SINUMERIK 840D sl. Service - Configuring Commissioning. Manual (2011-2020)

NC commissioning

8.4 Friction compensation with adaptive characteristics

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8.4.7

Friction compensation with torque injection pulse

Parameterizing machine data

The following axis machine data must be parameterized in order to use an acceleration-

dependent torque injection pulse also for friction compensation:

Designation

Unit

Machine data

Acceleration-dependent amplitude of the

---

MD32576 $MA_FRICT_TORQUE_STEP

torque injection pulse

Delay time of the torque injection pulse

[s]

MD32577 $MA_FRICT_T_PULSE_DELAY_TIME

Ramp-up time of the torque injection pulse

[s]

MD32578

$MA_FRICT_T_PULSE_SMOOTH_TIME

Weighting factor for the amplitude of the

---

MD32588 $MA_FRICT_T_STEP[0...9]

torque injection pulse

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8.5 Nodding compensation

8.5

Nodding compensation

8.5.1

Measuring technique and machine data

Benefits

The nodding compensation enhances precision for machining of the workpiece by

compensating for compliance within the machine and is beneficial for traveling column

machines, for example, in that it improves machining accuracy and surface quality.

Software option

You need licenses for the following options in order to use this function:

• To tune a machine axis with a compensation relationship and position-dependent

adaptation:

"Nodding compensation ECO" (6FC5800-0_S20-0Yx0)

• For the tuning of more than one compensation relationship:

"Nodding compensation ADVANCED" (6FC5800-0_S21-0Yx0)

Call the function at the control in the "Commissioning" → softkey "NC" → softkey "Nodding

compensation" operating area. The softkey is not shown until the option has been set.

Example

Nodding motion in the Z axis when accelerating in the X axis:

Definition of compliance

From the acceleration or deceleration of an axis as the cause for nodding - and the deviation of

an axis as compliance at the position - a factor can be determined, which describes the

interrelationship between the accelerating or decelerating axis motion, and the position

deviation in the compensated axis. No mass is included in the calculation. The compliance factor

is the inverse value of the stiffness.

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8.5 Nodding compensation

Measuring procedure

There are two techniques that can be selected for determining compliance:

• Milling standardized workpiece and selecting the optimum milling path

For a standardized workpiece, a cycle is available to mill several milling paths with different

compliance factors. The compliance factor can be empirically determined based on the

workpiece surface quality.

For the cycle settings, you can also select face milling for the workpiece in order to carry out

several tests with different compliance factors on one workpiece.

• Determining positional deviations using a probe

The position deviation is precisely measured at different positions. Based on this, the

compliance factor can be calculated once the acceleration or deceleration that has been

achieved is known.

Machine data

Axis machine data for nodding compensation:

Number

Name

Effect

Unit

MD37302

$MA_NOCO_FILTER_TIME

Time constant for smoothing nodding

[s]

compensation values

MD37310

$MA_NOCO_INPUT_AX_1

Machine axis, which causes nodding mo-

[1...31]

tion

MD37320

$MA_NOCO_INPUT_AX_2

MD37330

$MA_NOCO_INPUT_AX_3

MD37312

$MA_NOCO_ADAPT_AX_1

Machine axis, whose position influences

[1...31]

nodding motion

MD37322

$MA_NOCO_ADAPT_AX_2

MD37332

$MA_NOCO_ADAPT_AX_3

MD37314

$MA_NOCO_ADAPT_NUM_AX_1

Number of positions of the adaptation

[1...3]

characteristic of nodding compensation

MD37324

$MA_NOCO_ADAPT_NUM_AX_2

MD37334

$MA_NOCO_ADAPT_NUM_AX_3

MD37316

$MA_NOCO_ADAPT_POS_AX_1

Positions of the adaptation characteris-

[mm]

tic of nodding compensation

MD37326

$MA_NOCO_ADAPT_POS_AX_2

MD37336

$MA_NOCO_ADAPT_POS_AX_3

MD37318

$MA_NOCO_COMPLIANCE_1

Nodding compensation compliance fac-

[s²]

tor

MD37328

$MA_NOCO_COMPLIANCE_2

MD37338

$MA_NOCO_COMPLIANCE_3

Additional information is provided in Chapter "Compensations" in the Monitoring and

Compensating (https://support.industry.siemens.com/cs/document/109766213 ) Function

Manual.

