP1 command from an application Sequence running in the SAM Drive STOP1 User Mask STOP1 Forced Mask User Stop1 Stop1 Input Cmd 64 64 S Status S ABCD a 647 7 64 Latched STOP1 Reset Delay first Stop1 cause latched for diagnosis E Stop1 actions Fatal Error Figure 32 STOP1 Activation 64 64 Q D L S 62 all except User Stop1 input and Stop1 command 1 SAS020 B CDR Page 5
15. TRUE The field is modified from the PAM application according to the ENABLED value of the PAM brake declaration Modification by panel is also possible Methods e lock lock of the brake output is deactivated e unlock unlock of the brake output is activated Parameters related to Brake Option Name Type Units Description Ai BrakeOptionInstalled UNS16 0 option not installed 1 option installed Mi BrakeLockDelay UNS16 ms used to initialize LOCK DELAY field default 40 ms Mi BrakeEnabled BOOL ms Indicate motor with brake default TRUE Table 12 Brake Object parameters Page 62 SAM Configuration Manual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL EMERGENCY STOP FUNCTIONS Refer to ProMotion Help SAM Parameters and Fields Topic and select System and motor parameters for host access Brake behavior related to ENABLED field Hardware Option ENABLED Behavior availability not installed FALSE Error report disabled brake lock FALSE logically not installed TRUE Brake error signaled brak lock follow order logically installed FALSE Error report disabled brake lock FALSE logically installed TRUE Brake error signaled brak lock follow order logically Table 13 Brake Object behavior Brake error Bit 10 of status B indicates a brake error refer to chapter Status and Display on page 53 When set the brake erro
16. required for running a PAM and SAM System are supplied on the ProMotion Collection CD rom Each collection gathers several versions together with several utilities and documentation The ProMotion Help file provides also for comprehensive information about SAM Tools Installing SAM Tools PC Hardware Platform Minimum PC Configuration Required 80486 processor 8 MB RAM memory 16 color VGA graphic adapter 1 serial port 15 MB disk space for SAM Tools only 30 MB for complete Promotion package e Windows 95 or 98 installed Recommended PC Configuration Pentium processor 16 MB RAM memory 16 color SVGA graphic adapter 1 serial port 15 MB disk space for SAM Tools only 30 MB for complete Promotion package e Windows 95 or 98 installed Installation for multi version use The hierarchical structure proposed to be able to have different PAM amp SAM systems and 32 bits new applications installed on a single PC is described in Figure 1 It is sharply recommended to use this structure to get the best efficiency amp 3 C000607 C E my 121 app sam socatool 202 C appincs Struct2 bmp Figure 1 Multi version structure SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 9 SAM CONFIGURATION MANUAL SAM Toors How to migrate from an old structure to the new structure If your previous installation does not correspond to this structure proceed as follow 1 Quit the insta
17. response at the application program level They are represented in the SAM Status and produce an indication on the Front Panel Status Indicator An application program can define how a SAM Drive responds to error fault conditions i e STOP 0 STOP 1 or STOP 2 response The responses to certain critical fault error conditions are defined by firmware forced response and not user alterable or maskable User Safety Inputs On every SAM Drive discrete user safety inputs USER STOP 0 and USER STOP 1 are provided to permit a fault error response to be initiated by external circuitry USER STOP 0 and USER STOP 1 are isolated 24 VDC PLC type user inputs They provide sufficient redundancy to satisfy the criteria for category III safe standstill per standard EN954 1 Fatal Error Output FATAL ERROR is a SAM Drive output isolated relay contact which is closed whenever no fatal error condition exists or when the internal voltage supplies are not available The FATAL ERROR contact normally controls current to a contactor supplying AC power to the SAM system Upon occurrence of a fatal error the FATAL ERROR contact opens removing AC power from the SAM system Page 52 SAM Configuration Manual P n 9031 011 987 November 14 2000 EMERGENCY STOP FUNCTIONS SAM CONFIGURATION MANUAL ion Brake Output Opt The Brake Option is used for controlling an electromechanical brake on a motor equipped with this option The output is on enab
18. 031 011 987 November 14 2000 SAM CONFIGURATION MANUAL CHECKING SAM TO MOTOR WIRING Servomotor type poles POS RES range pole pairs for Table 14 step 11 AHD55x4 AHD70x4 AHR92x4 AHR115x6 AHR142x6 ABMR190x6 AHD190x8 4 poles 0 1 0 2 pole pairs 180 41 0 6 poles 0 1 0 pole pairs 120 41 0 120 1 0 8 poles 4 pole pairs All BAUTZ Mxxx 6 poles 0 1 0 types pole pairs 120 41 0 120 1 0 Table 15 POS RES Values for ACC AC Servomotors SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 67
19. 1 Average position lag with no With correct R_VISCFRICTORQ compensation R_VISCFRICTORQ compensation average position lag during motion is 0 Watch the difference in vertical scales as it Sconf008 cdr is automatically adjusted to the measure range Figure 27 Static friction compensation examples for step 8 SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 49 SAM CONFIGURATION MANUAL SAM PosiTION CONTROLLER ITS TUNING Adjusting the Viscous friction compensation 9 Setup the control panel for a medium speed move i e Travel Speed 7200 Acceleration amp Deceleration 36000 Rel Move 7200 10 If the axis viscous friction torque is known enter the value in mNmS 100 Rad as R VISCFRICTORQ If viscous friction is unknown enter zero 11 On the Trace Control window press to initiate a trace operation 12 Click on to initiate an axis movement Press on the Trace Control window when the button becomes active to upload the trace to the monitor 13 On the uploaded trace estimate by eye the average value of POSI LAG during the constant speed portion of the motion Adjust R_VISCFRICTORQ then repeat steps 11 and 12 until average POSITION LAG is approximately zero during the constant speed portion of the movement If POS LAG is gt 0 increasing R VISCFRICTORQ drives position lag in the negative downward direction 4800 SPEED REF MEM DSP INT 0x01a3 INT16 4800 SPEED REF MEM DSP INT 0x01
20. 6 SAM Configuration Manual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL EMERGENCY STOP FUNCTIONS Execution STOP1 causes the following actions See Figure 33 within the affected axis e Immediate Controlled Stop axis decelerates to zero speed at a specified rate e The STOP1 EXECUTED status bit in SAM Main Status is set e The STOP2 EXECUTED status bit in SAM Main Status is set The following actions are taken following execution of the controlled stop e Output transistors of power stage are disabled removing drive current to the axis motor e Brake Control Option turns off current flow to motor brake e fthe STOP 1 was activated internally by the SAM Drive the FATAL ERROR contact opens PAM or SAM Tools or from an internal sequence does not open the FATAL ERROR A STOP1 due to activation of the USER STOP 1 Input or a STOP1 command from the o contact Stop1 Stop1 Stop0 ON aN ON Reaching timeout is Power OFF OFF a STOPO condition 4 Ki TmpStopDecel i Ki TmpStopDecel K Stop1Delay fStop iDeley Speed Ref E Ene Stop1Timeout K Stop1Timeout default 1 second 1 1 default 1 second m A m Chee a unlocked unlocked Brake locked locked Mi BrakeLockDelay Fatal Error opens Fatal open except if STOP1 is due spen Error closed to an external activation closed STOPO 1 Executed 0 STOP1 1 Exec
21. 7 Trace window Time Scale Shows the time reference for the trace data The time scale is a function of the sample rate specified in the Trace Command file associated with the trace data Time t 0 is the trigger point point at which the trigger condition is satisfied The pre and post trigger percentages displayed are set by command in the Trace Command file Variable Scale The graphical display of each variable is adjusted automatically to show the full excursion of the variable over the sampling interval within the available vertical space and the variable scale shows the relationship between vertical amplitude of the variable and it s actual value Units of the variable scale are the units of the variable see Table 6 Note that the variable scale for successive traces of a variable may be different if the total excursion of the variable changes Trigger Point This dashed vertical line indicates the point at which the trigger condition is satisfied This point becomes the time origin t 0 for the trace Trigger Position The position or value of each variable at the trigger point Channel Title This is a four part expression comprised of a channel label memory type memory address and data type Channel label is a user defined name for the variable memory type and memory address define the location of the variable is the SAM Drive s RAM memory and data type defines the format i e integer real etc of the variable
22. G MODE PDPOS 8 Set R IGain R_PGain Inertia R StatFricTorq R ViscFricTorq 0 9 If the required speed loop cutoff frequency F oy and axis inertia J are known a starting R_DGain setting may be calculated as follows 4000 zx eJ F R DGain using the M StallTorq value displayed on M StallTorq the control panel If not set R DGain 10 SAM Configuration Manual Page 44 P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM PosiTION CONTROLLER ITS TUNING 10 Press L_POWER ON Verify that the SAM Drive status indicator displays 1 continuously If not a fault error condition exists which must be eliminated before proceeding A Before proceeding to next steps make sure that the motor may move enough in both directions without any danger neither for humans nor for the machine 11 Click on to produce a short movement of the axis motor If the motor goes into oscillation or produces an unacceptable level of audible noise before during or following the movement reduce the R_DGain setting by 25 If there is no oscillation or unacceptable audio noise increase the R_DGain setting by 100 12 Repeat step 10 until the highest setting of R DGain without oscillation or unacceptable audible noise is found A Be continuously aware that the motor is moving and its load may thus hit machine limits 13 Click on PowERor then to reset position lag to zero 14 Calculate a starti
23. M Drive status indicator displays 0 continuously 4 Activate the resolver pan control none panel While manually turning the motor shaft in the clockwise direction as viewed from in front of the motor mounting surface looking toward the motor and frequently refreshing the control panel display monitor the value of On the control panel select Regulation Mode Reg_Mode_Free Set PosReg TORQ_FLOW 1000 Set CurReg FREE_FREQ 0 If SAM status indicator does not indicate 0 press Reset STATUS button Press Power ON button Goal is enabling SAM to produce a constant current vector locked on the angle CurReg TETA Try turning the motor shaft by hand On the control panel e Set CurReg FREE FREQ 10 SAM produces a current vector which rotates at a frequency of 1 2 Hz approximately POS RES increases as the motor shaft is rotated At some point POS RES rolls over to a negative number and increases toward zero as the motor shaft is rotated SAM status indicator displays 1 indicating power stage is enabled The motor shaft rotates to the closest position where it is in alignment with the current vector Magnetic flux produced by motor current from the SAM Drive creates an electrical d tente which prevents the motor shaft from turning freely When rotated a few degrees in either direction and released motor shaft returns to its original position Motor shaft rotates slowly in the clo
