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VirtualCNC Online Help File - MAL Manufacturing Automation

1. Electronic Drives D A Convertor bit bit DAC Voltage Range d Mo Current Amplifier Gain Ka Alt Transfer Function Motor Constant Kt NnvA Nm Rigid Body Dynamics Model with Rotary Motor Driven Mechanism Disturbance External Mass Spring Damper System at Saturation Motor Limit Control Signal Copyright 2015 Manufacturing Automation Laboratories Inc Page 47 Virtual CNC 1 5 5 Transfer Function Model s domain and z domain Configuration Click the Feed Drive icon in the Axis Servo Drive module and when the Feed Drive icon 1s highlighting select one radial button below the Transfer Function Model either s domain or z domain and click the Settings button Axis Trajectory Configuration Toolpath Files Generation Axis Servo Control SIMULATION Axis Servo Motion Controle Control Sampling Period Ts 00 fs Selection Summary AXIS DRIVE Reference Position Actual Position SS Er X Axis O X Axis Y Axis Z Axis Feedback Measurement Controller A Axis B Axis X Axis FEED DRIVE E Leadscrew Servo Drive Transfer Function Model Disturbance Flexible Ballscrew Drive Constant Linear Servo Motor z domain Rotary Servo Drive Manufacturing Automation Laboratory UBC Copyright 2015 Manufacturing Automation Laboratories Inc Page 48 S CNC pue p mini meas Axis Trajectory Conf
2. Copyright 2015 Manufacturing Automation Laboratories Inc Page 2 Zb CNC 0 1 Introduction Virtual CNC 1s a comprehensive virtual simulation software package developed for predicting the performance of a realistic and modular CNC system in a computer simulation environment It can be used as a learning tool as well as an optimization tool for a real CNC system Furthermore Virtual CNC assists users in the axis feed drive and controller design Virtual CNC has the following features Definition of new 3 Axis and 5 Axis machine Creating tool path or loading a saved tool path file CL file or APT file Configuring the trajectory generation including the kinematic profile interpolation type and smoothing type Flexible ball screw feed drive design and analysis Allow to try out various feed drive design alternatives control laws and sensors with different resolutions Advanced analysis of frequency analysis axis tracking error and contour error Allow to export the simulation results including the axis tracking error and contour error Copyright 2015 Manufacturing Automation Laboratories Inc Page 3 P CNC 0 2 Installing and Running Virtual CNC Run the Virtual CNC installer by double clicking the VirtualCNCIntallation exe and then double click VCNC exe to run Virtual CNC Loading and Creating Project Files From the File menu you can load any of the example files found in the
3. 4 A z az geet 4 27 Numerator P m m m 2 m 3 Order of Numerator ok B z Please enter the coefficients of the polynomials Denominator 2 3 H aZ uo a Order of Denominator OK A z Please enter the coefficients of the polynomials A z az iz taz Copyright 2015 Manufacturing Automation Laboratories Inc Page 50 SI CNC There are a significant number of control laws which can be implemented in CNC systems Typically any axis control law has two components the feedforward part which processed the reference position commands and the feedback part that shapes the measured states such as position velocity and acceleration to stabilize the closed loop dynamics The below figure 1s the axis control law in a standard form 1 5 6 Controller Configuration Feedforward Control Feedback Measurment Feedback Control D Z and D Z are the matrices corresponding to the feedforward and feedback transfer functions respectively in the discrete time domain X k is the reference axis command state vector and X k 1s the axis measurement state vector Virtual CNC has a number of user reconfigurable control law which have all been experimentally proven on the open CNC system The conventional control laws include Adaptive Sliding Mode Control ASMC Lead Lag Control LL C Digital Position P Analog Velocity PI control P PI Digital Position P Control P Di
4. N of the constant external disturbance If you select From File Option you should load a file after clicking the Browse button Copyright 2015 Manufacturing Automation Laboratories Inc Page 54 S CNC If you select Disturbance Signal Generator option after clicking the Settings button you can open the interface below Then you can define the disturbance signal Current Axis Step Ramp Square Wave O Sine Wave Sawtooth Wave Wait Time Cycle Time Copyright 2015 Manufacturing Automation Laboratories Inc Page 55 Virtual CNC 1 5 7 Feedback Measurement Configuration Click the Feedback Measurement icon in the Axis Servo Drive module to open the interface of Feedback Measurement Then choose one type of the three options of feedback measurement to the feed drive The three options are position velocity and acceleration B Feedback Measurement os mc Current Axis Axis 7 Position Feedback Measurement Linear Iv Position Resolution mm count mm 2 Velocity Feedback Measurement Linear Velocity Resolution mm s count Measurement Noise Variance mm s 2 Acceleration Feedback Measurement Linear Acceleration Resolution mm s 2 count Measurement Noise Variance mm s 2y2 Gen Ai Copyright 2015 Manufacturing Automation Laboratories Inc Page 56 D virus CNC Now you have finished all configurations In
5. Stop Stops the controllers therefore stopping the machine via software Trajectory Control Start start or Resume the programmed trajectory Trajectory Trajectory Control Pause Pause the programmed trajectory at its current Trajectory position WARNING This will stop the machine in its current position suddenly causing a large deceleration and jerk Trajectory Control Stop This stops the trajectory similar to Pause Trajectory however it resets everything so that it will start from the beginning next time Trajectory Control Feed Rate Allows the trajectory speed to be adjusted from 0 Override below Stop to 200 of original trajectory speed 100 is Trajectory original speed Trajectory Control Tracking Safety to limit Tracking Error if individual axis Error exceeds limit the output voltage is shut off Save Results Save data collected during Trajectory execution output formats are csv and mat Spindle Control Spindle Speed If this option is selected it adds the entered Adjust RPM spindle RPM to the originally commanded RPM Can be negative spindle Control Spindle Speed If this option 1s selected it scales the originally Adjust 96 commanded RPM by the entered value 0 to 200 spindle Control CMD RPM Displays the currently commanded RPM Spindle Control CMD Volt Displays the voltage currently sent to the machine for RPM control Copyright 2015 Manufacturing Automation Laboratories Inc Page 65 Axis Co
6. Transfer Function in s Domain G 5 LODEL T eb eb eb 5 AS as eas e ass e ass tt Numerator B s hys bs bos bus D MET Order of Numerator 2 OK B S Please enter the coefficients of the polynomials 2 s 1 sn 29337 67 831 2875656 5194 Denominator n A s ays as ays 3 n 3 ays Tu Order of Denominator 94 Ok A S Please enter the coefficients of the polynomials O M s 3 Gei s i 0 098696 66947 283815 9224 Copyright 2015 Manufacturing Automation Laboratories Inc Page 42 PZ CNC Click the LOAD button to select and open the tf file which was exported before as the transfer function of the flexible ball screw drive model After loading the exported flexible ball screw transfer function you can see the detail 1nformation of the flexible ball screw transfer function including the numerator order of numerator denominator and order of denominator of the flexible ball screw transfer function After clicking the OK button you finish importing the flexible ball screw transfer function Copyright 2015 Manufacturing Automation Laboratories Inc Page 43 es D virtua CNC Click the Feed Drive icon in the Axis Servo Drive module and when the Feed Drive icon is highlighting select the Linear Servo Motor radial button and click the Settings button 1 5 3 Linear Servo Motor Configuration Bb Virtual cnc File Help Trajectory Axis Servo Control SIMULATION Ge