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8.5 Nodding compensation

8.5.2

Nodding compensation - overview

What is displayed in this dialog?

A summary of the following data is provided in the "Nodding compensation" overview:

• Accelerating axis: Axis, which results in nodding motion.

• Compensated axis: Machine axis, whose nodding motion is compensated.

• Adaptation axis: Machine axis, whose position influences nodding motion.

• Position [mm] on the adaptation axis

• Factor for compliance [μm / m/s²]

Supplementary conditions:

• Inadmissible entries are color-coded in the table in the "Nodding compensation - overview"

dialog. An explanation is output in the message line below the table.

• A rotary axis is not permissible as accelerating axis, compensated axis or adaptation axis.

• For a gantry axis grouping, only the guide axis is listed. On completion of the tuning, a query

is made whether the compensation values of the guide axis are copied to the synchronous

axes.

• In order that the "Nodding compensation" function may also be used for rotary axes, the

following option is required: RMCC/NOCO nodding compensation (6FC5800-0_N63-0Yx0)..

This option is not part of this description - and is not displayed in this dialog.

⇒ additional actions:

• "New" softkey to create a new compensation:

- Mill test part

- Enter manually

• Softkey "Change" to change the compliance and position dependency of the axes involved.

• Softkey Deactivate/activate, to deactivate existing compensation relationships and

reactivate them again.

• "Delete" softkey, to delete all values in the machine data of this compensation relationship.

The online help for nodding compensation on the SINUMERIK Operate supports you

during optimization.

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8.5 Nodding compensation

Activating/deactivating nodding compensation

To analyze the effect of the nodding compensation on the machining, you can deactivate

individual or all compensation relationships without deleting the original parameterization.

Deactivation is useful for the following applications:

• Diagnostics and problem analysis:

The effect of a specific compensation relationship on the workpiece surface should be tested.

Because a superimposition of compensation relationships from different axes and different

compensation relationships is possible, the effect of an individual or all successive

compensation relationships should be tested. For this purpose, the compensation is

deactivated temporarily; the determined compliance values are retained.

• Series commissioning:

The compensation values are loaded via the series commissioning archive and can be

deactivated during the machine tuning, to tune the machine without the effect of the

nodding compensation. On completion of the tuning, the compensation values are

reactivated. As check, a test part can be milled.

Procedure:

1. In the "Nodding compensation - Overview" select the "Deactivate/activate" softkey to

deactivate the compensation relationships.

2. Select the individual compensation relationships or select the "Deactivate all" softkey.

3. The "Back" softkey returns you to the "Nodding compensation - Overview".

4. If the nodding compensation should act again, reset the deactivated compensation

relationships to the "active" status.

The compensation relationships are deactivated bit-by-bit in MD37300 $MA_NOCO_ENABLE.

8.5.3

Determining compliance from the best milling path

Measuring technique: Best milling path

For a standardized workpiece, a cycle is available to mill several milling paths with different

compliance factors. The necessary compliance factor can be empirically determined based on

the surface quality of the milled workpiece.

Note

Active transformation

In order to guarantee a fault-free cycle sequence, active transformations are to be deactivated

before starting the cycle.

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8.5 Nodding compensation

For the cycle settings, you can also select face milling for the workpiece in order to carry out

several tests with different compliance factors on one workpiece.

Accelerating axis:

Geometry axes X, Y, Z

Compensated axis:

Machining plane G17: Z axis

Type of machining:

[no] path milling only

[yes] face milling and path milling

Parameter

Meaning

Unit

Retraction plane [abs]

[mm]

Safety clearance [inc]

[mm]

Path milling feedrate

[mm/min]

Face milling feedrate

[mm/min]

Corner point 1 X [abs]

[mm]

Corner point 1 Y [abs]

[mm]

Height of blank [abs]

[mm]

Corner point 2 in relation to X0 [inc.]

[mm]

Corner point 2 in relation to Y0 [inc.]

[mm]

Feed depth for face milling in relation to Z0 [inc.]

[mm]

without face milling: Feed depth for path milling in relation to

[mm]

Z0 (inc.)

with face milling: Feed depth for path milling in relation to Z1

(inc.)

Number of milling paths

---

Minimum value of the compliance factor

[μm / m/s²]

Maximum value of the compliance factor

[μm / m/s²]

Compliance factor of the best milling path

[μm / m/s²]

Note

Test run before machining

To perform a test run before machining, enter a suitable value for the infeed depth.