24. OW 52 Error Response erret e ttr erp cet ee eee Ep des 52 User Safety Inputs 5 eie LA eee eere 52 Fatal ErrotOutput 4 oe enata ee tea lee eed erede eke 52 Brake Output 53 Status ard Display iret re ee PAR dr ee 53 DROP EE 54 ACUV AU OM EE 54 EX CUUION iini ce t donee p e ride e ep rer ead 55 fint rt t Idm rt tr um T 56 ACtUVAtlOT ci dott tete rt E e 56 iti doi atti cie tni 57 STOP2 52 ons italie 58 cioe be eer t Here obruti breve ber tege dete o opes etd 58 EXE CUIO 1i bo ied tige cody te nda 59 6 idet reete o ede Y ER e ded e ds 60 en acm n c E e de c nete 60 Execution 2rd tice dett cde oe te dE E ac de nec ie da 60 Fatal iro ET H 61 SAM Brake icc desee auae dela ne dea nada nane daz 61 Description iaceo e 61 Brake handling brake enabled sss 62 Brake Object class Cbrake ssssseeeee emen 62 Parameters related to Brake Option sssssssssseseeeeeee 62 Brake behavior related to ENABLED field
25. SAM Configuration Manual Ordering Number 9032 011 987 Issue November 14 2000 This version replaces all previous versions of this document It also replaces the SAM System User s Manual 1997 Inmotion Technologies and ACC Motion have made every effort to insure this document is complete and accurate at the time of printing In accordance with our policy of continuing product improvement all data in this document is subject to change or correction without prior P n 9032 011 987 Issue November 14 2000 notice ACC Motion SA 1995 2000 Zone industrielle La Rippe by ACC Motion SA CH 1303 Penthaz All rights reserved Switzerland SAM CONFIGURATION MANUAL TABLE OF CONTENTS SAM Configuration Manual Page 2 P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL TABLE OF CONTENTS Table of Contents Table of Content nea c eerte ae iret eec e des er bett dte 3 Eist of Elgures D e EE e EH e n Lau e RE REM vtta He fedis d 5 Tables 2 sini padece UM EC tae 6 INTRODUCTION nn A cette Rai eh ie eel 7 Scope of this 7 Related Documents ee e eee i el 7 Intended Use of SAM 7 Personal Safety uibs me ra d tive pe PI Po 7 Warnings Cautions and Information Notices 8 SAM
26. a3 INT1B T T 1280 i i 1000 4 780 4 1280 4 1000 4 780 4 500 4 500 4 280 4 280 4 E 104 20 4 0 3 02 01 0 01 02 03 04 ns 07 08 og 0 3 02 01 0 01 02 0 3 04 05 06 07 0 8 08 Position lag with no R VISCFRICTORQ compensation With correct RVISCFRICTORG compensation average position lag during constant speed is nearly 0 Watch the difference in vertical scales as it Sconf009 cdr is automatically adjusted to the measure range Figure 28 Viscous friction compensation examples for step 13 Adjusting the Inertia compensation 14 If the axis inertia is known enter the value in 10 as R INERTIA If inertia is unknown enter zero Set Rel Move 3600 15 On the Trace Control window press to initiate a trace operation SAM Configuration Manual Page 50 P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM PosiTION CONTROLLER ITS TUNING 16 Click on to initiate an axis movement Press on the Trace Control window when the button becomes active to upload the trace to the monitor 17 On the uploaded trace estimate by eye the average value of POSI LAG during the acceleration and deceleration portions of the motion Adjust R INERTIA then repeat steps 15 and 16 until Pos LAG is approximately zero during the acceleration and deceleration por
27. ad Brake2 Secon gt Diagnostic Y 4 gt _SBRA SAH033 b CDR GND Ext e Figure 38 Brake Option Functional Diagram SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 61 SAM CONFIGURATION MANUAL EMERGENCY STOP FUNCTIONS Brake handling brake enabled Automatic handling At power on the brake is unlocked when the power stage is acknowledged ON At power off and STOPO the brake is simultaneously locked when the power stage is turned off see section STOP 0 on page 54 During STOP1 execution the brake is locked a few milliseconds before power off action The delay is corresponding to the value of the field LOCK DELAY default value is 40 ms In case of STOP1 time out occurring while speed does not fall quickly enough to zero turn off of power stage and brake lock are applied simultaneously see section STOP 1 on page 56 Manual handling Lock and unlock method available from panel when using SAM Tools Brake Object class Cbrake Name Type Access Units Description ENABLED BOOL RW option situation LOCK STATE BOOL RO ordered state of the brake LOCK DELAY UNS16 RW ms delay before locking used by STOP1 Table 11 Brake Object fields Refer to ProMotion Help SAM Parameters and Fields access Topic and select Brake fields for host The field ENABLED is initialised to TRUE if e Ai BrakeOptioniInstalled TRUE AND e Mi BrakeEnabled
28. anual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM OPERATING SOFTWARE Definitions Commands Manager The Commands Manager handles communications with PAM application program Sequence execution and coordinates activities within the SAM Using a dedicated RS 232 port it communicates with a PC running SAM Tools and a Test Device accessory Motion Generator The Motion Generator executes those portions of various pipe block functions which are implemented at the axis level Secondly it generates independent motion profiles including point to point and continuous motions in response to commands and parameters from the application program A Limiter compares the flow of motion data against limiting values of positive and negative travel speed acceleration deceleration torque and direction imposed by the application Whenever a trajectory values exceeds a limit the limiter sets an appropriate status bit which is normally used to stop the motion The user normally establishes limiter parameters based on the application s requirements Position Controller The Position Controller see Figure 10 is a firmware algorithm that provides field proven closed loop PID control with enhanced feed forward compensation A notch filter which can be activated and tuned by parameter may be utilized to improve system performance in the presence of strong torque disturbances when a mechanical resonance frequency might
29. are decompressed and parameters into RAM CRC checking is used to verify the integrity of the RAM contents Execution of the operating software begins with the Configuration phase during which all SAM Drive adjustments and settings are established digitally using either default parameter values from flash EEPROM or configuration files previously downloaded from a host or service PC running SAM Tools SAM may be commanded to save parameters upon which the current values of all parameters are stored in flash EEPROM A host or service PC may upload a complete parameter set for archiving a configuration Run Mode Upon completion of the Configuration phase the operating software enters the run mode phase which handles communication with the host commands execution and finally controlling the motor Page 30 SAM Configuration Manual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM POSITION CONTROLLER ITS TUNING SAM Position Controller Its Tuning Introduction Section titled SAM Position Controller Principles discusses and illustrates the concepts terms and equations utilized in the tuning procedures A block diagram and description of the Position Controller is included in this introductory section This chapter presents next step by step procedures for tuning a SAM Drive SAM Position Controller Principles Short Description SAM Drives incorporate a modern flexible closed loop controller calle
30. ask valid only for System 2 0_2 pods oual ynej urew x puo eq uoneunp ep o Fx ponad puo eq uoneorddy I jno euin dojs uo 09015 HOA vz Or uondo E 1 syndyno Ol uondo uo Jamod je 0192 jou peeds yndul dO1s paalaoad epoo ysoy pyeaul x bjeis jueJno enp ejqejnoexe jou PWD 1sou EBEN panjacel ejep puewwoo 1s0u pejnoexe 45 xui SoH EB uoneziuoJuou s Bunrew 1 jno eum uo pejgesip xu isoH x awed peidnuioo uo pejqesip xui SOH anire uorssiusueg yur son lt OI IN x L n E O o O Lu JE IE gt o o D STATUS C CD HEX 0x004B258 OxF780004 0x0000002 0 0004000 Table 10 SAM Configuration Manual Page 53 P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL STOP 0 Activation EMERGENCY STOP FUNCTIONS The STOP 0 error response see Figure 30 can be activated by conditions internal and external to the SAM Drive including USER STOP 0 input is set to low state STOPO command from the PAM or from SAM Tools via the service port STOPO command from an application sequence running the SAM Drive A status condition pre defined by Drive firmware STOPO
31. bles have to be defined with their addresses and their size see ProMotion hlp Trace information section For both types of variable DSP and i960 the scale factor units volts has to be defined as in following examples SpeedRef given units in the filed list are 2 uPOS REG period which give at 8 kHz 0 915 t min It means that 1 Isb of the SpeedRef variable represents 0 915 t min Then if we want for example 1V 1000 t min scale factor will be 1009 1092 26units volt 0 915 PosLag given units in the filed list are 2 which give 5 49 10 degree It means that 1 Isb of the PosLag variable represents 5 49 10 degree Then if we want for example 1V 1deg scale factor will be 1 549105 182 volt SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 25 SAM CONFIGURATION MANUAL SAM OPERATING SOFTWARE SAM Operating Software Introduction The functionality of SAM Drive comes largely from its resident operating software The functions are distributed among its two microprocessors Figure 9 highlights the principal software functions and shows links between software and hardware functions SAM Tools Commands Manager Motion Generator safety circuits Position Measurement Current Regulator Position Regulator SASO28 A cdr Figure 9 SAM Drive Software Functions Page 26 SAM Configuration M
32. ce with the EC Directives and standards applicable to SAM products assemblers must read understand and apply the specified procedures and practices regarding safety set forth in the PAM and SAM System User s Manual 6 parts When modifying PAM and SAM System Software parameters variables or any other A configuration setting the user must keep in mind that motors are powerful enough for causing fatal injuries to humans and severe damage to machines SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 7 SAM CONFIGURATION MANUAL INTRODUCTION gt EH Warnings Cautions and Information Notices Special attention must be paid to the information presented in Warning Caution and Information notices when they appear in this manual Examples of these notices along with a description of their purposes follow An Information Box contains supplemental information or references to supplemental information on a topic The Stop Box highlights important conceptual or procedural details that must be understood and applied in order to successfully use the product A Warning informs the user of a hazard or potential hazard that could result in serious or fatal injury if the precaution or instruction given in the Warning notice is not observed Page 8 SAM Configuration Manual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM Toors SAM Tools Preliminary Remark All software components that are