7. Virtual CNC 1 5 4 Rotary Servo Drive Configuration Click the Feed Drive icon in the Axis Servo Drive module and when the Feed Drive icon is highlighting select the Rotary Servo Drive radial button and click the Settings button Trajectory Axis Servo Control SIMULATION Generation Configuration Toolpath Files Axis Servo Motion Control Control Sampling Period Ts 001 s Selection Summary AXIS DRIVE Reference Position Actual Position ESE __ pe A Axis X Axis Y Axis ot Z Axis me UN em O A Axis B Axis C Axis Leadscrew Servo Drive Transfer Function Model Disturbance Flexible Baliscrew Drive s domain Linear Servo Motor z domain Manufacturing Automation Laboratory UBC This opens the interface of Rotary Drive Parameters Three sections of the parameters for the rotary drive should be set up properly Dynamic Loads Mechanical Settings and Electronic Drive By clicking the Block Diagram button on the bottom you can see the block diagram structure of Rigid Body Dynamics Model with Rotary Motor Driven mechanism Copyright 2015 Manufacturing Automation Laboratories Inc Page 46 S CNC Dynamic Loads Contact Inertia Inertia in Linear Model Non Contact Inertia Contact Damping Damping in Linear Model ii ae Non Contact Damping Nm rad s Mechanical Settings Coulomb Friction Gear Reduction Ratio Backlash
8. X Axis Axis Drive Model General System S domain Axis Controller Proportional Integral Derivative Controller Axis Y Axis Axis Drive Model General System S domain Axis Controller Proportional Integral Derivative Controller Interpolation Type Linear Circular Interpolation Profile Selection 9 Linear Model Non Linear Model p Domain Response Results Tool path E Control Signal Contour Error Tracking Error Motor Torque Violation Spot lt gt D Y Ba L Ba d A Q Diamond Profile Settings Magnitude mm Tool Position Information S P1 Pi xy 0 00 0 00 P2 xy 35 36 35 36 P3 x y 0 00 70 71 S Starting Position P4 x y 35 36 35 36 wp Direction of Motion Command Feedrate 8000 mm min Copyright 2015 Manufacturing Automation Laboratories Inc Page 70 Virtual CNC Overview of how VCNC Real Time works VCNC Simulink Diagram BM Controller Simulation Ccreates Simulink Diagram gt Reference Trajectory Output Results Real Time Simulink Diagram Replace Plant with dSpace connected to Real Plant f Simulink Real Time eg ipis Fa Controller Output Results Workshop rajectory Lee Compile C code Load C Code onto Real time computer Launch VCNC GUI Real Plant Machine dSpac
9. examples folder VCNC Virtual CNC Examples or can create a new project Ctrl O i Cat E oe BR Toolpath Files Trajectory Axis Servo Control SIMULATION Generation Axis Configuration 3 Axis Machining 9 5 Axis Machining n Manufacturing Automation Laboratory UBC Copyright 2015 Manufacturing Automation Laboratories Inc Page 4 D vince CNC The following example files are provided with Virtual CNC They can be found in the Virtual CNC Examples Directory under your main VCNC directory 0 3 Example Files To open an example file select File Open in the main Virtual CNC window The examples are included within the VCNC Virtual CNC Examples folder and are divided into four subfolders Ex01 Kinematic Configurations Two examples for kinematic configurations The example project Ex01A_3 Axis Rigid Drive Example vcnc is configured X axis Y axis and Z axis feed drive as the lead screw rigid drive The example project Ex01B_5 Axis Rigid Drive Example vcnc is configured the X axis Y axis and Z axis feed drive as the lead screw rigid drive and configured B axis and C axis feed drive as the rotary drive Ex02 Flexible Ball Screw Drive Systems An example for flexible ball screw drive systems The example project Ex02 Flexible Ball Screw Drive Systems vcnc is configured X axis Y axis feed drive as the flexible ball screw and Z axis feed drive as the lead screw rigid drive The result shows that
10. CommandFileExample 5axis_sim dat Trajectory Generation Kinematics Profile Trapezoidal Velocity Servo Feed Drive System Sampling Time s Feed Drive Controller Disturbance Rigid Body Leadscrew Drive Pole Placement Controller Constant Disturbance General System in S Domain Proportional Integral Derivative Controller Constant Disturbance General System in S Domain Proportional Integral Derivative Controller Constant Disturbance Rigid Body Rotary Motors Pole Placement Controller None Rigid Body Rotary Motors Pole Placement Controller None n Manufacturing Automation Laboratory UBC After the simulation you can select the axes to check the simulation results and click the 1cons m in the Simulation and Results Toolbox to get the corresponding plot You also can use the Advanced Analysis Toolbox to gain the detail information about the Frequency Response Axis Tracking and Contouring error Copyright 2015 Manufacturing Automation Laboratories Inc Page 58 D virus CNC 1 6 1 Virtual CNC Real Time Implementation Quick Start Guide A sample application of the real time implementation will be shown below for a 3 axis Fadal machining center Step 1 Loading a Model Open VCNC and load the example file located in Virtual CNC Examples Ex0O1_Kinematic Configurations ExO1A_3 Axis Rigid Drive Example vcnc This is done by going to File gt Open in VCNC Step 2 Simulating the Model The settings within VCNC can be changed h
11. Generation SS Trajectory Limits iii Kinematic Profile Q rapezoidal Velocity Joint Axis RERO Trapezoidal Acceleration qns Cubic Acceleration X Optimized Feedrate EY E Input Shaping Interpolation Type Continuous Interpolati v HSM Smoothing Fiz Joint Limits Set li Spline Compressor Trajectory planning with respect to the given velocity acceleration jerk or torque limits of each drive axis Manufacturing Automation Laboratory UBC If you check the Spline Compressor the spline compressor will be applied for your project as a smoothing type Copyright 2015 Manufacturing Automation Laboratories Inc Page 22 D vince CNC 1 5 Axis Servo Control Configuration In Virtual CNC you can select control law lead screw ball screw or linear drive parameters as well as amplifier motor friction field and sensor so that most machine tools can be reconfigured automatically The axis commands are passed on to the control law which shapes the overall response of the feed drive transfer function consisting of Digital to Analog D A converter amplifier servo motor inertia viscous damping guideway friction and lead screw backlash The axis can be configured to have acceleration velocity and position sensors with defined accuracy and noise parameters The position error of each axis is evaluated in the feedback loop and combined to predict the contouring er
12. Module you ll configure and build the kinematical structure of a machine tool for your CNC system and check if the machine structure configuration 1s feasible Bunn NS CONNENSSSSSMM emm Axis d Trajectory Configuration Toolpath Files Ce Axis Servo Control SIMULATION Axis Configuration Manufacturing Automation Laboratory UBC To configure a 5 axis machine select the 5 Axis Machining radial button first and then click the Configure button to open the 5 Axis kinematics Module configuration interface Copyright 2015 Manufacturing Automation Laboratories Inc Page 8 CJ CNC Five axis Machine Toolbox Spindle Rotating SR Rotary Table RT Hybrid HT Kinematic Chain for SR Machine z oom Machine Coordinate System MC S 0 0 0 Show Coordinate Workpiece Location Optimization Cartesian Drives Offset of Cartesian drives w rt MCS X 0 Y O0 Z 0 Work Piece Rotate coorindate system Rotation of axis with respect to LCS T2 1stRotation deg 2nd Rotation deg Axis amp Angle X X Offset w rt linear drive X 0 Y 0 R primary e Axis Rotation of axis with respect to LCS T3 1stRotation deg 2nd Rotation deg Axis amp Angle X X Offset Rotation of axis with respect to the LCS of primary axis 1stRotation deg 2nd Rotation deg Axis amp Angle X X Offset Tool Rotate coorindate system Rotation of
13. axis with respect to LCS of secondary axis 1st Rotation 2nd Rotation Axis amp Angle X Offset w r t MCS x 0 Y 0 ra 0 The 5 Axis machine must be configured with the following five steps Step 1 Selecting the Structural Type There are three options for the structure type Spindle Rotating SR Rotary Table RT and Hybrid HT e With the Spindle Rotating SR structure both rotary axes are built on to the spindle part so the orientation motion 1s driven by the spindle e With the Rotary Table RT structure both rotary axes are built on to the linear XY table and the workpiece 1s fixed on top of the rotary table The orientation movement is driven by the workpiece e As a hybrid form of the above structures Hybrid HT is designed as one rotary axis built on the spindle and the other on the XY table Copyright 2015 Manufacturing Automation Laboratories Inc Page 9 D vince CNC Then you should specify the Kinematic Chain based on the machine structure type selected on the step The Kinematic chain relates 6 coordinate systems The Machine Coordinate System contains 5 subsystems Cartesian Drives Work Piece Primary Secondary and Tool Particularly the Primary and Secondary systems should be set with a rotary axis from X Y and Z Step2 Configuring the Kinematic Chain After the rotary axes are specified the offset and rotation of each subsystem can be set The constant offset values for X Y Z should be set