8.5.4

Nodding compensation - manually enter

Entering compensation data

For the manual input of the compliance factor, all degrees of freedom in the compensation

relationships between accelerating and compensated axes are possible. Further, position-

dependent adaptation values can be entered at the user interface.

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8.5 Nodding compensation

Procedure without adaptation:

1. First select the accelerating axis, and then the compensated axis. This can also be the same

axis.

2. If no position dependency exists, then accept the default setting "No".

3. Enter the compliance factor.

Procedure with adaptation:

1. First select the accelerating axis, and then the compensated axis. This can also be the same

axis.

2. If a position dependency exists, select "Yes" and then the adaption axis.

3. Then enter the number of interpolation points and the respective compliance factor for each

interpolation point.

In this dialog you can subsequently change the compliance and the position dependency for the

configured axes.

8.5.5

Determining compliance using a probe

Preconditions

If not yet already available, create a commissioning archive with the drive data and connect the

probe to a free DRIVE-CLiQ interface. Only linear measuring systems are permitted as probes.

NOTICE

Deactivate Safety Integrated temporarily

If axes still have Safety Integrated activated, a message is displayed to inform you that Safety

Integrated must be deactivated in order to configure the probe.

Following configuration of the probe, Safety Integrated must be activated once again.

Initiating trace recording

Procedure:

1. Select "Trace: Yes" to determine the compliance factor of the selected axis using a probe.

2. Select the measuring system for the encoder position actual value:

⇒ Select the drive to which the probe is connected, for example SERVO_3.3:6

⇒ Select an encoder, for example "Encoder 3".

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8.5 Nodding compensation

Create a part program which comprises the following components:

- Trigger tag $AN_CUTRACE

- Dwell time of at least 200 ms so that the offset of the probe can be taken into

consideration in the graphic representation.

- Traversing with constant velocity.

- The accelerating axis is accelerated to at least 1 m/s².

Example:

SOFT

; acceleration with active jerk limitation

DYNNORM

; G command for activating the normal dynamic

response

$AN_CUTRACE=1

; trigger tag

G4 F0.2

; Dwell time

G91 G01 F20000 Y-50

; relative traversing motion with programmed

feed

G4 F0.5

; Dwell time

Y50

; traversing motion

G4 F0.5

; Dwell time

M30

; End of program

Initiate the trace recording with the "Start trace" softkey. Then initiate the part program with

<NC-Start>.

Note

Starting the trace

Once trace recording has been initiated by the trigger in the part program, it is no longer

possible to cancel the recording process.

As soon as recording is complete, the following data is displayed in a graphic representation:

- Encoder position actual value (p0479) of the probe

- Acceleration of the accelerating axis

Enter the compliance factor (positional deviation/acceleration) and repeat the

measurement. To clarify the effect of the compliance factor against the first measurement,

scaling of the graphic following the first measurement is retained.

Once you have determined the optimum compliance factor for the axis, rescaling of the

graphic can be performed with the "Rescale" softkey.

As soon as the compliance factor is changed, the measurement must be repeated for

verification. Only then will the "Accept" softkey become active.

⇒ additional actions:

• "Start trace" softkey to initiate recording of the trace.

• "Rescale" softkey to automatically scale the graphic.

• "Cancel" softkey to return to the overview display without any modifications.

• "Accept" softkey to adopt the new compliance values.

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8.6 Adaptations

8.6

Adaptations

8.6.1

Intelligent load adjustment - function

Benefits

The "Intelligent load adjustment" function is used to optimize the following characteristics of a

machine tool by adapting dynamic response and control parameters:

• Shorter processing times

• Increased dynamic response

• Greater accuracy

• Enhanced precision

The machine manufacturer is supported in the commissioning of the function by dialogs on the

user interface: "Commissioning" → softkey "NC" → Menu forward key → softkey"Adaptations"

operating area. The softkey is shown after setting the option, and only for the "Manufacturer"

access level.

Precondition

Software option

In order to use this function a license is required for the following option:

"Intelligent load adjustment" (6FC5800-0_S11-0Yx0)

Function description

The"Intelligent load adjustment" function adjusts the dynamic response and control parameters

to the current value of the moment of inertia or the mass of the axis. Adaptations are switched

on and off by means of CYCLE782.