33. ckwise direction at constant speed e 36 RPM for 4 pole motors 24 RPM for 6 pole motors e 18 RPM for 8 pole motors If SAM Drive status indicator displays other than 0 or displays 0 in sequence with other characters other fault error conditions exist which must be removed before proceeding with this procedure If POS RES decreases with clockwise rotation of the motor shaft a wiring error exists in the connections between the motor mounted resolver and connector X24 on the SAM Drive Verify SAM Drive to resolver feedback wiring and correct any wiring errors or substitute a known good feedback cable and motor of the same type and model If SAM status indicator displays other than 1 other fault error conditions exist which must be removed before proceeding If no resistance is felt verify all motor windings connections from SAM Drive connector X12 to the motor windings connections Verify that DC Bus voltage is present at the SAM Drive If motor shaft rotation is counter clockwise or the motion is erratic or there is no rotation check for loose broken or crossed connections from SAM Drive to motor windings connections SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 65 SAM CONFIGURATION MANUAL CHECKING SAM TO MOTOR WIRING procedure normal response indication corrective action On the control panel Motor shaft rotation stops e Set CurReg FREE FREQ 0 10
34. d position Current Controller The Current Controller is a closed loop controller which supplies a three phase pulse width and sine wave modulated current command to the Power Stage It monitors the output currents and regulates the direct Ip and transverse lg current components The Current Controller employs totally digital control which provides improved performance and repeatability compared to standard analog technology Control algorithms for AC synchronous motors AC Servo motors and asynchronous motors AC induction motors are built in and selectable by parameter A downloadable parameter file which correctly configures the Current Controller and Power Stage is available for every model servomotor that is available together with the PAM and SAM System Configuration files for other types of motors are also available Built in thermal load modeling of the axis motor utilizing motor and drive parameters provides reliable and responsive motor overload protection under all operating conditions Status Registers Four 16 bit status registers provide a complete picture of SAM current operational state with respect to error fault and alarm conditions For easier and quicker event detection a fifth 16 bit Main Status register provides a summary picture of SAM current operational state Page 28 SAM Configuration Manual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM OPERATING SOFTWARE Operating Stat
35. d the Controller or Position Controller which is responsible for keeping an axis on it s required speed and position trajectories Closed loop control is required for compensating indeterminate disturbances disturbances of unpredictable magnitude or timing If indeterminate disturbances are significant relative to the required accuracy only comparatively high PID loop gains can provide the necessary precision However with higher PID loop gains comes the classic compromise of precision vs stability Position overshoots are also very common The effects of known disturbances such as inertia during acceleration friction and others are most easily eliminated using feed forward compensation rather than high position loop gain If indeterminate disturbances are small the required accuracy may be achieved mainly using feed forward compensation with lower controller loop gains and less chance for stability problems The integral gain can also be set to zero as in a simpler PD control scheme so that no position overshoot occurs Software Objects regarding Position Control The Controller is software based and employs digital signal processing techniques The Controller is tuned by adjusting its parameters to achieve desired performance Using standard control panels and traces supplied with SAM Tools drive tuning is accomplished quickly and easily following the procedure in this chapter Figure 12 shows a functional diagram of the Posi
36. derivative control loop In this illustration Fop and are the same 50 Hz as the critically damped PD case see Figure 13 and F 0 63e 32Hz Note that the initial response for the first 10 ms is about the same as Figure 13 but as a result of the integral feedback static position lag is reduced to zero 200 Position Lag 0 El 200 4 400 600 4 800 4 1000 TR344 1200 0 3 0 25 0 2 0 15 0 1 0 05 0 0 05 0 1 0 15 0 2 0 25 0 3 Figure 16 PID Control Critically Damped Response In Figure 17 Foy Fop 100Hz and F 63Hz All three cutoff frequencies are increased by 10096 compared to Figure 16 resulting in a significant reduction of position lag and settling time Because the ratios of cutoff frequencies remain the same the general shape of Figure 16 is the same as Figure 17 50 Position Lag n 50 4 100 150 4 200 4 250 300 T T ERI 03 0 25 0 2 0 15 0 1 0 05 0 005 01 015 0 2 0 25 0 3 Figure 17 PID Control Response with increased Cutoff Frequencies SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 37 SAM CONFIGURATION MANUAL SAM PosiTION CONTROLLER ITS TUNING Figure 18 shows the effect of reducing to 35 Hz Fo is reduced to 20 Hz in order to retain 0 63 F The reduction Fo and Fop increases stability but sl
37. e V1 0 02 7 Clear the whole trace configuration CLEAR CONFIGURATION CONFIGURE SAMPLING 80 4000 CONFIGURE CHANNEL 1 SPEED REF MEM DSP INT Ox1A3 INT16 CONFIGURE CHANNEL 2 P0S_LAG MEM_DSP_INT Ox1a0 INT16 CONFIGURE TRIGGER 1 1 0 Symbol name NE Symbol value s F301_A GIF Figure 5 Trace Commands Dialog Box Trace stopped SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 21 SAM CONFIGURATION MANUAL SAM Toors Figure 6 Trace Control Panel Related Field Symbol Mem Type Type Units 1 Isb Rf SPEED REF SpeedRef MEM DSP INT INT16 0 915 t min 8kHz Rf ACCEL REF AccelRef MEM DSP INT INT16 3433 23 t min 8kHz Rf POS LAG 16 PosLag MEM DSP INT INT16 275t Rf TORQ FLOW TorqFlow DSP INT INT16 4096 stall Torque Rf TORQ QUIET TorqQuiet DSP INT INT16 4096 stall Torque Rf TORQ REF TorqRef MEM DSP INT INT16 4096 stall Torque Rf IKAN Ikan MEM DSP INT INT16 Af UDCBus UdcBus MEM DSP INT INT16 4096 Udc max Af IQRef IQRef MEM DSP INT INT16 4096 Imax Af IQMes IQMes MEM DSP INT INT16 4096 Imax Mf_SIN_A Sina MEM DSP INT INT16 Mf COS A Cosa MEM DSP INT INT16 Mf POS RES PosResB DSP INT INT16 27 Of INPUTS VALUES Inputs MEM 960 BIN16 none Setpoint MEM 960 INT32 27 94 10 t min CPU 2kHz Table 6 Most interesting variables to trace it re
38. e of box is used for controlling the state of Boolean inputs which can only be true or false An in the check box means the input is in its true state and a blank check box means the input is in it s false state SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 17 SAM CONFIGURATION MANUAL SAM Toors List Box The value of the corresponding field parameter highlighted in a contrasting color Select an item from the drop down list displayed in the box changes the value then press ENTER on the keyboard List Combo Box Displays a pop down list of selections Button Clicking on a button initiates one or more specific pre programmed actions A button may operate in any of several ways depending on how it is specified in the control panel The possibilities see Figure 3 include buttons having no argument buttons with fixed arguments built into the button specification buttons with an adjustable argument whose value is taken from a numeric entry box and dual action buttons which produce an action when depressed and an action when released Activating a Control Panel Opening its file from the SAM Tools Log window activates a control panel To open a control panel file perform the following steps 1 From the menu select 2 Inthe File Open dialog box select the file name including path of the control panel to be activated then press All control panels have the file extension
39. ely required Upgrading bootware and firmware from System version 1 2 xx or older requires a special procedure Refer to Promotion hlp help file for more information SAM Configuration Manual Page 14 P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM Toors Replacing a SAM drive To be able to change a SAM drive in good conditions it is recommended to have a saved parameters file of each axis To create such a file the following procedure is used 1 Upload parameters with template App20XX SPA 2 Save parameters as contextual name e g Axis3 spa Then its is very simple to change a SAM drive Proceed as described in the PAM and SAM System End User s Manual If parameters are managed within the PAM application this procedure is not necessary When replacing simultaneously the SAM software version more information is available in ProMotion Help How to install a new SAM System topic Control Panels Overview A particularly powerful and useful feature of SAM Tools is the capability to create custom control panels on the Service PC monitor Control panels provide direct simplified access to a SAM Drive via the service port for tasks such as testing monitoring or servicing an axis Panels may be customized to the extent that buttons and displays have customized legends relevant to the machine or application or language of the country where used Control panel attributes are stored in software files p
40. er 14 2000 Page 45 SAM CONFIGURATION MANUAL SAM PosiTION CONTROLLER ITS TUNING until the best overall R_PGain setting is obtained The trace zoom feature may be used to expand the area of interest the available space When comparing data from successive traces be sure to note also m SAM Tools automatically scale the vertical axis of each trace such that the display fills the vertical axis scaling used On the uploaded traces 180 units of POS LAG represent approximately 1 degree of osition lag as measured at the motor shaft d Lo E Over damped response Critically d damped response Under damped response I Pain R PGain is fine Decrease PGain Sconf003 cdr Figure 25 Reference Waveforms for Proportional plus Derivative Tuning Step 17 m If adjusting the Controller for PID mode operation Jump to step 1 of next section 19 Set the Feed forward compensation see Feed forward Compensation on page 49 20 Restore original value of the least significant digit of S MStopO AB recorded in step 5 21 In the Ri RegMode entry box select REG MODE PDPOS Upon completion of this procedure only the tuning parameters in RAM memory have been revised The tuning parameter values in flash memory remain unchanged Parameter values in RAM memory are lost upon power down or resetting of the SAM Drive To permanently save the tuning parameters as well as all other parameters in flash memory pre