14. based on its reference system Similarly if there 1s a constant rotation between the current system and its reference system then the Rotate Coordinate System check box should be chosen The 1st and 2nd rotation axis and its angle value can then be configured separately Step3 Building the 5 Axis Machine The configuration results can be displayed by clicking Build in and the machine with rotary axes will be presented The coordinate of each system can be turned on or off by clicking the Show Coordinate button and the Hide Coordinate button The Rotate Zoom and Pan buttons will help you view the virtual machine structure better Step4 Checking the Configuration Feasibility It 1s necessary to check the configuration feasibility before proceeding by clicking the Configuration Feasibility Check button Step5 Save and quit If the configuration 1s feasible after step 1 4 you should click the OK button to save the configuration and click the close button to quit Copyright 2015 Manufacturing Automation Laboratories Inc Page 10 1 3 Reference Toolpath File Configuration S CNC Virtual CNC accepts reference toolpath generated on CAD CAM system in the form of industry standard Cutter Location CL format Each block in the CL file contains NC block numbers tool paths in the form of linear circular and spline segments the cutter dimensions tool center coordinates and feed speed for machining a particular part on a CNC m
15. mum m S M NS UN m uu mum EM E 9 Oo 9 OS So NN o NN So UN Modeling of Feed drive system i 1 j H 5 e Non Linear Friction Oe Dynamics E g Excluding viscous damping i l E I t Ratio Ee GE FR From i Mot c i oe D E Actual Axis Controller DAC Voltage ol Inertia and Backlash fj Quantization Saturation Gain Viscous Dampi Position fi with ZOH Velocity Measurement j Noise Xa J rr e To TV T 1 i Controller s Xn Jet EE il Position Measurement Noise Ti When the Feed Drive icon is highlight in the interface of Axis Servo Control module you can see the configuration interface Axis Trajectory Configuration JOD wes Generation Axis Servo Control SIMULATION Axis Servo Motion Control Control Sampling Period Ts I5 AXIS DRIVE Reference Position Actual Position eege O X Axis Y Axis Z Axis Eescht VS RARE Controller A Axis B Axis X Axis FEED DRIVE C Axis Leadscrew Servo Drive Transfer Function Model Disturbance Flexible Ballscrew Drive s domain None Linear Servo Motor z domain Rotary Servo Drive amp Manufacturing Automation Laboratory UBC Copyright 2015 Manufacturing Automation Laboratories Inc Page 25 Virtual CNC 1 5 1 1 Leadscrew Servo Drive Configuration The leadscrew servo drive includes two types Rigid Body Dynamics Drive and Flexible Ballscrew Drive If you select the Rigid Body Dynamics Driv
16. rive Transfer Function Model Disturbance Flexible Ballscrew Drive s domain Linear Servo Motor z domain Rotary Servo Drive amp Manufacturing Automation Laboratory UBC Copyright 2015 Manufacturing Automation Laboratories Inc Page 40 QD virtua CNC H cw ic Loa Total Reflected Inertia J kgm 2 Viscous Damping B Nms rad Use Advanced etin gs Flexible Ball Screw Setngs Electronic Drive D A Converter bit bit DAC Voltage Range V Current Amplifier Gain Ka AN Transfer Function rom Motor Constant Kt Nm A Torque Limit ax Nm Mechanical Drive Pitch Length mm Gear Reduction Ratio Transmission Ratio rg mnvrad Include Friction Model Settings After opening the interface of Leadscrew Drive Parameters you should check Flexible ball screw and click the settings button in the Dynamic Loads section to open the Interface for loading the flexible ball screw transfer function Copyright 2015 Manufacturing Automation Laboratories Inc Page 41 Virtual CNC Transfer Function in s Domain 6 0 x Wi Af eh egt ag nd d As ays cas eas 7 as tat Numerator B s hys bs bys bys b Order ot Numerator OK Ga B S Please enter the coefficients of the polynomials Denominator 3 n l n n 2 n A S dys tas 45 taS t td Order of Denominator L oe A S Please enter the coefficients of the polynomials
17. the flexible ball screw feed drives have vibrations Ex03 Active Damping of Drives Two examples for active damping of drives These projects are based on the example project Ex02 Flexible Ball Screw Drive Systems vcnc and implement two methods to actively Copyright 2015 Manufacturing Automation Laboratories Inc Page 5 SS vince CNC dampen vibrations occurring in flexible ball screw feed drives input shaping and accelerometric feedback The example project ExX03A Input Shaping vcnc applies input shaping within the trajectory generation module The example projectEx03B Accelerometric Feedback vcnc uses active damping within the P PI controller Ex04 Trajectory Generation with Splines Two examples for configuring the trajectory generation with splines These example projects are namedEx04A 3Axis Trajectory Generation with Splines Optimized Feedrate vcnc and Ex04B 5Axis Trajectory Generation with Splines Optimized Feedrate venc and optimize the feed rate profile when generating the trajectory path for 3 axis and 5 axis configurations respectively Copyright 2015 Manufacturing Automation Laboratories Inc Page 6 SD virus CNC 1 0 User Manual 1 1 Overview of Virtual CNC Virtual CNC could predict the performance of a realistic and modular CNC system in a computer simulation environment But before the simulation you should configure the trajectory generation axis feed drive controller and so on Virtual
18. the Simulation Module you will see the simulation results by running simulation First you should define the output resolution reduction ratio and specify part tolerance 1 6 Simulation Configuration File Help Axis Trajectory Configuration Toolpath Files Generation Axis Servo Control Simulation and Results Select Ax es to Plot F X Axs H Y Axis E Z Axis JAAxis B Axis C Axis Position DA External m Velocity Disturbances Acceleration Disturbance Specified Part Tolerance a mm m Jerk mos Error oos Sat Reference m Contouring Error Trajectory Advanced Analysis Violation Spot Motor Torque Force Detection Frequency Response Toolbox m Control Signal Friction Torque Force Axis Tracking Toolbox Contouring Toolbox Manufacturing Automation Laboratory UBC co to get the corresponding plot To proceed to the Simulation Summary click the Run Simulation button and open the interface Simulation Summary which shows a summary of the machine setup including the axis configuration tool path file trajectory generation and feed drive system Click the Continue button and the system will start the simulation and show the simulation results Copyright 2015 Manufacturing Automation Laboratories Inc Page 57 es D virtua CNC mem Bl virtual CNC File Help Axis d Trajectory Configuration Toolpath Files E Axis Servo Control Axis 5 Axis Toolpath File C VCNC Examples
19. with much more jerk while Cubic Acceleration will give smoothest feed profile You can choose one type by selecting the radial button and clicking the Settings button Then each interface of the three types will be open in the right part of the window Copyright 2015 Manufacturing Automation Laboratories Inc Page 14 D virus CNC The velocity limit acceleration limit and jerk limit should be set properly Trapezoidal Velocity Trapezoidal Velocity Velocity Continuity Position Acceleration mm mm s4 ALim mm s 2 2500 Time sec Time sec DLim mm s 2 VLim mm s 250 Velocity mms Time sec Time sec 00 Low Smoothness Kinematic Profile Generates trajectory using trapezoidal velocity which has discontinuous acceleration profile and infinite jerks Copyright 2015 Manufacturing Automation Laboratories Inc Page 15 D virus CNC Trapezoidal Acceleration Trapezoidal Acceleration Acceleration Continuity Position Acceleration Alim mmi s uf mm 521 2500 Time sec Time sec DLim mmis 2 VLim mm s 2500 JLim mm is 3 Jerk 50000 mm s3 Time sec Time sec Generates trajectory using trapezoidal acceleration profile which has continuous acceleration and discontinuous jerk profiles Copyright 2015 Manufacturing Automation Laboratories Inc Page 16 Virtual CNC Cubic Acceleration Cubic Acceleration Acceleration Continuity