The following dynamic response and control parameters can be adapted:

• Acceleration (dynamic mode)

• Jerk (dynamic mode)

• Servo gain factor (position control gain factor)

• Torque feedforward control

• Drive adaptation factor 1...4: A maximum of 4 drive variables from parameter p2782[0...3]

"Mode adaptation" can be adapted.

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8.6 Adaptations

Example

For a rotary table with highly variable loading, the effective acceleration (DYNNORM) should be

adapted to the current moment of inertia. The "Intelligent load adjustment" function is used to

increase acceleration (DYNNORM) at minimal loading to 150%.

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J_min

⇒ MD16506[0] $MN_CADAPT_INPUT_VALUE_1

J_max

⇒ MD16507[0] $MN_CADAPT_INPUT_VALUE_2

150%

⇒ MD16508[0] $MN_CADAPT_OUTPUT_VALUE_1

100%

⇒ MD16509[0] $MN_CADAPT_OUTPUT_VALUE_2

Constraints

You can determine the inertia of the axis using automatic servo tuning or the "Moment of inertia

estimator" function module. The function module is enabled under Setup → Drive → Dialog

"Configuration - Motor Module".

For the output variables "Drive adaptation factor 1...4 (Page 232)", you configure a telegram

(Page 194) of the type 146, 148 or 149 and activate the function module "Controller parameter

adaptation".

Further information on function modules can be found in the Function Manual SINAMICS S120

drive functions (https://support.industry.siemens.com/cs/ww/en/view/109771805 ).

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8.6 Adaptations

8.6.2

Intelligent dynamic response adjustment - function

Benefits

The "Intelligent dynamic response adjustment" function is used to optimize the following

characteristics of a machine tool by adapting control parameters:

• Shorter processing times

• Increased dynamic response

• Greater accuracy

• Enhanced precision

The machine manufacturer is supported in the commissioning of the function by dialogs on the

user interface:

"Commissioning" → softkey "NC" → Menu forward key → softkey"Adaptations" operating area.

The softkey is shown after setting the option, and only for the "Manufacturer" access level.

Precondition

Software option

In order to use this function a license is required for the following option:

"Intelligent dynamic response adaptation" (6FC5800-0_S23-0Yx0)

Function description

The "Intelligent dynamic response adjustment" function adjusts the control parameters for axes

with a stability that changes at different positions or at different traversing velocities as a

function of the position or velocity.

The following control parameters can be adapted:

• Servo gain factor (position control gain factor)

• Torque feedforward control

• Drive adaptation factor 1...4: A maximum of 4 drive variables from parameter p2782[0...3]

"Mode adaptation" can be adapted.

Constraints

For the output variables "Drive adaptation factor 1...4 (Page 232)", you configure a telegram

(Page 194) of the type 146, 148 or 149 and activate the function module "Controller parameter

adaptation".

Further information on function modules can be found in the Function Manual SINAMICS S120

drive functions (https://support.industry.siemens.com/cs/ww/en/view/109771805 ).

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8.6 Adaptations

8.6.3

Setting up the adaptations

Setup procedure

The following procedure is recommended for commissioning the functions:

• Set licensed SINUMERIK Option S11 for the "Intelligent load adjustment" function.

The SINAMICS "Moment of inertia estimator" function module can be used to determine the

moment of inertia of the axis.

• Set licensed SINUMERIK Option S23 for the "Intelligent dynamic response adjustment"

function.

• Enter the adaptation in the "Adaptations - Overview" dialog, "New >" softkey.

• Enable adaptation with "Reset (po)".

The online help on SINUMERIK Operate shows you how to enter adaptations.

Note

No adaptation active

Without active adaptation, the dynamic response and control parameters in the machine data

are effective.

Adaptations - Overview

Example of a grinding machine with adaptations:

In this dialog, all adaptations are shown in a tabular overview.

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8.6 Adaptations

The dynamic response and control parameters can be adjusted as functions of the following

input variables:

• Moment of inertia

• Position

• Velocity

Inputting an adaptation writes the following machine data:

Mode

MD16501 $MN_CADAPT_MODE

Input axis

MD16504 $MN_CADAPT_INPUT_AX

Input variable

MD16502 $MN_CADAPT_INPUT = 1 (default setting)

Input value

MD16506 $MN_CADAPT_INPUT_VALUE_1

MD16507 $MN_CADAPT_INPUT_VALUE_2

Output axis

MD16505 $MN_CADAPT_OUTPUT_AX

Output variable

MD16503 $MN_CADAPT_OUTPUT

Output value

MD16508 $MN_CADAPT_OUTPUT_VALUE_1

MD16509 $MN_CADAPT_OUTPUT_VALUE_2

⇒ Additional actions:

• Press the "New >" softkey to enter a new adaptation table.