41. ermitting control panels to be stored recalled and recreated as needed A control panel is a customizable graphical interface to the SAM Drive which provides the capability to interrogate and manipulate SAM parameters and fields SAM Tools software provides the interface between a control panel and a SAM Drive converting operator and actions to the appropriate commands and updating the panel based on the drive s responses SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 15 SAM CONFIGURATION MANUAL SAM Toors ACC Standard Control Panels ProMotion includes a library of standard panels useful for various aspects of SAM system monitoring tuning and control A description of the ACC standard panels is found in Table 4 These standard panels may also be used as the starting point for a user creating customized panels for a specific application file name used to analog pan define which variables to convert in analog outputs on Test Device brake pan check brake behavior endat pan display EnDat features of multiturn encoders and resolvers hardinfo pan display hardware information init_loc check and initialize local position init_mon check and initialize 2 position feedback init_pol pan check linear and some direct drive motors System 2 0 and up io pan check and configure I Os magnali pan check linear and some direct drive motors System 1 3 and 1 5 mai
42. es SAM software controls in a very strict way in which state the Drive is Depending on the actual state several actions and transitions are possible and others are not SAM state is displayed on its front panel reset of _ gt 24VDC On I Hardware OK d System Check System No OK H System in Error System OK Initialization Start Running E Booting E Check Firmware Ready for Expand Firmware No firmware Download Firmware OK Start Booting Start Configuring Installation Start Running Configuring 5 Check Configuration Ready for Install Parameters J Bad Configuration Config 5 o Start Configuring Running StopO Stop1 internal Fatal Error Stop0 internal Reset Fatal Error NI Error code StopO Stop1 In Reset Fatal Error Reset Stop sas017 b Blinking dot CPU is running Figure 11 Operating software Initialization phase SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 29 SAM CONFIGURATION MANUAL SAM OPERATING SOFTWARE Initialization A compressed version of the operating software also named Firmware along with an uncompressed copy of a Boot up program also named Bootware and all parameters reside in nonvolatile flash EEPROM Upon startup the Bootware is copied into RAM and executed It performs some hardware and communication initialization then copies the Firmw
43. ese functions cannot be considered safe as defined in IEC 60204 1 or IEC 61803 Safety functions must be implemented as specified in the PAM and SAM System User s Handbook Part 3 Safety and Protective Functions Opening a New Panel Document 1 From the SAM Tools Log window select then 2 In the NEW dialog box see Figure 4 select PANEL Document A new window containing a blank panel is opened 3 Toassign a file name to the panel file select then In the FILE SAVE AS dialog box enter a file name and select a path which is the correct mode for creating and modifying panels When utilizing a panel o When a new panel document is created the panel window is opened in Edit Mode window as a control panel the panel must be in Execute Mode New PARAMETERS Document PANEL Document Sconf011 cdr Figure 4 New Dialog Box Creating Control Panel Components Creating control panel components is a menu driven process in which buttons and boxes are created by selecting from a list of parameters fields and methods accessible from control panels The nature of a field parameter selected dictates the type s of entry or display box created For buttons the selected method dictates the button type s created Creating Entry and Display Boxes To create an entry or display box in an open Panel document perform the following steps 1 If the panel is not in Edit Mode select from the
44. he closer the model comes to reality the torque necessary for each movement may be calculated and applied directly to the motor independent of any feedback Due to its open loop nature feed forward compensation does not contribute to axis instability and it is simple to setup In many applications utilization of feed forward compensation provides improved trajectory tracking accuracy using a less complex Position Controller mode with lower gains improved stability and no position overshoot The Position Controller remains active It functions to compensate for the remaining differences between the model and real system Figure 9 on page 26 shows SAM implementation of feed forward compensation e For inertia compensation a torque component proportional to acceleration is created e For viscous friction a torque component proportional to speed is added e For dry friction a constant torque component with sign based on the speed reference is summed into the composite torque command e For weight a torque component equal to a parameter setting is added Benefits of using Feed Forward an example Figure 21 shows the response of a critically damped proportional plus derivative axis when commanded to move 1800 degrees 5 turns at a velocity of 9000 degrees sec and an acceleration of 360 000 degrees sec The upper trace of Figure 21 is the velocity profile of the move and the lower trace shows position lag Note that position lag i
45. ion ref commanded or set point position speed ref commanded or set point speed J motor plus load inertia The tracking precision that is the ability of the axis to remain on it s trajectory in the face of disturbances depends on position loop gain however this loop by itself is unstable due to the double integration The speed loop serves to stabilize the system For a given axis configuration position loop gain speed loop gain and their ratio have a range of values which produce optimum axis performance Outside this range tracking precision degrades or the axis becomes unstable From control system theory two terms speed loop cutoff frequency F oy and position loop cutoff frequency Fcp are very useful for determining optimum values of position loop gain and speed loop gain The cutoff frequency is the frequency at which the output amplitude is reduced by a factor of 2 6 dB compared to the output amplitude at zero Hertz SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 33 SAM CONFIGURATION MANUAL SAM PosiTION CONTROLLER ITS TUNING For a sinusoidal speed reference at cutoff frequency speedreference 2 speed speedlag 1 speed acceleration 2 e Foy speedlag K J acceleration Therefore pb 5 2m J For the position loop with a double integral 2 m 1 position acceleration For Therefore 1 K CP
46. is load must be tightly coupled to the motor Free play or backlash between the motor and load complicates the tuning process and prevents satisfactory performance in most applications The optimum controller adjustment is not necessarily with all gain settings just below the point of instability A preferable strategy is to adjust the Controller to a point where the desired performance is achieved with some additional margin The process of tuning may subject motors SAM Drives and Dynamic Braking Resistors to conditions exceeding the operating conditions encountered during execution of the application for which the SAM system components were sized SAM System components are protected against overloads but system integrators must be cognizant of this possibility and not operate the equipment outside its limits Motors may run faster or slower than expected or in the opposite direction or even go into oscillations System integrators must take necessary precautions such as limiting maximum torque to prevent erratic motor operation from harming personnel or the driven equipment or the machine Page 42 SAM Configuration Manual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM POSITION CONTROLLER ITS TUNING Select the Position Controller Operating Mode The SAM Position Controller may be configured by parameter to operate in any of the modes listed in Table 9 which also summarizes important performance characteris
47. k in 6 parts documents the Hardware This SAM Configuration Manual contains information related to Software Intended Use of SAM Products The SAM product line constitutes a Power Drive System according to international standard IEC 611803 and Power Conversion Equipment according to UL standard 508C Its intended use is for powering and controlling moving parts within industrial machines SAM products are supplied as subassemblies to professional assemblers for incorporation into machines apparatuses or systems Assemblers are responsible for insuring that the SAM products are used for their intended purpose only and for compliance with all applicable regulations According to the European Directive 80 392 EEC regarding machinery putting a SAM Power Drive System into service is prohibited until the machinery into which it is to be incorporated has been declared in conformity with the provisions of this Directive Personal Safety The SAM product line is intended for connection to standard main voltages up to 480 VAC and for running motors up to 8000 rpm High voltage and moving parts can cause severe or fatal injury ACC Motion and Inmotion Technologies provide this and other manuals for assisting assemblers in using the products in a correct efficient and safe manner Assemblers must insure that all persons responsible for design test maintenance and use of SAM have the proper professional skill and apparatus knowledge For complian
48. l Diagram 27 Operating software Initialization 29 PD Position Controller 5 ott De bert gie etes 32 PD Control Critically Damped 35 PD Control Over damped Response 35 PD Control Under damped Response 36 PID Control Critically Damped 37 PID Control Response with increased Cutoff Frequencies 37 PID Control Over damped Response 38 PID Control Under damped 38 PID Control Under damped 38 PD Axis Response without Feed forward Compensation 39 PID Axis Response without Feed forward Compensation 40 PD Axis Respond with Feed forward 40 Tuning Control Panel with Least Significant digit of M StopO AB Designated case tec D ERAI gs 44 Reference Waveforms for Proportional plus Derivative Tuning Step 17 n ME DE 46 Example waveforms for Step 6 48 Static friction co
49. le 5 These standard traces may also be used as the starting point for users creating custom traces for specific applications file name description marker stc trace SAM application markers regcur stc current regulation regpos stc used with tuning pan to adjust feed forward components of the Position Controller resolver stc display resolver signals resshift stc display resolver interface voltages setpoint stc display set point from PAM speed stc display speed reference st_ab stc display status AB st_cd stc display status CD tetapos stc display measured position and polar angle timing stc display internal SAM tasks duration tmagn20 stc display polar angle teach in sequence trace_io stc display inputs tuning stc used with tuning pan to adjust gains of the Position Controller Table 5 List of ACC Standard Traces Producing a Trace This paragraph describes the procedure for setting up a Trace using an existing Trace Command file 1 From the Log window s menu select MIRC Sa 2 Inthe Trace Commands dialog box see Figure 5 press ton In the Open dialog box select the subdirectory containing the trace commands file to be utilized Trace Command files have the file extension STC Click Em Page 20 SAM Configuration Manual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM Toors Trace Commands The selected trace command file See Figure