20. you can plot fit and export the transfer function Copyright 2015 Manufacturing Automation Laboratories Inc Page 37 SD virus CNC Lu Interface Transfer Functior l WE a PEER x Method Setup i Cut Off Frequency Hz 1 ing rati 0 8 Automatic Damping ratio Include rigid mode Number of modes 1 v 0 6 VO setup 0 4 Input node Degree of freedom to consider x Oy z J r roll J p pitch J y yaw Output node Degree of freedom to consider y z r rol p pitch y yaw You should define all the parameters in the Method Setup and I O setup sections first It includes defining Manual or Automatic if you want to include rigid mode Cut Off Frequency Damping ratio and the number of modes input node and output node After finishing the definition of all the parameters click the Plot button the magnitude and phase angle of the frequency response function will be shown Click the Fit button and the frequency response function curves from the finite element model are fitted and plotted Click the Export button to export and save the transfer function file of the flexible ballscrew drive model which 1s saved as a tf file The coefficients of the ballscrew drive transfer function can be extracted from the tf file and input in the transfer function model in s domain Copyright 2015 Manufacturing Automation
21. ALim mm s 2 Position TET 2500 mm Acceleration tmm s2 Time sec Time sec VLim mmis Dtm mmis 250 2500 ER JLim mm s 3 ms Jerk 50000 mm s3 Time sec Time sec High Smoothness Kinematic Profile Generates trajectory using cubic acceleration profile which suggests the smoothest motion with a smooth jerk profile Copyright 2015 Manufacturing Automation Laboratories Inc Page 17 P CNC Optimized Feedrate Bspline Feedrate ALim mm s 2 Position u 2500 mm Acceleration Imm s2 Time sec tene sec VLim mm s DLim mm s 2 250 2500 Velocity JLim mm s 3 mms Jerk 50000 mm s3 Time sec Optimized Kinematic Profile Generates trajectory using optimized feedrate profile which suggests the time optimal motion with a continuous jerk profile Copyright 2015 Manufacturing Automation Laboratories Inc Page 18 S virus CNC Input Shaping is a filtering technique to block those harmonics of the command which coincide with the structural modes of the axis drives Frequency and damping of the structural mode 1s required in order to set a shaper which avoids excitation of that mode 1 4 2 Input Shaping There are currently three types of input shapers available in Virtual CNC ZV Zero Vibration ZVD Zero Vibration and derivative and EI Extra Insensitive The ZV shaper brings a half vibration period delay The ZVD shaper causes a delay equal to a full vibration peri
22. CNC has five modules to simulate Axis Configuration Toolpath File Trajectory Generation Axis Servo Control and Simulation Axis Trajectory Configuration Toolpath Hies Generation Axis Servo Control SIMULATION Axis Configuration In Axis Configuration Module you can build and configure a 3 Axis or 5 Axis machine structure and check the feasibility Toolpath File In Toolpath File Module you should create or load a toolpath file as the reference toolpath file Trajectory Generation In Trajectory Generation Module you should select the trajectory requirements which include constant trapezoidal cubic acceleration and optimized feedrate profiles The interpolation type also has two options point to point and continuous interpolation Axis Servo Control In Axis Servo Control Module you can configure the feed drive controller feedback and disturbance based on your own axis Servo drive and control law Simulation You ll get the simulated results including actual toolpath tracking error and contouring error by running simulation In the advanced analysis toolbox you also can analyze the frequency response axis tracking and contouring Copyright 2015 Manufacturing Automation Laboratories Inc Page 7 e PZ CNC 1 2 Axis Configuration The Axis Configuration module has two options 3 Axis Machining and 5 Axis Machining Nothing needs to be configured for 3 axis machine In the 5 Axis Machine Configuration
23. Laboratories Inc Page 38 y F j Virtual CNC Method Setup SE Cut Off Frequency Hz 2000 WEEN Damping ratio 002 Include rigid mode Number of modes 4 VO setup put node 51 Degree of freedom to consider Ox Oy Oz Oriol Op pitch y yaw Outputnode 50 Degree of freedom to consider x Oy Oz Or Op pitch y yaw Magnitude dB Angle deg 220 3 4 10 10 10 10 10 Frequency Hz 10 10 10 10 10 Close the configuration interfaces of the flexible ballscrew Copyright 2015 Manufacturing Automation Laboratories Inc Page 39 es D virtua CNC 1 5 2 3 Loading the Transfer Function of a Ballscrew Drive If you want to import the transfer function which was exported from the flexible ball screw module to replace the parameters of J and B in rigid body model you should open the interface of the Leadscrew Drive Parameters first Selecting the Leadscrew Servo Drive and clicking the settings icon you can open the interface of Leadscrew Drive Parameters Axis Trajectory Configuration Toolpath Files EGER Axis Servo Control SIMULATION Axis Servo Motion Control Control Sampling Period Ts 000 s Selection Summary AXIS DRIVE Reference Position Actual Position if I E X Axis X Axis Feed Drive e Y Axis Leadscrew e Z Axis zT surement Controler A Axis B Axis X Axis FEED DRIVE C Axis gt Leadscrew Sei
24. achine tool In the Toolpath Files module interface options of reference toolpath type can be selected Command Line File or CL APT file Trajectory Generation Toolpath Files Please select a type of toolpath file Command Line Files Define toolpath by Command Lines Create toolpath file using command lines CL APT Files Axis Servo Control SIMULATION Please select the type CL APT file generated by CAD CAM processing systems APT CL Files aptsource Select a toolpath file Preview Toolpaih Copyright 2015 Manufacturing Automation Laboratories Inc Manufacturing Automation Laboratory UBC Page 11 Ti CNC If you select CL APT file you should select a CL APT file which has been generated from on CAD CAM system If you select Command Laine File two options are given to define a toolpath e Click the button Create toolpath file using command lines to open the Command Line Window to define a toolpath e Click the button Browse to select a toolpath file Some simple toolpath files are also provided in the Examples CommandFileExample folder After selecting or defining a reference toolpath click the button Preview Toolpath to check the toolpath and the button Preview File to check the file 1 4 Trajectory Generation Configuration In trajectory generation section the tool path 1s interpolated into tiny segments according to different interpolation strategies The data of each
25. c Negatwe Coulomb Friction Tc Static Faction on Guxdeway Pos amp ive Static Friction Ts Negative Static Friction Ts Velocity Constants Posstive Velocity Constant 1 Omega1 Negative Velocity Constant 1 Omegat Positive Velocity Constant 2 Omega2 Negatwe Velocity Constant 2 Omega2 See Fnction Curve Nm Nm Nm Nm rad s rad s rad s rad s Then you can select between two types of models Coulomb Friction and Stribeck Friction and specify the friction parameters The friction curve will be shown after you click the See Friction Curve icon Copyright 2015 Manufacturing Automation Laboratories Inc Page 30 Virtual CNC Friction Curve by considering Coulomb Friction only Fnction Torque T Stribeck Friction Curve for two lubricated metallic surfaces in contact Fnction Torque T Copyright 2015 Manufacturing Automation Laboratories Inc Page 31 D virus CNC Ball screw drives provide thrust and linear motion at the machine tool table by transmitting power from a rotary motor through a ball screw mechanism They are commonly used in machine tools because of their relatively high stiffness to cutting force disturbances and low sensitivity to variations in workpiece inertia as a result of their inherent gear reduction ratio 1 5 2 Flexible ball screw Configuration If you select a ball screw drive for one axis you should configure the axis drive i
26. ctory Generation fee Kinematic Profile Interpoaltes linearly and stops at the end of each segment lrape idal Vel ity Trapezoidal Acceleration Cubic Acceleration Optimized Feedrate CEOE Set Interpolation Type Point to Point Interpol v HSM Smoothing amp Manufacturing Automation Laboratory UBC Copyright 2015 Manufacturing Automation Laboratories Inc Page 20 Virtual CNC Continuous Interpolation Bl Virtual cnc Trajecto Toolpath Files pesos Axis Servo Control SIMULATION Configuration Generation Trajectory Generation Spline Interpolation Kinematic Profile a ee a aaa am THEIR ity e M Angular Trapezoidal Acceleration Tolerance Cubic Acceleration Optimized Feedrate Orientation Vectors ll Input EM Set Interpolation Type Cornering Tolerance Splining Continuous Interpolati v Tolerance Linear amp Rapid Moves HSM Smoothing Joint Limits Spline Compressor Manufacturing Automation Laboratory UBC Copyright 2015 Manufacturing Automation Laboratories Inc Page 21 S CNC The HSM Smoothing has two options Joint Limits and Spline Compressor 1 4 4 HSM Smoothing Configuration If you check the Joint Limits you should click set 1con to configure the parameters 1n the Trajectory Limits interface J Virtual CNC Axis Trajectory Toolpath Files Axis Servo Control SIMULATION Configuration Generation Trajectory