• Press the "Change >" softkey to change values or the number of table rows.

• Press the "Filter >" softkey to filter the overview by individual columns.

• Press the "Diagnostics" softkey to display the currently effective values.

• Press the "Delete" softkey to delete the selected adaptation table.

Adaptations - Configuring the drive

Procedure:

1. Select a drive parameter for the adaptation:

[1] Speed controller P gain (Kp)

[2] Speed controller integral time inverse value (1/Tn)

[3] Current setpoint filter 1 denominator/numerator frequency

[4] Current setpoint filter 2 denominator/numerator frequency

[5] Speed setpoint filter 1 denominator/numerator frequency

[6] Speed controller reference model natural frequency

2. To select the following drive parameters, you must enable another function modules

(⇒ constraints):

[7] APC/AVS/APC-ECO derivative-action time (Tv)

[8] APC filter 2.1 denominator/numerator frequency

3. The values for "Adaption of lower/upper limit value" are permanently in effect and are preset

to the maximum range of 0...3000%.

4. To enable the adaptation for the drive dataset (DDS), enter the corresponding number.

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8.6 Adaptations

Note

Unique parameter assignment

If a drive adaptation factor of 1...4 is assigned as output variable to an input variable with a

parameter [1]...[8], this assignment will be retained for another input variable.

Example:

The output variable "Drive adaptation factor 1" with the parameter [1] Speed controller P gain

(Kp) is assigned to the input variable "Inertia". Thus when adapting the input variable "Position"

the parameter [1] Speed controller P gain (Kp) is also assigned to the drive adaptation factor 1.

⇒ Additional actions:

• Press the "Cancel" softkey to cancel the inputs.

• Press the "Accept" softkey to save the data in the drive.

Constraints

The following settings are checked for the adaptation of drive parameters:

• The same telegram (146, 148 or 149) is configured in the NC and in the drive.

• The "Controller parameter adaptation" function module is enabled for this drive.

The function module is enabled under Setup → Drive → Dialog "Configuration - Motor Module".

• A SINUMERIK license for the option "Advanced Position Control ECO"

(6FC5800-0_M12-0Yx0) is required to use the "Active Vibration Suppression (AVS/APC-ECO)"

function module with SINUMERIK. This allows the following control parameter to be adapted:

[7] APC/AVS/APC-ECO derivative-action time (Tv)

• A SINUMERIK license for the option "Advanced Position Control" (6FC5800-0_M13-0Yx0) is

required to use the "Advanced Positioning Control (APC)" function module with SINUMERIK.

This allows the following control parameters to be adapted:

[7] APC/AVS/APC-ECO derivative-action time (Tv)

[8] APC filter 2.1 denominator/numerator frequency

8.6.4

Example: Enter an adaptation for acceleration

Entering a new adaptation

Objective: The acceleration (DYNFINISH) of the X axis should be adapted depending on the

moment of inertia of the X axis.

Procedure:

1. In the operating area, select "Commissioning" → "NC" → Menu forward key → "Adaptations"

and then the "New >" softkey. The "Enter adaptation" dialog is opened.

2. Select the mode, and the X axis as input axis.

3. Select "Acceleration (DYNFINISH)" as output variable.

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8.6 Adaptations

4. Expand the table to enter the following values:

Input value [kgm²]

Output value [%]

0.010000

150.0

0.012000

130.0

0.014000

110.0

0.016000

110.0

0.018000

100.0

5. Press the "Accept" softkey to display the adaptation in the "Adaptations - Overview" dialog.

6. A "Reset (po)" is required to activate the values in the machine data.

The adaptation table is shown in the "Adaptations - Overview" dialog:

Rules for entering adaptations:

• In a simple adaptation table, only one of the two input values is permitted to be zero.

• In a complex adaptation table, the first and last input values are permitted to be zero. When

changing, the input values must be entered in ascending order.