50. led it is off not conducting conducting when the power stage is when the power stage is disabled As an alternative the Brake Option can also be used for controlling a relay which short circuits the motor for quick stopping Status and Display the detailed list of Front Display codes and SAM Status description topic For each SAM System software version ProMotion Help SAM Default action mask Status Bits is shown in ProMotion Help topic shows the detailed default values of all status masks Table 10 shows this list as an example uey eyeeJ6 x 20 STATUS B 1ejep jepoou3 x yoajap 1 uonnjose x jeAose1 uonnjose1 yBIH ndo Hepuos s on x 440 abeys iewod 40419 499U2 wey dsd jun dsd x mo Aiddns uoneumes 10 Jamod x snq odj STATUS A L AB HEX OX59F9F401 wem ooo I TTTTTTITITITLELLLLLLLLLLLLLLLI 2 8 8 5 81 3 8 518 8 8 5 81 8 8 Ee olo em olo asemu P lt Joue yoay wey EB esodund 10 periases aoe LLL Pep dois pio i0 0 dois STATUS_D SAM Default action m
51. llation program 2 Launch File Manager 3 Remove all old versions of ProMotion on the PC 4 Edit AUTOEXEC BAT file and remove the following lines e SET SOCATOOL e SET PAMAGL e SET PAMSRCE SRCE e SET PAMTEMP C SOCATOOL TEMP e SET PATH xxx C SOCATOOL remove only the path to SOCATOOL 5 Rebootthe PC 6 Restart the Master Setup During installation a name for the root directory is requested It must be as short as possible to guarantee that the old versions are running properly By default this directory name is ACC Longer directory name should not be used How to install a ProMotion version 1 From the CD Rom and Master Setup choose the desired ProMotion version and follow the instructions 2 From the CD Rom without the Master Setup explore the CD ROM choose the desired ProMotion version open the directory called Disk1 and launch the application SETUP EXE How to install a Service Pack A Service Pack is an upgrade of a ProMotion version It is designed for only one version of ProMotion Proceed like a ProMotion installation Be sure that you install the corresponding Service Pack How to install several ProMotion versions 1 If any ProMotion version is already installed with the new structure rename the SOCATOOL directory with file manager with an explicit name i e V121 for ProMotion version 121 2 Install the new ProMotion version as usually 3 Touse older PAM amp SAM system
52. m dd 2 Fey The ratio is called the damping ratio CP When the damping ratio is gt 1 a system is referred to as over damped when the damping ratio is 1 a system is under damped When the damping ratio 1 the system is critically damped A critically damped system provides classically stable operation with optimum response best compromise for minimum overshoot with short settling time In that case Foy Fop Then Ky E K J J Therefore K 2 K This relationship is important because it shows that for constant damping Kp is proportional to This means that in order to maximize Kp and therefore minimize position lag while maintaining stability K must be made as large as possible SAM Configuration Manual Page 34 P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM POSITION CONTROLLER ITS TUNING In practice limited by several factors including the SAM Drive current loop bandwidth which is directly related to the PWM frequency selected for the drive standard 8 kHz optional 4 kHz Other factors including resonance frequency of the axis mechanics and signal to noise ratio of the speed measurement limit how large Kg be In practice is increased to the point where the axis goes into sustained oscillation then reduced by a factor of 2 to obtain good speed loop stability Ky is 2 then determined using the relationship E and fine tuned if desi
53. mpensation examples for step 8 49 Viscous friction compensation examples for step 13 50 Inertia compensation examples for Step 17 51 STOP Activatlonivcs ac ete tenent d pede Mens 54 STOPO Execution 2 t eR eder tate nhe deitate RR aden 55 STOPT AcCVatlonxiss rae Oe tero pete EM 56 STOPTEXSGCULIOF eue HE 57 STOP Activations cies nde edo e ord adi eae ets 58 STOP2 Exec tlori 1 27 21 nat ue add dedico 59 USER SIGNAL Activation 60 STOP2 ExeCUtlOr 22 1 rete dr gare eva deca Ele dee 60 Brake Option Functional 61 SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 5 SAM CONFIGURATION MANUAL LisT OF TABLES List of Tables Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 Table 12 Table 13 Table 14 Table 15 Description of Components of SAM Tools Main Window Components 11 SAM Tools Subdirectory and file extension conventions 12 ACC Standard Upload Templates vv version number i e all20xx spa for version eer ere he etin ters 14 ACC Standard Panels not available in all software versions refer to ACC Socatool Panels sub directory content
54. n 2 e1000 K Eg a 2 512 boca DGaine coU TUM qu 2 1000 F Lejr Paone ee 1 2m i J 4 M _ StallTorgq 135 IGain 2 T SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 41 SAM CONFIGURATION MANUAL SAM PosiTION CONTROLLER ITS TUNING gt p p SAM Drive Tuning Procedure Overview This section presents step by step tuning procedures Tuning parameters are entered and adjusted using standard control panels provided with SAM Tools Axis responses are captured and displayed on a PC monitor using the SAM Tools traces feature Preliminaries to Tuning Prior to beginning any axis tuning procedure the SAM Drive must be properly configured with the correct motor parameters for the axis configuration Any fault or error conditions must be eliminated A PC running SAM Tools and a SAM to Service PC test monitoring cable ACC p n 9032 010 689 are required to perform the procedure To properly tune a SAM Drive the actual axis mechanical load should be connected to the motor In that case the system integrator must be very careful for not ordering any motor movement that be destructive or dangerous while tuning Load simulators i e inertia wheels are useful for preliminary setup but are not recommended when performing final controller adjustments because they seldom duplicate the behavior of the actual axis load The ax
55. n 9031 011 987 November 14 2000 Page 43 SAM CONFIGURATION MANUAL SAM PosiTION CONTROLLER ITs TUNING 4 Activate the control panel titled TUNING PAN TUNING PAN is found in the Promotion PANELS subdirectory SAM Tools COM2 TUNING PAN File Edit Panel Window Help 2121180 Power ON M StallTorq Nm 1000 1500 Torque STEP Power S_MStop0_AB hex 05918001 4915 Reset STATUS Main Status 0xo0000004 R_PGain 500 R_IGain Re MOVE deg 1600 0 R_DGain Rm j degel n R_ViscFricTorg mNmS 100 Rad Travel Speed deg s 3600 E Ju is A ps Inertia 10 6 kqm 2 95 Acceleration deg s 2 36000 A R_StatFricTorg mNm 40 Deceleration deg s 2 36000 ExT N org mNm Ri_RegMode all B REG MODE PDPOS SAVE Parameters Ready IBOOT_RS V1 2 18 SFGZ Y1 2 29 RUNNING m SConf002 cdr Figure 24 Tuning Control Panel with Least Significant digit of M_Stop0_AB Designated 5 the TUNING control panel record the current value of the least significant digit of S_MStop0_AB see Figure 24 Do not forget to record the current value of S MStopO AB as it will have to be introduced again at the end of the tuning procedure 6 Now change the least significant digit of S MStopO AB to 0 This is necessary to prevent position lag from causing a STOP 0 during tuning 7 In the Ri RegMode list entry box select RE
56. n pan check general behavior mask pan define Status Masks mot_enco pan special panel for motors fitted with an sine cosine encoder motor pan view and modify motor parameters move pan define and run repetitive movements on motor System 1 3 and 1 5 msampler pan check SAM interface to PAM emitted position trajectory regcur pan check Current Controller parameters regsamp pan display fast input sampling resolver pan check resolver and motor wiring and setting sap_all pan display all SAM application variables sensor pan display and define all feedback settings stat_ab pan display Status A and B stat_cd pan display Status C and D st_com pan display EasyBus communication status st_enco pan display Sine Cosine encoder status st main pan display Main Status status m pan on 1 3 statmain pan on 1 5 st mes pan display internal resolver status statmes pan on Syst 1 3 and 1 5 status pan display all status fields t device pan define which variables to convert in analog outputs on Test Device temper pan display temperatures and voltages torq pan display and define SAM in Torque mode tst move pan define and run repetitive movements on motor Syst 2 0 and up tuning pan check and adjust Position Controller parameters z mark pan display reference mark of encoders Table 4 ACC Standard Panels not available in all software versions refer to ACC Socatool Panels sub di
57. ncreases significantly during the acceleration and deceleration portions of the move due to the effects of the motor plus load inertia which cannot be totally removed by the Controller s position loop gain During the constant speed portion of the move average position lag is approximately 50 due to the static and viscous friction produced by the motor and load The AC component of position lag during the constant velocity portion of the move is due to the inherent cyclical error of the resolver providing position and velocity feedback for the axis Speed Reference 1750 1500 4 1250 750 4 500 250 4 _ MH 0 300 T 200 DUM 100 E m 100 T 1000 1 200 Figure 21 PD Axis Response without Feed forward Compensation SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 39 SAM CONFIGURATION MANUAL SAM PosiTION CONTROLLER ITS TUNING Figure 22 shows the same move with the Controller operating in PID mode and adjusted for optimum response The action of the integral feedback loop tends to drive position lag toward zero during the intervals of constant acceleration and constant speed however the peak to peak position lag is not reduced Speed Reference 1750 150 1250 1000 750 500 250 0 Position Lag 300 200 4 100 m Ja 100
58. ng value of R_PGain as follows M StallTorq 10 R PGain R DGain 1 J where J is the axis total inertia For M StallTorq use the value displayed the control panel If axis inertia is unknown set R PGain R_DGain If the axis goes into oscillation reduce R PGain by 50 If oscillation persists reduce PGain by increments of 50 until oscillation stops 15 If the Trace Control panel see Figure 6 page 22 is not visible on the monitor press on the SAM Tools toolbar to bring in back into the foreground 16 On the Trace Control panel press to initiate a trace operation 17 On the TUNING control panel momentarily click and release to inject a torque disturbance and trigger the trace Press on the Trace Control panel when the button becomes active to upload the trace to the monitor The upload operation requires several seconds 18 On the uploaded trace note the general shape of POS LAG at the positive transition point of FLOW The objective is to find the best setting of R PGain for minimal overshoot and shortest settling time Referring to the waveforms in Figure 25 increase or decrease R_PGain and repeat steps 14 through 17 until a satisfactory critically damped response is obtained Use large increments of R PGain 50 or so initially until the upper and lower boundaries of a critically damped response are found then smaller increments SAM Configuration Manual P n 9031 011 987 Novemb