27. e you can configure it by clicking the radial button before the Leadscrew Servo Drive first and then clicking the Settings button to open the configuration interface of the rigid body dynamics drive If you select the Flexible Ballscrew Drive you can configure it by clicking the radial button before theLeadscrew Servo Drive first and then clicking the Flexible Ballscrew Drive button to open the configuration interface of the flexible ballscrew drive Bl vius cnc RER Trajectory Tooipath Files Generation Axis Servo Control SIMULATION Configuration Axis Servo Motion Control Control Sampling Period Ts 0 001 s Selection Summary AXIS DRIVE Reference Position Actual Position O X Axis X Axis Feed Drive Y Axis Leadscrew Z Axis TS tir ment Controller None AAxis B Axis X Axis FEED DRIVE C Axis gt Leadscrew Servo Drive Transfer Function Model Disturbance Flexible Ballscrew Drive s domain None Linear Servo Motor z domain Rotary Servo Drive amp Manufacturing Automation Laboratory UBC Copyright 2015 Manufacturing Automation Laboratories Inc Page 26 D virus CNC When selecting the Leadscrew Servo Drive and clicking thesettings icon you can open the interface of drive parameters and input physical parameters of the drive 1 5 1 2 Leadscrew Servo Drive Rigid Body Dynamics Three sections of the parameters for the rigid body dynamics drive should be se
28. e Real Time Computer VCNC Real Time Graphical User Interface User Control Copyright 2015 Manufacturing Automation Laboratories Inc Page 71 Virtual CNC 1 7 Export Results Export Results function under File menu can be used to export the useful simulated toolpath and error data by users After simulation you can export the simulated results including the tracking error and contour error by clicking the File menu and selecting Export to open the interface of exporting results B Virtual CNC LL Hap New Ctrl N Open Ctri O p Export Ctri E Save Giras Le TE Trajectory Axis Servo Control Generation Exit Simulation and Results Select Ax es to Plot Pixies FlYAis FiZAus Anis OBAis C is gt Run Simulation Positio i m osition Fong Output Resolution Reduction Ratio Ns m Velocity Disturbances 1 m Acceleration Disturbance iN Specified Part Tolerance mm Jerk mos Error dins Reference Contourina E Trajectory SE amnia m ontourng Erori Advanced Analysis Violation Spot m Motor Current m Motor Torque Force Detection Frequency Response Toolbox m Control Signal E Friction Torque Force Axis Tracking Toolbox Contouring Toolbox oo to get the corresponding plot Manufacturing Automation Laboratory UBC A You can select different types of data to export by clicking the pop up menu Select the data first whic
29. ector EE Voltage to control axis Mii SAEI EE a Voltage to control axis EE Voltage to control axis ee Voltage to control axis B AXIS CONTROL 10 to 10 Voltage to control axis volts C AXIS CONTROL 10 to 10 Voltage to control axis spindle Control 10 to 10 Voltage to control spindle RPM spindle Feedback 5 Volts error OV okay Spindle on off 5Volts on OVolts off Copyright 2015 Manufacturing Automation Laboratories Inc Page 60 Virtual CNC Step 3 Configuring the Real Time Build Information Once the simulation has been run with the Real Time System checkbox clicked the Run On Machine button can be pressed to start the process of preparing the code for real time testing Trajec vor y Axis Servo Control Generation Output Resolution Reducbon Rabo Ns 1 Onturbance dd Specited Pan Tolerance Actual zm Tracking Error 0 mmi aes as Feed Orive cr Advan i Analysis Violation Spot w Motor Current um Motor Torque force mm Detection Frequency Response Toolbox m Control Ke m Friction Toue Forte Aus Trackong Toobox gt Macafactunng Automanons Laboratory UBC Step 4 Configuring Build Parameters First the Configure button in the RT Config window needs to be pressed to configure the real time build parameters This will open the Configuration Parameters window The default settings should generally be correct and the OK button can be pressed to confirm and return to the RT Co
30. equency FA p louise eg me Se OK Cancel Before the plot maybe you need Modify Insert or Delete the configuration of the row you want Copyright 2015 Manufacturing Automation Laboratories Inc Page 36 D views CNC Taken Modify as an example you can select the row Number you want in the Frequency table and click the Modify button to open the FRF configuration interface The Nodes parameters and the plot settings should be configured based on your model properly After configuration click the OK button to save Plot the frequency response function again after the FRF configuration and see a new FRF result Plot Settings Start Frequency 100 End Frequency 1000 Hz 51 Plot Type Displacement Distance from COM to FRF Point x Plot Data Type Magnitude Phase Degrees of Freedom To Consider Damping Ratio 0 01 Mode Specific m Damping Ratios Add Node 2 Format Mode DampingRatio XT T MEN Node 2 Number 50 4 0 0277 7 x rly riz 7 y yaw Distance from COM to FRF Point x Degrees of Freedom To Consider Dele Rosie o 7 x a y Fiz Fir roll a p pitch P y yaw Set the transfer function as the transfer function of the axis X AXIS e Reduced order TF In the structure design interface of the flexible ballscrew drive clicking the Reduced order TF button in the Analysis Toolbox
31. gital Position PD Control PD Digital Position PID Control PID Digital Pole Placement Control PPC Generalized Predictive Control GPC and Feed Forward and Feedback Control FFFB Copyright 2015 Manufacturing Automation Laboratories Inc Page 51 S CNC Click the Controller icon in the Axis Servo Drive module and when the Controller icon is highlighting you can select different types of controllers by clicking the pop up menu Bl Virtual cnc IE File Help Axis Trajectory e A Configuration Toolpath Files Generation Axis Servo Control SIMULATION Axis Servo Motion Control Control Sampling Period Ts 001 Is l Selection Summary AXIS DRIVE Reference Position mg Actual Position SS __ TD o X Axis X Axis Feed Drive Y Axis poses Z Axis Controller None A Axis Feedback B Axis X Axis CONTROLLER Ve CAxis Disturbance Select Controller ee E None Adaptive Sliding Mode Control ASMC Lead Lag Control LLC Digital Position P Analog Velocity PI Control P PI Digital Position P Control P Digital Position PD Control PD Digital Position PID Control PID Digital Pole Placement Control PPC Manufacturing Automation Laboratory UBC Generalized Predictive Control GPC Feedforward and Feedbackward Control FFFB None Using the Digital Position PID Control PID as an example by selecting PID option and click
32. h includes Tracking Error Contour Error Reference Trajectory Simulated Response Controller and Toolpath The data file can be an Excel xls file or MATLAB mat file Copyright 2015 Manufacturing Automation Laboratories Inc Page 72 S CNC Then click the Browse button to choose a file path as the directory and enter the file name in the text box You can save the results to the directory you have defined before by clicking the Save button Select data to export None v Excel xls MATLAB mat File path ia II Contour Error Reference Trajectory Pos Vel Acc Jerk Simulated Response Pos Vel Acc ControllerSignal Controller Toolpath Copyright 2015 Manufacturing Automation Laboratories Inc Page 73 Zb CNC 1 8 Support Contacting Manufacturing Automation Laboratories Inc Manufacturing Automation Laboratories Inc 2829 Highbury St Vancouver BC Canada VOR 3T7 Tel 604 827 4370 Fax 604 228 9269 Email Sales sales malinc com Technical Support support malinc com Web http www malinc com Manufacturing Automation Laboratories Inc manufacturing automation laboratories 1 T Copyright O 2015 Manufacturing Automation Laboratories Inc Page 74
33. iguration Toolpath Files Generation Axis Servo Control SIMULATION Axis Servo Motion Control Control Sampling Period Ts 000 fs Selection Summary Z Axis Celer AXIS DRIVE Reference Position Controler Actual Position ESE seg GE X Axis X Axis Feed Drive pr E Z Domain A Axis B Axis X Axis FEED DRIVE E Leadscrew Servo Drive Transfer Function Model Disturbance Flexible Baliscrew Drive s domain Constant Linear Servo Motor EET Rotary Servo Drive Manufacturing Automation Laboratory UBC This opens the interface of the transfer function configuration You can input the transfer function parameters of the feed drive in the s domain or z domain The parameters include the polynomial orders and coefficients of the numerator and denominator Copyright 2015 Manufacturing Automation Laboratories Inc Page 49 Virtual CNC Transfer Function in s Domain B s hys Aha b s 7 5 5773 Ts b p A 2 3 e n n n n s ays a s as ass i a Numerator B s hys p t ez A ba Bub m Order of Numerator bt L mme B s Please enter the coefficients of the polynomials Denominator 3 n n n 2 n A S dag tas a s a38 Order of Denominator OK A s Please enter the coefficients of the polynomials X Axis General System z domain Transfer Function in z Domain B z _ bz e bz bz bz eb 2 3 GG E n 437
34. ing Settings button you can set up the PID controller parameters K Kand K Copyright 2015 Manufacturing Automation Laboratories Inc Page 52 Eu CNC Controller Parameters SC us RN Kc erem Feed Drive LINEAR e 1m 6 end amp een Feedforward Friction Compensation FFC Digital Position PID Controller Reference Xr ss Feed Drive Position Position i 1 Model x Copyright 2015 Manufacturing Automation Laboratories Inc Page 53 Virtual CNC 1 5 6 Disturbance Configuration Click the Disturbance icon in the Axis Servo Drive module and when the Disturbance icon is highlighting you can choose one type of the three options of disturbance to the feed drive The three options are Constant External Disturbance From File and Disturbance Signal Generator Bl Virtual cnc Axis Trajectory Toolpath Files i Axis Servo Control SIMULATION Configuration Generation Axis Servo Motion Control Control Sampling Period Ts 001 Is Selection Summary AXIS DRIVE Reference Position Actual Position SS __ Cont or el X Axis X Axis Feed Drive Y Axis Linear Z Axis Feedback Measurement Controller A Axis B Axis e CAxis Disturbance From File mat Browse Disturbance Signal Generator Setting amp Manufacturing Automation Laboratory UBC If you select Constant External Disturbance option you should define a value Unit
35. ive icon in the Axis Servo Drive module and when the Feed Drive icon is highlighting select the Leadscrew Servo Drive radial button and click the Flexible ballscrew Drive icon below This opens the structure design interface of the flexible ballscrew drive 1 5 2 1 Modeling a Ballscrew Drive a cres oS Design Toolbox Analysis Toolbox Rigid Body Modity BULD insert New Delete Load Model Rigid Bodies by izz Lm w ll rusa zg ones Jmee an ieee 9 65e 005 Encade1 8 5e 005 Encode i 8 5e 005 9 3121e 007 _ Modal Analysis b Items to Display 2 GN m Reduced order TF V Node Number V Ballscrew Nuts V Rigid Bodies V Joints Show all Pan Zoom Rotate Lan Panel Selected Node No Cancel By clicking the Load Model button in the Analysis Toolbox you can select an existing flexible ballscrew drive model under the file path Virtual CNC Ballscrew ubcBS mat After loading the structure of the example ballscrew can be shown in the interface In the Design Toolbox you can select one of the four types of the structure Ballscrew Nut Rigid Body and Joint Then by clicking one item of the table and the Modify Insert New or Delete button you can design the structure Copyright 2015 Manufacturing Automation Labora
36. manufacturing automation AW laboratories MAL MANUFACTURING AUTOMATION LABORATORIES INC 2829 Highbury St Vancouver B C CANADA VER 3T7 http www malinc com Tel 604 228 9213 Fax 604 228 9269 Virtual CNC Help File D vince CNC Contents Eeer 3 0 2 Installing and Running Virtual CNC ccscscsccscsceccccscscsccccccscnccccecscscecceecscecescecscucescecsceceseccecs 4 03 Exame GI 5 10 User ET E 7 1 1 Overview Of Virtual el Te 7 T2 Axis CONTISUPATION 5 0 2 sc5 noces sen enrcorsesne a oi 8 1 3 Reference Toolpath File Configuration ccscscsccscscscsccscscsccccecscnccccccscscescecscsceccccecscesescececes 11 1 4 Trajectory Generation Configuration cscccscecsccscsceccccscsceccccccscececcecscscescecscsceccecscsceseecececes 12 1 4 1 Kinematic Profile Configuration ccceccccscecsccscsceccccccscsceccececnceccececscececcecscucescececnceseecess 14 1 4 2 ulee ET el EE 19 1 4 3 Interpolation Configuration 1 eee eee eee eene enne nennen herren te snse sese sese sess ese senos 20 1 4 4 HSM Smoothing Configuration ccccsccscsccscsccsceccscsccccsccccsceccscessscsscecsceccscescscesescssecees 22 1 5 Axis Servo Control CONFIZUrAaTION cccsceccccscsceccccscsceccccccsceccececscecsececscscescecscnceccecececesescecces 23 1 5 1 Feed Belle TECH LTE 24 1 5 1 1 Leadscrew Servo Drive Configuration cscsccscsccssccscscecsccscscsccccccscscecsecscsceccecec
37. n this section Click the Feed Drive icon in the Axis Servo Drive module and when the Feed Drive icon is highlighting select the Leadscrew Servo Drive radial button and click the Flexible ballscrew Drive icon below Trajectory Toolpath Files Cie Axis Servo Control SIMULATION Configuration Axis Servo Motion Control 4 Control Sampling Period Ts 00 jis Selection Summary AXIS DRIVE Reference Position SE X Axis Actual Position xd Feed Drive e Y Axis Leadscrew Z Axis Feedh Vaarniemen Controller A Axis B Axis Avis gt Leadscrew Ser e Transfer Function Model Disturbance Flexible Ballscrew Drive s domain Rone Linear Servo Motor z domain Rotary Servo Drive Manufacturing Automation Laboratory UBC Copyright 2015 Manufacturing Automation Laboratories Inc Page 32 D virus CNC This opens the structure design interface of the flexible ballscrew drive Configuration of a ball screw drive includes three steps Modeling Analysis and Loading the result Design Toolbox Analysis Toolbox Ballscrew Modal Analysis Reduced order TF Node Number Ballscrew Nuts Rigid Bodies Joints Selected Node No Copyright 2015 Manufacturing Automation Laboratories Inc Page 33 Cd CNC Click the Feed Dr
38. neration Toolpath Files Configuration Axis Servo Motion Control Control Sampling Period Ts 001 i Selection Summary AXIS DRIVE Reference Position Actual Position ESE nt T Bin X Axis O X Axis Feed Drive Y Axis em Z Axis Ee amen Controller A Avis B Axis X Axis FEED DRIVE C Axis Leadscrew Servo Drive Transfer Function Model Disturbance Flexible Ballscrew Drive s domain z domain Rotary Servo Drive Manufacturing Automation Laboratory UBC This opens the interface of Linear Drive Parameters Two sections of the parameters for the linear motor drive should be set up properly Dynamic Loads and Electronic Drive By clicking the Block Diagram button on the bottom you can see the block diagram structure of Rigid Body Dynamics Model with Linear Motor Driven mechanism Copyright 2015 Manufacturing Automation Laboratories Inc Page 44 S CNC m 2 UU en degere Bi u Linear Drive Parameter Dynamic Loads Mass m e Damping Coefficient c Ns mm Spring Constant k N mm Electronic Dri D A Converter Bit bit DAC Voltage Range V Current Amplifier Gain Ka AM Transfer Function Motor Constant Kt fs N A Force Limit 4 N gt Rigid Body Dynamics Model with Linear Motor Driven Mechanism g gt bi Ta Mass Spring Damper System Copyright 2015 Manufacturing Automation Laboratories Inc Page 45
39. nfig window Copyright 2015 Manufacturing Automation Laboratories Inc Page 61 PZ CNC Please Configure and then Bai to run on machne VENC to d Space Mapping ADC and DAC VO Port Confgwe CH X axis H Pn 1 Spd Fb CH2 An ot Pin 9 Sod On Off 2 Bui CH3 Z axis ay CHE Am Open Run Time Control CHS B axis CHS Cats Hebe ceni Slave peocespor object e RTI Help ATI wanstle derop Step 5 Building the Real Time Implementation The Build button in the RT_Config window can then be pressed The system will then build compile and load the C code onto the dSPACE board Once it is complete it will open a Spindle Configuration dialog window Copyright 2015 Manufacturing Automation Laboratories Inc Page 62 Zb CNC Please Configure and then BT to run on machine VENC to d Space Mapping ADC and DAC VO Port t 1 Configure CH1 X axis H Pn1 SpdFb CH2 Y 3X9 OUT Pin 9 Sod OnO Sua CH3 Zap CHE Aarm CHS B axis Let en Spindle configura a E E Step 6 Spindle Control Configuration The spindle RPM is set by the dSPACE outputting a voltage The relationship between the RPM and voltage is assumed to be linear Therefore the minimum and maximum RPM range of the machine 1s required as well as the minimum and maximum voltage that the machine is expecting for the Spindle RPM control Linear interpolation is then automatically used to determine the required