59. nts 1 In the Ri RegMode list entry box select REG MODE TORQUE In this mode the Position Controller is totally inactive and torque commands are supplied by an external source Free Mode Adjustments 1 In the Ri RegMode list entry box select MODE FREE In this mode the Position Controller is totally inactive and torque commands are supplied by an external source SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 51 SAM CONFIGURATION MANUAL EMERGENCY STOP FUNCTIONS Emergency STOP Functions Overview For additional information on safe drive functions and machine level safety and protective functions refer to the PAM and SAM System User s Handbook Part 3 Safety and Protective Functions Error Response Dedicated hardware in conjunction with extensive monitoring by the SAM Drive firmware detect and respond to error fault conditions occurring within the drive Four fault error response levels are defined STOP 0 immediate deactivation of the drive Power Stage STOP 1 controlled stop constant deceleration ramp followed by Power Stage deactivation after a delay STOP2 controlled stop as in STOP 1 but no Power Stage deactivation USER SIGNAL additional controlled stop similar to STOP 2 for non error fault conditions as defined by the application STOP 0 STOP 1 STOP 2 and USER SIGNAL conditions are treated as events by PAM and SAM which means their occurrence initiates a defined
60. olling To insure that a SAM Drive is properly configured for the motor it is controlling this procedure should be performed whenever a SAM Drive is installed in a SAM system or whenever existing motor parameters are invalid or suspect When downloading motor parameters be certain to select the correct file for the motor model connected to the SAM Drive Downloading incorrect motor parameters may cause unpredictable motor or drive behavior and possibly be harmful to the drive or motor Application related Parameters Some parameters related to the application position controller parameters etc have to be tuned to obtain the best performances of the system Refer to SAM Drive Tuning Procedure on page 42 for tuning procedure SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 13 SAM CONFIGURATION MANUAL SAM Toors Uploading Parameters SAM Drive configurations parameter sets may be uploaded to a Service PC for viewing editing saving or other purposes using SAM Tools During an upload the complete set of parameters in RAM is uploaded The uploaded parameter set when downloaded to an identical same model SAM Drive configures the drive exactly the same as the SAM Drive from which the parameter set was extracted The parameter values currently in RAM are uploaded to the Service PC where they are saved in the PARAMS subdirectory SAM Tools assigns the filename PARAMxxx SPA where xxx is incremented by one each
61. oring and archiving user created parameter panel and trace files Page 12 SAM Configuration Manual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM Toors Parameters SAM Tools provides the capability to download parameter files to a SAM Drive and upload parameters from a SAM drive into a file on the Service PC The parameter upload and download features provide the means for recording saving and replicating axis software configurations Downloading Parameters Parameters are downloaded into SAM Drive RAM memory where they remain until changed by command from a host PC PLC or SAM Tools via the service port Upon resetting the SAM Drive or upon power up all parameters are initialized to values saved in flash memory Upon receipt of a save parameters command the drive firmware copies an image of all parameters from RAM into flash memory Parameter value changes are immediately accessible to the drive firmware however the firmware uses certain parameters only during initialization To be saved parameters have to be copied into the flash memory using the SAVE command in the Parameters menu Doing that existing parameter values are overwritten and lost Existing SAM Drive parameter values may be preserved by uploading them to the service PC prior to downloading new parameters Motor Parameters Motor parameters must be downloaded to properly configure a SAM Drive for the motor it is contr
62. ot visible on the monitor press 1 on the SAM Tools toolbar to bring in back into the foreground Press to initiate a trace operation 5 Onthe Tuning Control Panel momentarily click and release to inject a torque disturbance and trigger the trace Press on the Trace Control window when the button becomes active to upload the trace to the monitor SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 47 SAM CONFIGURATION MANUAL SAM PosiTION CONTROLLER ITS TUNING 6 On the uploaded trace note the general shape of POS LAG at the transition points of TORQFLOW The objective is to find the setting of R IGain which reduces POS LAG to zero in the shortest time without increasing over shoot Referring to the waveforms in Figure 26 increase or decrease R IGain and repeat steps 4 through 6 until a satisfactory critically damped response is obtained Use large increments of R_IGain 50 or so initially until the upper and lower boundaries of a critically damped response are found then smaller increments until the best overall IGain setting is found The trace zoom feature may be used to expand the area of interest FHALAGIF FSHLACIF PSIGAGF Over damped response Critically damped response Under damped response increase R_IGain R IGain is fine decrease R IGain Sconf007 cdr Figure 26 Example waveforms for Step 6 7 Set the Feed forward compensation see Feed forward Compen
63. ote that the overshoot is significantly larger and settling time has increased but steady state position lag is smaller due to increased position loop gain Position Lag 100 100 4 200 4 300 4 400 TR347 500 tl 02 025 02 015 01 005 0 005 Of O15 02 025 03 Figure 15 PD Control Under damped Response Some Theory regarding PID Position Control PID control is similar to proportional plus derivative control but includes an additional loop with a gain K and an integrator This additional loop serves to eliminate static position lags resulting from static disturbances This loop can only correct static disturbances or disturbances with frequencies below it s cutoff frequency Foi This loop is by itself unstable due to the three integrations and is stabilized by the other two loops Unlike the proportional plus derivative case F cannot be set equal to Fop Stable operation is typically obtained at I E F 20 639 F with 1 5 K 2025 U e I Higher system stability is achieved by setting F Fc and Fo 0 63 Fo5 The system response may be fine tuned using a step response test SAM Configuration Manual Page 36 P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM PosiTION CONTROLLER ITS TUNING PID Controller Performance verses Tuning Figure 16 shows the effect of adding integral control to a proportional plus
64. otherwise limit the closed loop pass band The Position Controller employing totally digital techniques provides the benefits of precision and repeatability Two SAM Drives with identical tuning parameters respond identically in the same axis environment Other Controller operating modes including speed controller open loop vector controlled operation and direct torque control can be selected A position feedback device typically a resolver or encoder provides velocity and position feedback to the Position Controller Position Regulator Error Status notch filter torque limiter Position amp Velocity lt lag 2m Torque measured values dA LX gt gt Reference Proportional Gain Integral Gain Derivative Gain Position amp Velocity Feed set points Forward Inertia Static Friction Viscous Friction Torque _ Weight set points e SAS006_bCDR Figure 10 Position Controller Functional Diagram SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 27 SAM CONFIGURATION MANUAL SAM OPERATING SOFTWARE Position Measurement The Position Measurement function utilizing input from the Feedback Interface provides measured position and velocity data Position feedback is used by the Current Controller for commutating the motor currents and by the Position Controller for regulating motor speed an
65. ows the response 500 Position Lag _ 500 1000 1500 2000 T T T T T T T T T 18 0 3 0 25 0 2 0 15 0 1 0 05 0 005 0 1 0 15 02 0 25 03 Figure 18 PID Control Over damped Response Figure 19 shows decreased stability when Fo is increased to 40 Hz thus increasing F F to 0 8 while keeping F F 50Hz 500 Position Lag 250 Bi 250 TR333 1000 ts 03 0 25 02 0 15 0 1 0 05 0 0 05 0 1 0 15 02 0 25 03 Figure 19 PID Control Under damped Response In Figure 20 Fop is reduced to 35 Hz with F 32Hz and E 0 91 The result once again is decreased stability Mapa Position Lag 500 500 1000 1500 TR335 tg 200p T 0 3 0 25 02 0 15 0 1 0 05 0 0 05 04 0 15 02 025 0 3 Figure 20 PID Control Under damped Response SAM Configuration Manual Page 38 P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM POSITION CONTROLLER ITS TUNING Some Theory regarding Feed Forward Compensation When a driven system and it s behavior are well known it is possible to create a simplified mathematical model which takes into account the influences of disturbances such as weight static and viscous friction and the effect of load inertia during acceleration deceleration With a degree of precision which increases t
66. presents the pipe position of PAM Units depending on the working frequency 4 or 8 kHz are calculated as follow SpeedRef given units in the filed list 2 t POS REG period we have then at 8 kHz 279 60 0 915turn min 6000 AccelRef given units in the filed list 22 t POS REG period we have then at 8 kHz 272 e 60 3433 23turn min Setpoint units 2 MAIN CPU period MAIN CPU period is 2 kHz then 9592 60 27 94 e10 turn min JM 000 Interpreting and utilizing the Trace Display The trace display includes a number of useful features and capabilities to aid in measuring and analyzing the captured data including movable markers an optional grid and zooming capability Components of Basic Trace Display This paragraph provides a description of the components of a trace and how they are utilized and interpreted Figure 7 shows a two variables trace with components identified Page 22 SAM Configuration Manual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM Toors Trigger point Trigger position SAM Tools COM1 TRACE333 TRC Channel title W MEM DSP INT x013b INT16 gua Variable scales auto adjusted P poslag zm 1 INT16 0 25 0 2 0 15 EU 0 05 0 0 05 0 0 15 0 2 0 25 0 3 Chanel Ready SBEZV1 3 03 SFEBVI 300 RUNNING graphical area Time scale Sconf005 cdr Figure
67. r bit of status B indicates any of following error conditions e short circuit e open load condition e brake output transistor over temperature When the brake is enabled but no hardware option is available SAM DA 400 xxN the brake error bit is set By default when set the brake error bit generates a STOPO see chapter STOP 0 on page 53 SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 63 SAM CONFIGURATION MANUAL CHECKING SAM TO MOTOR WIRING Checking SAM to Motor Wiring Motor and Feedback Wiring Errors Errors in the resolver feedback wiring and motor windings wiring between a motor and SAM Drive may produce erratic motion This procedure provides a systematic method for isolating wiring errors between a Servomotor with standard single speed resolver and a SAM Drive Of the 720 possible ways to make resolver feedback connections to a SAM Drive only one arrangement is correct Of the remaining 719 incorrect configurations most produce a Resolver A Measurement Error 2 amp C on the SAM Status indicator A few incorrect resolver wiring configurations produce only erratic motion and in some cases an Excess Position Lag error 2 amp y on the SAM Status indicator This procedure is for isolating the causes of erratic motion where no Resolver A Measurement Error is indicated The situation with motor winding connections is similar Only one of the six possible arrangements i
68. rectory content Control Panel Components and their Operation This section describes the components of a control panel and their operation Figure 3 illustrates a sample control panel containing each of the available control panel component types with each component type labeled Each of the panel component types is described in the following paragraphs Page 16 SAM Configuration Manual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM Toors General Instructions for Control Panel Dialog Boxes For most types of dialog boxes SAM Tools places a border around the box when it has been opened and no other operations are allowed until the box is closed The border color is red initially and changes to blue when the value is changed Once the content of a box has been changed press the ENTER key to update the corresponding SAM Drive parameter field or press ESC the ESCAPE key to restore the original value and exit the box In order to display the current value of SAM Drive fields parameters a control panel must be updated Control panels are automatically updated when initially opened and when reactivated A user may update a control panel at any time by pressing the REFRESH PANEL button on the SAM Tools toolbar In order to display the current value of fields and parameters a control panel must be updated Control panels are automatically updated when initally opened and when re activated A user may update a con
69. red using a step response test PD Controller Performance verses Tuning Figure 13 shows the response of a SAM Drive and AHR 142C6 motor to a step torque disturbance equal to stall torque of the motor In Figure 13 the Controller is tuned for critically damped response Fep Foy 50Hz Note that the motor overshoots once by about 2096 then settles to a steady state position lag of 1050 units 5 8 degree 250 Position Lag 0 L 250 500 750 1000 1250 4 TR337 t s 1500 03 025 02 045 014 005 0 005 01 015 02 025 03 Figure 13 PD Control Critically Damped Response Figure 14 shows the same system response with 50 Hz and Fop 25 Hz damping ratio 2 over damped Note that at this damping ratio there is no overshoot however the settling time is longer and the steady state position lag is four times greater due to the reduction in position loop gain 1000 Position Lag 1000 2000 3000 4000 TR338 T T T T T T T T T 0 3 0 25 0 2 0 15 0 1 0 05 0 0 05 01 0 15 02 025 03 5000 Figure 14 PD Control Over damped Response SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 35 SAM CONFIGURATION MANUAL SAM PosiTION CONTROLLER ITS TUNING Figure 15 shows the same system response when Fey 50 Hz and Fop 100 Hz damping ratio 0 5 under damped response N
70. s it is enough to rename the directory SOCATOOL like above and to rename the selected directory in SOCATOOL How to install a Service Pack on a structure with several ProMotion versions Verify that the corresponding ProMotion version is installed and activated The directory SOCATOOL corresponds to the selected ProMotion version Page 10 SAM Configuration Manual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM Toors Setting up the COM Port When SAM Tools is installed COM1 port of the Service PC is selected by default To select COM port 2 perform the following For Windows 95 and 98 1 Access SAM Tools properties 2 Select shortcuts tab 3 Under target add COM 2 separated by a space i e xxxx SAM TOOLS EXE COM2 Getting Started with SAM Tools Top Level Window Status and Display Components Figure 2 shows the SAM Tools top level Window with the status and display components identified Table 1 provides a description of these components fi SAM Tools COM1 Biel A Device Firmware Parameters Advanced Log View Window Help BEEN Link Status Bootware Version Firmware Version Menu Bar Tool Bar Mainwin3 bmp Figure 2 SAM Tools Top Level Window link at time of last handshake Bootware Version display Bootware version residing in SAM Drive log message display Contains SAM Tools main pop down menus tool bar Contains buttons for activating SAM Tool functions
71. s bit in SAM Main Status is set STOP2 does not affect the Power Stage Brake Control or FATAL ERROR contact Stop2 Power ON Stage TmpStopDecel Speed Ref Brake On Output Fatal open Error closed STOP2 1 Executed 0 SAS024 B CDR Figure 35 STOP2 Execution SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 59 SAM CONFIGURATION MANUAL EMERGENCY STOP FUNCTIONS USER SIGNAL Activation The USER SIGNAL error response is similar to STOP2 except that it does not influence directly the SAM Drive operation It is used only for signaling to PAM and or to an internal sequence that a faulty condition occurred such as a motor temperature beyond warning limit so that the machine can be slowed down or stopped in a controlled way USER SIGNAL see Figure 36 can be activated in the following ways e A status condition pre defined by the application USER SIGNAL Action Mask to initiate a USER SIGNAL becomes true User Signal Action Mask ABCD Status lt 64 64 647 Qa P F 64 9 Latched USER SIGNAL 1 USER SIGNAL o W Figure 36 USER SIGNAL Activation Execution USER SIGNAL causes the following actions within the affected axis e The USER SIGNAL status bit in SAM Main Status is set User agna 1 User Q4en2R h ndr Figure 37 STOP2 Execution A USER SIGNAL does not open
72. s correct The 5 incorrect wiring arrangements cause erratic motion and in some cases an Excess Position Lag error 2 amp y on the SAM Status indicator Incorrect motor or drive parameters can produce symptoms similar to those caused by motor or feedback wiring errors Prior to performing this procedure verify that the SAM Drive contains the correct motor and drive parameters see reference to downloading motor and drive parameters for the axis configuration This procedure utilizes the Control Panel control panel name which is a standard panel provided with SAM Tools Checking Procedure When performing this procedure the motor may run at any speed and in any direction A Prior to performing this procedure take measures necessary to prevent risk of damage to the driven equipment and injury to personnel The correct wiring is described in the PAM and SAM System User s Manual Part 2 System Design and Integration Refer to it whenever necessary SAM Configuration Manual Page 64 P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL CHECKING SAM TO MOTOR WIRING step procedure normal response indication corrective action none none In this procedure the motor shaft must be rotated by hand and it must turn freely If necessary uncouple the load from the motor Connect SAM Drive on axis to be tested to service PC running SAM Tools Apply 24 VDC power to SAM After initialization SA
73. s regarding Position 31 Some Theory regarding PD Position 33 PD Controller Performance verses Tuning 35 Some Theory regarding PID Position 36 PID Controller Performance verses 37 Some Theory regarding Feed Forward Compensation 39 Benefits of using Feed Forward an example 39 Converting SAM Controller Parameters to usual units 41 SAM Drive Tuning Procedure sssssseeeeeeeneeene nennen 42 E 42 Preliminaries to Tuning eree reinis eem 42 Select the Position Controller Operating 43 PD Controller Adjustment Procedure esse 43 PID Controller Adjustment 47 Feed forward Compensation Adjustment 49 Torque Mode Adjustments ssssssseeeeeeeene nemen 51 Free Mode Adjustments eee eite nnnm treten 51 Emergency STOP Functions narsiai enm ennemis 52 OVCIVI
74. sation on page 49 8 Restore original value of the least significant digit of S MStopO AB recorded in step 5 of the Proportional plus Derivative tuning procedure 9 In the Ri RegMode Parameter Value list entry box select REG MODE PIDPOS Upon completion of this procedure only the tuning parameters in RAM memory have been revised The tuning parameter values in flash memory remain unchanged Parameter values in RAM memory are lost upon power down or resetting of the SAM Drive To permanently save the tuning parameters as well as all other parameters in flash memory press the SAVE PARAMETERS button on the Tuning control panel To create a file copy of the SAM Drive parameters see Uploading Parameters on page 14 Page 48 SAM Configuration Manual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM PosiTION CONTROLLER ITS TUNING Feed forward Compensation Adjustment Procedure This procedure is applicable for PD and PID controller modes only The Torque and Free controller modes do not utilize feed forward compensation The general sequence for setting feed forward compensation values is weight dry friction viscous friction then inertia 1 2 Setup the trace titled REGPOS STC which is found in the Promotion CMDS subdirectory On the Tuning control panel note the current value of R_IGain If R_IGain is non zero record the value then temporarily set IGain 0 Adj
75. ss the SAVE PARAMETERS button on the Tuning control panel To create a file copy of the SAM Drive parameters see Uploading Parameters on page 14 SAM Configuration Manual Page 46 P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM PosiTION CONTROLLER ITS TUNING PID Controller Adjustment Procedure This paragraph presents the step by step procedure for tuning any SAM Drive whose Position Controller is to be configured to operate in PID Proportional plus Integral plus Derivative mode accuracy than adding an integral part to the PD controller when the goal is to follow a tricky trajectory i e pick and place cam profile AND when load disturbances are relatively small i e 2076 of motor rated torque Keep mind that using the SAM Feed forward compensation provides better The first part of this procedure is identical to the procedure for tuning a proportional plus derivative axis 1 Perform step 1 through step 18 of the PD Controller Adjustment Procedure tuning procedure on page 43 2 In the Ri RegMode dialog box select MODE PIDPOS 3 If the axis inertia J is known a starting value IGain may be calculated using the following relationship M _ StallTorgq R IGain oR PGain e 10009 7 For M_StallTorq use the value displayed on the control panel If R_IGain cannot be calculated set E Toamna TA 4 Ifthe Trace Control panel is n
76. the FATAL ERROR contact SAM Configuration Manual Page 60 P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL EMERGENCY STOP FuNCTIONS Fatal Error FATAL ERROR is a SAM Drive output isolated relay contact set which is closed indicating no fatal error exists whenever all of the following conditions are satisfied e All internal supply voltages are okay the DC Bus voltage is not considered an internal supply voltage e Initialization and internal checking sequences have been successfully completed e Neither a STOPO nor STOP 1 internal error response has opened the FATAL ERROR relay The FATAL ERROR output opens immediately upon occurrence of any of the following events e Anyinternal voltage supply fails e Aninternal SAM Drive STOPO or STOP1 error response opens the FATAL ERROR contact SAM Brake Option Description The SAM Brake Option is available on all SAM DA 400 xxB xxx xxx Only the lowest current rated SAM DA 400 07 N xxx xxx are not fitted with this option This Option is fitted with a solid state output which reacts to short circuit and also to open circuit i e a brake wire gets broken Such errors are signalized as Brake error 24VDC Ext Y Undervoltage J 3 Y Brake A SL Driver r2 Current Short Circuit Qr Limitation gt Detection Brake1 y Y Open Lo