40. ntrol Toggle Between Axis Control CMD Voltage Axis Control Saturation Low Axis Control Saturation High Axis Control Maximum Movement mm Axis Control Invert Gain Axis Control Plot Axis Axis Control Encoder Gain mm count Axis Control Jog axis Axis Control Increment mm Uu CNC Allows the user to switch between the axis 1 e X or A Y or B Z or C Displays the current voltage being sent to the drive amp Sets minimum output voltage that can be sent to drive amp Sets maximum output voltage that can be sent to drive amp Sets absolute maximum movement that that axis can move from starting position when exceeded output is set to O volt Set the axis feedback gain to be inverted WARNING Do not switch during operation unstable behavior will occur Shows a detailed plot of that particular axis Displays the current encoder gain mm count can also be used to set a new encoder gain Moves the axis using the controller amount specified by the Increment box Sets the jog increment unit is mm Copyright 2015 Manufacturing Automation Laboratories Inc Page 66 SS veu CNC The advanced analysis function module is used to check the performance of the controller 1 6 3 Advanced Analysis Toolbox It includes three options Frequency Response Toolbox Axis Tracking Toolbox and Contouring Toolbox Bl Virtual cnc File Help Trajectory Axis Servo Control Generation Configuration T Toolpa
41. od and consequently larger trajectory distortion effect However ZVD shaper is significantly more robust than ZV shaper which makes it preferable for the cases where the actual frequency may deviate from the modeled one by more than 5 EI shaper also causes one full vibration period and is slightly more robust than ZVD Bn NN O File Help Toolpath Files Traj es Axis Servo Control gt SIMULATION Generation Axis Configuration Input Shaper Type gt x lt ZV Zero Vibration ZV Zero Vibration v v Y v N ZV Zero Vibration interpolation Type HSM Smoothing E Joint Limits EE E Spline Compressor Input Shaping Singer amp Seering 1990 amp Manufacturing Automation Laboratory UBC Copyright 2015 Manufacturing Automation Laboratories Inc Page 19 S CNC Interpolation Type affords options between Point to Point Interpolation and Continuous Interpolation 1 4 3 Interpolation Configuration The tool path is treated as normal linear code GO1 in Point to Point Interpolation mode and the feed will decrease to zero at the end of each line In Continuous Interpolation mode the linear tool paths will be connected with smooth corners if necessary so the feed profile will be more efficient Point to Point Interpolation Blvesscec Axis Trajectory Toolpath Files Axis Servo Control SIMULATION Configuration Generation Traje
42. omation Laboratories Inc Page 68 Cd CNC In the right side of the interface you can configure the input signal by defining the parameters You can choose a Linear Model or Non linear Model as the type of the time domain response as well After configuration by clicking Run Analysis button you can see the analysis result Bl Axis Tracking Analysis Axis Information Corresponding Axis X Axis End Time Drive Model General System Z domain Axis Control Pole Placement Controller Sampling Time Ts 0 001 Magnitude Please select the input for the axis tracking analysis O D sinewave T a t t t Time Domain Response Default Run Analysis Cancel Contouring Toolbox The Contouring analysis includes four types of profiles Diamond Circle Triangular and Cornered Angle In the right side of the interface you can configure the profile by defining the parameters You can choose a Linear Model or Non linear Model as the type of the time domain response as well Before running you should check which results are expected and displayed Copyright 2015 Manufacturing Automation Laboratories Inc Page 69 f Virtual CNC After configuration by clicking Run Analysis button you can check the analysis results based on the reference profile XY Axis Information Axis
43. output voltage If there 1s no spindle feedback available the Bypass Spindle Speed Feedback checkbox can be checked This will disable the feedback and the controller will assume the spindle 1s operating at the requested RPM The Set button can then be pressed and the real time GUI window will open Labeled as VCNC RT Interface Copyright 2015 Manufacturing Automation Laboratories Inc Page 63 D views CNC Spindle configura A Ki Step 7 Using the Real Time Interface to Control the Machine The real time GUI is used to control the machine using the designed controller and trajectory The table included below explains the operation of each button Toppa Between v end D Ane ZAxwm Ch D Zeg 1 08 06 04 02 9 0 02 04 06 08 X CMD Votage Pot Xen X Sanrotne Lew X Encoder Gan eege V Saterstioe Lew V Eacoger Qar mmicount K Satur ation Her noi ete v Saturgtion High bonne Myers mg y Mapumum Movement immi ZA xm Movement mm nirerert Leed Fremen meni E t ineert X Gan inet Y Gan meet Z Gan WARNING If Emergency stop on machine is pressed you must turn off the controller before re enabling the machine Copyright 2015 Manufacturing Automation Laboratories Inc Page 64 S virtua CNC Real Time GUI Description Graphical User Interface Function Description Function Name Machine Control Start Starts the controllers running on the machine Machine Control
44. owever the default setting should work for the example After making any changes to the system parameters the Run Simulation button can be pressed located in the Simulation tab page After clicking the Run Simulate button check the Real Time System checkbox as shown below Then click Continue as you regularly would for running a simulation Axis Configuratior Axis Servo Control Axis Continue Ctm 4 Real Teme System Toolp dF ihecxampeoaxis_ sim dat J Real Time System dFiecxampiewaxis sim dat Traject Kineme Servo Feet Sampling Disturbance Rigid Body Leacs 3 Integral Derivative Controller Constant Disturbance Rigid Body Leadscrew Drive Proportional Integral Derivative Controller Constant Disturbance Rogid Body Leadscrew Drive Proportional Integral Derwatrve Controller Constant Disturbance Rigid Body Rotary Motors Pole Placement Controller None Rsgid Body Rotary Motors Pole Placement Controller None Manufacturing Automati Copyright 2015 Manufacturing Automation Laboratories Inc Page 59 SS uiua CNC Note If the system is to be tested on a real machine the computer running VCNC must have a dSPACE DS1103 device connected to it This system will build the controllers and trajectory into a C coded file that is automatically loaded to the dSPACE board The dSPACE board needs to be connected to the machine using the connection mapping shown in the table below Real Time dSpace Connector Map Conn
45. own m the dialog box Copyright 2015 Manufacturing Automation Laboratories Inc Page 28 Electronic Drive Total Inertia Calcul Masses and Inertia Mass of Table Mass of Workpiece Mass of Leadscrew Shaft Inertia of Motor Shaft Leadscrew Shaft Pach Length Pach Diameter Gear Reduction Ratio D virus CNC The current amplifier can be defined either by a constant gain Ka or by a transfer function When you check the Transfer Function and click the Edit icon you can define the polynomial order and coefficients of the numerator and denominator of the amplifier transfer function Copyright 2015 Manufacturing Automation Laboratories Inc Transfer Function in s Domain Bis Aas hs bat eh Le A GG o dis n 1 AUS n T n HM ag a 945 E Numerator Bis hs bs bus bs b Order of Numerator OK Cie B S Pisase enter the coeficients of the polynomats Denominator n l 2 n 3 As m as r S 4 55 zo Tt Oe Order of Denominator OK Clear Als Please enter the coefc ents of the polynomials Page 29 Mechanical Drive Cd CNC In this section you can include the friction in the feed drive model By checking the Include Friction Model and clicking Settings button the interface of Non linear Friction Model Parameters will open Model Coulomb Faction Only Stnbeck Curve Coulomb Friction on Gusdeway Posstive Coulomb Fncbon T
46. ror at each control interval Configuring the Axis Servo Control Module includes configuring the FeedDrive Controller Disturbance and Feedback Measurement for each axis The axis drive and the control sampling period should be selected first and then the servo control will be configured based on the specified axis The A Axis B Axis and C Axis are available only in the 5 axis machining Copyright 2015 Manufacturing Automation Laboratories Inc Page 23 Axis Configuration Toolpath Files Axis Servo Motion Control Control Sampling Period Ts Is AXIS DRIVE Reference Position X Axis Y Axis Z Axis A Axis Virtual CNC Trajectory Axis Servo Control SIMULATION Generation Actual Position p Controller B Axis X Axis FEED DRIVE C Axis Leadscrew Servo Drive Transfer Function Model Disturbance Flexible Ballscrew Drive s domain None Linear Servo Motor z domain Rotary Servo Drive Manufacturing Automation Laboratory UBC 1 5 1 Feed Drive Configuration The parametric model of the overall feed drive 1s shown below Virtual CNC includes four types of models to select for the axis feed drive Leadscrew Servo Drive Linear Servo Motor Rotary servo Drive and Transfer Function model include two types s domain and z domain Copyright 2015 Manufacturing Automation Laboratories Inc Page 24 Virtual CNC Te F Cutting Force