77. tics of each Controller mode Select an operating mode based on the axis configuration and performance required then tune the Controller using the adjustment procedures for the operating mode selected Controller Mode Performance Characteristics PD position control Classical PD proportional plus derivative control loop Average speed lag is zero Static position lag is proportional to disturbance torque PID position control Classical PID proportional plus integral plus derivative control loop Average speed lag is zero Static position lag in response to a disturbance torque is zero torque control Front end of Position Controller is disabled Application controls torque output directly free Position Controller produces a rotating current vector This mode is used for motor wiring check Table 9 Position Controller Modes PD Controller Adjustment Procedure This paragraph presents the step by step procedure for tuning any SAM Drive whose Position Controller is to be configured to operate in PD or PID mode Step 1 through step 18 of this procedure also used when adjusting PID Controller 1 Connectthe Service PC running SAM Tools to the Service port of the SAM Drive to be tuned 2 Verify SAM Drive to Service PC communications by performing a handshake 3 Setup the trace titled TUNING STC see Table 5 page 20 TUNING STC is found in the Promotion CMDS subdirectory SAM Configuration Manual P
78. time SAM Tools saves a parameter set The user may rename and relocate uploaded parameter sets using the standard Windows file commands from the MEE Menu Two types of parameter upload procedure are available a standard upload and an Upload with Template In the Upload with Template operation a user created template attached to the parameter file controls which parameters are uploaded and which are not Some pre defined templates are available in ProMotion see Table 3 file name upload allvvxx spa all parameters in alphabetical order appvvxx spa all parameters except drive specific ones Table 3 ACC Standard Upload Templates vv version number i e all20xx spa for version 2 0 Upgrading Boot Firmware The following procedure is for upgrading bootware and firmware of SAM Drive see Initialization on page 30 for definitions of bootware and firmware 1 Upload parameters with template App15XX SPA N Save parameters as contextual name e g Axis3 spa Stop the SAM k Download the new bootware SBEZxxxx sbi OC Download saved parameters with contextual name N Download the new firmware SFEZxxxx sfi Save all parameters 8 Start the SAM If a 24 VDC supply failure occurs during wring of the bootware program into flash memory the SAM Drive will become inoperative requiring factory repair Therefore we recommend this procedure be performed only when absolut
79. tion Controller Parameters and fields accessible to the user are labeled SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 31 SAM CONFIGURATION MANUAL SAM POSITION CONTROLLER ITS TUNING R MaxPosLag Sf STATUS AB it Mf POS MES gt R_PGain R MaxTorq Ampi GIS GR ESS Rf_POS_REF y Rf POS LAG Al Rf REG Rf TORQ QUIET 5 REF R MaxVelLag Sf STATUS AB Mf VEL MES pol BIt 0 R DGain Rf VEL REF 2 REVEL LAG Rf SPEED REF R StatFricTorq ca R ViscFricTorq Ampli mS gt RLExtTorg T FEED Ampli ACC REF gt Rf ACCEL REF R Inertia ST RE FLOW o o Rf_TORQ_FLOW Rf FLOW DESTINATION ovo Sconf001 cdr Figure 12 PD Position Controller A short listing and description of Controller parameters is found in Table 7 such as set gains thresholds or clamping limits for various functional elements of the Controller Detailed list is available in ProMotion Help SAM Parameters and Fields topic The more dynamic Controller input and output variables are defined as fields and presented in Table 8 All Controller parameters begin with the prefix R_ or Ri_
80. tions of the movement If POS LAG is gt 0 increasing R_INERTIA drives position lag in the negative downward direction SPEED REF MEM DSP INT 0x01a3 INT16 Delta 14 T 380g SPEED REF MEM DSP INT 0x01a3 INTI6 Delta 0 1600 T 2 1250 4 1280 4 j 1 I H 1000 4 1000 i I poe i i 760 4 y 1 750 4 1 1 i i i i 500 4 500 i i i i i i i i 1 1 i i i 1 i 250 4 250 4 54 Va 40 POS LAG MEM DSP INT 0 01 0 INTIB Delta 31 40 POS LAG MEM DSP INT 0x01a0 INTIB Delta 0 d Pumas gos IT 0 03 02 01 01 02 03 04 05 08 07 08 08 03 02 01 0 Of 02 03 04 05 06 OF 08 09 Position lag with no INERTIA compensation With correct R INERTIA compensation average position lag during constant speed is nearly 0 Watch the difference in vertical scales as it SconfoTo cor is automatically adjusted to the measure range Figure 29 Inertia compensation examples for Step 17 18 Repeating the whole procedure may enhance the precision of all feed forward compensation Then use other Travel Speed Acceleration and Deceleration settings such as near the highest normal running speed acceleration and decelerations to be used in actual operation 19 Restore the value of R_IGain recorded in step 2 Torque Mode Adjustme
81. trol panel at any time by pressing the REFRESH PANEL button on the SAM Tools tollbar Numeric Entry Box This type of box accepts numeric values To change the value click inside the box then modify the existing value or enter a new value The units of numeric entry boxes are the units of their corresponding fields in the SAM Drive The units are generally included in the box label Numeric values are displayed in decimal hexadecimal and scientific format The format used is a function of the corresponding field and panel setup PLAY PAN 1 Ri_RegMode VALUE REG MODE FREE Power Stage e _ Buttons with REG_MODE_NOTORQUE a LL argument PowerStege ON List box REG_MODE_PISPEED REG_MODE_POLYPOS REG_MODE_RESERVED REG MODE TORQUE Run 360 deg sec Buttons with List Ri RegMode VALUE fixed argument combo REG MODE PDPOS box Button with deg sec 1000 adjustable argument Button with Numeric st PesiionLag deg 2125854 dual action entry box StatusMAIN_ STATUS 000000004 IX C_HostAcknowledge VALUE Boolean Status entry box display StetusMAIN STATUS bit2 1 box Sconf004 cdr Figure 3 Control Panel with Component types Identified Status Display Box These are single bit read only boxes used for displaying the value of a single SAM Status bit Boolean Entry Box This typ
82. usting the Weight compensation If the axis weight or constant force i e produced by a spring is known enter the value in mNm in the R EXTTORQ numeric entry box If weight is unknown read the value of field RF_TORQQUIET As the motor is stopped while the SAM power stage is on and the SAM PD or PID controller has been previously tuned the produced torque fits mainly to weight Enter then this value in the R EXTTORQ numeric entry box Adjusting the Dry friction compensation If the axis static friction torque is known enter the value in mNm in the R STATFRICTORQ numeric entry box If static friction is unknown enter zero Setup the control panel for a slow speed move i e Travel Speed 360 Acceleration amp Deceleration 3600 Rel Move deg 720 START AMI On the Trace Control panel press to initiate a trace operation Click on to initiate an axis movement Press on the Trace Control panel when the button becomes active to upload the trace to the monitor On the uploaded trace estimate by eye the average value of POSI LAG Adjust R STATFRICTORQ then repeat steps 6 and 7 until average POS LAG is approximately zero See Figure 27 If POSI LAG is gt 0 increasing R STATFRICTORQ drives position lag in the negative downward direction POS LAG MEM DSP INT 0x01a0 INT1G 20 POS LAG MEM INT 0 01 0 18 Lo T tls 20 0 3 02 01 0 Of 02 03 04 05 08 OF 08 09 03 02 0
83. uted STOP2 1 0 Executed SAS023_B CDR Normal case Error case Deceleration Delay lt Timeout Deceleration Delay gt Timeout Figure 33 STOP1 Execution SAM Configuration Manual P n 9031 011 987 November 14 2000 Page 57 SAM CONFIGURATION MANUAL EMERGENCY STOP FUNCTIONS STOP2 Activation The STOP2 error response is similar to STOP1 except the Power Stage is disabled and there is no external user input STOP2 see Figure 34 can be activated in the following ways e STOP2 command from the PAM or from SAM Tools via the service port e status condition pre defined by Drive firmware STOP2 Forced Mask to initiate a STOP2 becomes true e A status condition pre defined by the application STOP2 Action Mask to initiate a STOP2 becomes true e STOP2 command from an application Sequence running in the SAM Drive STOP2 Action Mask 2 Forced Mask pus gt 64 64 ABCD 0 Status 64 64 64 g B 4 64 4 Latched STOP2 1 Stop2 Figure 34 STOP2 Activation Page 58 SAM Configuration Manual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL EMERGENCY STOP FuNCTIONS Execution STOP2 causes the following actions see Figure 35 within the affected axis e Axis decelerates to zero speed at a specified rate e The STOP2 EXECUTED statu
84. x encloses the selected area 4 Release the mouse button An expanded display of the selected area is created 5 Toreturn to the previous version of the trace select from the menu To return to the original version of the trace select from the MEME menu Page 24 SAM Configuration Manual P n 9031 011 987 November 14 2000 SAM CONFIGURATION MANUAL SAM Toors Test Device The SAM Test Device is an optional tool which can be inserted between the SAM RS232 servicing plug and the Service PC cable With this device two internal variables can be available on two analog outputs i e for monitoring on an oscilloscope The analog pan t device pan panel see Figure 8 allows selecting which variable is displayed on which output Set the DSP variable described Set the i960variable described below to the analog output 1 below to the analog output 1 EV ANALOG PAN olx Analog 1 lt dsp Analog_1 lt 960 UA 1092 26 0 0807 20 Ad 35791394 DSP VAR ID Type i960 R_SPEED_REF xj DATA FORMAT INT32 F Analog 2 dsp Analog 2 860 182 0 0807 20 Ad l 35791394 DSP i960 R POS LAG M DATA_FORMAT_INT32 Set the DSP variable described Set the i960variable described below to the analog output 1 below to the analog output 1 Sconf006 cdr Figure 8 Test Device Analog panel DSP variables can be selected directly within the scrolling list i960 varia
85. xpanded the time and variable scales are adjusted accordingly to retain a calibrated image Any sector of a trace within the graphical area of a channel may be zoomed When zooming is possible a magnifying glass symbol is displayed beside the mouse pointer Zoomed traces may be printed but not saved Perform the following steps to time zoom a trace 1 Position the mouse pointer inside the graphical area of a channel at one end of the area to be expanded The magnifying glass symbol must be visible next to the mouse pointer indicating that zooming is possible 2 Press and hold the left mouse button 3 While holding the mouse button down move the mouse pointer left or right and up or down as necessary to box in the area to be expanded 4 Release the mouse button An expanded display of the selected area is created 5 Toreturn to the previous version of the trace select from the menu To return to the original version of the trace select from the menu In order to zoom on area of a trace perform the following steps 1 Position the mouse pointer inside the graphical area of a channel at one corner of the area to be expanded The magnifying glass symbol must be visible next to the mouse pointer indicating that zooming is possible 2 Press and hold the right mouse button 3 While holding the mouse button down move the mouse pointer left or right to the other end of the area to be expanded As the pointer is moved a bo

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