47. sceses 26 1 5 1 2 Leadscrew Servo Drive Rigid Body Dynamics REENEN ENNER nnne nnne 27 1 5 2 Flexible ball screw Configuration cccsccscscscsccscscsccccccscnccccccscsceccccecscececcecscsceccecscscecessecs 32 1 5 2 1 Modeling a Ballscrew Drive ois ess sas u o uv Eoo ER NONU n SYR UyS VENE PNENn EHE a SNR UNE E RS NER PA VR ee 34 1 5 2 2 Analysis of a Ballscrew Drive cscsccscscscsccscscsccccccscsccccccscnceccccccscsceccecscsceceececsceses 36 1 5 2 3 Loading the Transfer Function of a Ballscrew Drive eee eee eene 40 1 5 4 Rotary Servo Drive Configuration csccscscscsccscscsccccccscsccccccscnceccccecsceceececscscececcscscesescees 46 1 5 6 Controller Configuration ssssesessesessesesssoessecessscesssoesssossssoesssosossossssoesssoeosssessssesssssoseses 51 1 5 6 Disturbance Configuration sesessesessesessssesssoessscesssoesssoscosoesssossssososssesssososssesssoessssesseseo 54 1 5 7 Feedback Measurement Configuration sessesessesessssesssoesssoesssoesssoesssoesssoeossoessssessssesseseo 56 1 6 Simulation Configuration E 57 1 6 1 Virtual CNC Real Time Implementation Quick Start Guide eere eene 59 1 6 3 Advanced Analysis Toolbox ENKE RE eee eene EN ENKER ENER KEREN EN ENKER EN ENKER EEN ERR eN 67 LZ EXDOFE ReSUBES TEEN 72 TS SUDDO E 74
48. segment contain the position command for each axis which decide the trajectory that cutter moves along Different strategies can generate different feed profiles tangential velocity profiles as well as different command data for each axis which may affect the dynamic performance and the work piece contour error In the trajectory generation module you should configure four parts in the interface Kinematic Profile Kinematic Profile section 1s designed for various feed profile options The four feed profiles have different smooth orders Trapezoidal Copyright 2015 Manufacturing Automation Laboratories Inc Page 12 SI CNC Velocity 1s the simplest with much more jerk Cubic Acceleration will eive smoothest feed profile and Optimized Feedrate uses the optimized feed rate algorithm with a continuous jerk profile Input Shaping Input Shaping is a filtering technique to block those harmonics of the command which coincide with the structural modes of the axis drives Frequency and damping of the structural mode 1s required in order to set a shaper which avoids excitation of that mode There are currently three types of input shapers available in VCNC Interpolation Type Interpolation Type affords options between Point to Point Interpolation and Continuous Interpolation The tool path is treated as normal linear code GO1 in Point to Point Interpolation mode and the feed will decrease to zero at the end of each line In Contin
49. t up properly Dynamic Loads Electronic Drives and Mechanical Drive By clicking the Block Diagram button on the bottom of the interface you can see the block diagram structure of Rigid Body Dynamics Model with Leadscrew drive mechanism Dynamic Loads Total Reflected Inertia J kgm 2 Viscous Damping B Nms rad Use Advanced n Flexible Ball Screw Settings Electronic Drive D A Converter bit bit DAC Voltage Range V Current Amplifier Gain Ka A V Transfer Function Edt Motor Constant Kt Nm A Torque Limit Nm Mechanical Drive Pitch Length mm Gear Reduction Ratio Transmission Ratio rg mm rad Backlash Include Fnction Model Control Signal Copyright 2015 Manufacturing Automation Laboratories Inc Page 27 Rigid Body Dynamics Model with Leadscrew Driven Mechanism Nonlinear Guideway Friction Dynamics Due To Cutting Forces Disturbance Torque Saturation Backlash Xa Control A Actual Signal Transmission Position Amplifier Viscous Damping Ratio Dynamic Loads In this section the values of total reflected inertia and viscous damping are set up Alternately you can check and select Use Advanced After click the Settings button you can open the interface of Total Inertia Calculation and then need input the mass and inertia of each component of the lead drive After clicking the CALCULATE icon the total reflected inertia will be calculated and sh
50. th Files Simulation and Results Select Ax es to Plot X Axis Y Axis Z Axis A Axis B Axis C Axis m Position Output Resolution Reduction Ratio Ns m Velocity Em Acceleration Specified Part Tolerance mm m Jerk m Tracking Error 0 02 mm Reference D Contouring Error Trajectory Advanced Analysis Violation Spot Detection Frequency Response Toolbox Axis Tracking Toolbox Frequency Response Toolbox In the frequency response analysis module you can check the results of Bode Diagram Nyquist Plot Phase and Gain Margin etc of each axis Copyright 2015 Manufacturing Automation Laboratories Inc Page 67 D virus CNC BI Frequency Response Analysis Axis Information Corresponding Axis X Axis el ive Model F SES General System S domain Axis Control Proportional Integral Derivative Controller Sampling Time Ts 0 001 sl Analysis Response Analysis Feed drive system Plant model External Disturb ance Reference Axis Motion N Actual Commands Controller keng SS Position Frequency Range for Plotting Automatic Frequency Range Manual Frequency Range min rad s n Corn Phase GainMargin Bandwidth Axis Tracking Toolbox The Axis Tracking Analysis module analyzes the tracking performance for four types of inputs Step Input Ramp Input Sine Wave Input and Back and Forth Input Copyright 2015 Manufacturing Aut
51. tories Inc Page 34 Virtual CNC For example after selecting Ballscrew clicking the No 1 item in the ballscrew table and clicking the Modify BUILDbutton the interface of Ballscrew Parameter Configuration will be open Then you can configure the parameters of the ballscrew DI Ballscrew Parameter Configuration Ballscrew Number 1 Ballscrew Name Ballscrew Configure of the first element Number of the first element node Axis Orientation Model Colour for plotting DG Degrees of Freedom To Consider m rly CT dire ip pitch E y yaw Ballscrew Section Show Material List EL SAO SOE WEE LEET Eee SE CS After modeling a new ballscrew structure you should save your new model by clicking the Save Model button in the Analysis Toolbox Copyright 2015 Manufacturing Automation Laboratories Inc Page 35 CJ CNC You can analyze the FRF of a ballscrew drive by clicking the Modal Analysis button and export the transfer function result of the ballscrew drive by clicking the Reduced order TF button in the Analysis Toolbox 1 5 2 2 Analysis of a Ballscrew Drive Modal Analysis After clicking Modal Analysis button this interface will open Selecting a row in the Frequency table and clicking the Plot selected Frequency Response button you can see the plot of the frequency response function for the designated nodes number and the frequency range Modes and Frequencies F Clear All Fr
52. uous Interpolation mode the linear tool paths will be connected with smooth corners if necessary so the feed profile will be more efficient HSM Smoothing In High Speed Machining the joint limits are better to be concerned When HSM is chosen the constraints for each axis will be taken into consideration in trajectory generation Copyright 2015 Manufacturing Automation Laboratories Inc Page 13 Virtual CNC Bl virtual cnc EIE Axis Trajectory Toolpath Files Axis Servo Control SIMULATION Configuration Generation Trajectory Generation Kinematic Profile SE PPT ARTS Trapezoidal Velocity Velocity Continuity Trapezoidal Acceleration Cubic Acceleration Optimized Feedrate Input Shaping Position Acceleration mm mm s2 ALim mm s 2 Time sec Time sec Interpolation Type Point to Point Interpol v velocity Jerk mms mm s3 VLim mm s 250 00 HSM Smoothing Time sec Time sec T00 Low Smoothness Kinematic Profile Generates trajectory using trapezoidal velocity which has discontinuous acceleration profile and infinite jerks Manufacturing Automation Laboratory UBC 1 4 1 Kinematic Profile Configuration The configuration of Kinematic Profile includes four options trapezoidal velocity trapezoidal acceleration cubic acceleration and optimized feedrate The four feed profiles have different smooth orders Trapezoidal Velocity is the simplest

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