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8.7 Jerk filter

8.7

Jerk filter

8.7.1

Putting a jerk filter into operation

Benefits

To achieve high surface quality, the excitation of mechanical oscillations on the machine is kept

to a minimum. When milling freeform surfaces, it can be advantageous to smooth the setpoint

characteristics of the machine axes by means of a jerk filter. The parameterization of an axial jerk

filter depending on the processing technology (dynamic mode) has the following effect:

• Damping of machine vibrations

• Shorter processing time

Precondition

Software option

In order to use this function a license is required for the following option:

"Top Speed" (6FC5800-0_S13-0Yx0)

This option includes the use of the filter type FIR low-pass and the changeover from position

setpoint characteristic filter chains when the axes are at a standstill.

After the option is set, the "Jerk filter" softkey is displayed in the operating area "Commissioning"

→ Softkey "NC" → Menu forward key.

Jerk filter commissioning

Support for commissioning with SINUMERIK Operate is provided for the following jerk filters:

• FIR low-pass (dynamic mode)

MD32402 $MA_AX_JERK_MODE = 5

• Double moving averaging

MD32402 $MA_AX_JERK_MODE = 4

• Moving averaging

MD32402 $MA_AX_JERK_MODE = 2

The online help of SINUMERIK Operate supports you when entering jerk filters.

Function description

For motions outside the workpiece or during roughing, high axial jerk values are used in

combination with strong attenuating filters. This significantly reduces the processing time. An

FIR low-pass filter is parameterized depending on the dynamic mode in order to achieve the

optimum effect for the different types of processing. For an FIR low-pass filter, appropriate values

for the frequency and tolerance are entered for each specific dynamic mode. The machine data

MD32409 $MA_JERK_FIR_WINDOW = 1 (FIR low-pass - window type) is pre-selected.

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8.7 Jerk filter

If, when processing with DYNROUGH, minimum processing time and, for DYNPREC, maximum

machining accuracy are important, these requirements can be met with a FIR low-pass.

⇒ FIR low-pass: Robust setting for all axes in the channel

For the active dynamic mode in the part program, the same values are calculated for all of the

axes in the channel and written to the machine data. The calculation leads to an optimal result

if the dynamic response attributes of the axes are similar. The CALCFIR instruction is

reprogrammed after each switchover of the dynamic mode to explicitlyactivate the calculation

for the FIR low-pass filter.

Active dynamic response mode

The active dynamic mode of G code group 59 is read in again during run-up, during an operator

panel reset, and at the end of a part program by evaluating

MD20150 $MC_GCODE_RESET_VALUE[58] and MD20152 $MC_GCODE_RESET_MODE[58].

The following machine data is implicitly recalculated and activated depending on the dynamic

mode during run-up, during an operator panel reset, and at the end of a part program:

MD32407 $MA_JERK_FIR_FREQ

FIR low-pass - corner frequency

MD32408 $MA_JERK_FIR_ORDER

FIR low-pass - filter order

You can find more information on CALCFIR in the NC Programming (https://

support.industry.siemens.com/cs/document/109766213) Programming Manual.

More information on entering jerk filters and the switchover of position setpoint filter chains is

provided in the Axes and Spindles (https://support.industry.siemens.com/cs/document/

109766213) Function Manual.

8.7.2

Entering a new jerk filter

FIR low pass (dynamic mode)

FIR low-pass: Robust setting for all of the axes in the channel

For the active dynamic mode in the part program, the same values are calculated for all of the

axes in the channel and written to the machine data. The calculation leads to an optimal result

if the dynamic response attributes of the axes are similar. The CALCFIR instruction is also newly

programmed after each changeover of the dynamic mode to explicitly activate the calculation

for the FIR low-pass filter.

Precondition:

The maximum axial jerk for a path movement in MD32431 $MA_MAX_AX_JERK lies in the range

of 5 ... 500 m/s³ for the selected linear axis. If a value is outside this range, alarm 21900 is

pending.

Entering a new jerk filter:

Depending on the dynamic mode, enter the following value for the selected axis:

• Frequency [Hz]

• Tolerance for linear axes [mm/inch]

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8.7 Jerk filter

The following axis machine data is set active with the "Accept" softkey:

MD32400 $MA_AX_JERK_ENABLE = 1

Axial jerk limitation

MD32405 $MA_CALCFIR_FREQ

FIR low-pass - frequency [Hz]

MD32406 $MA_CALCFIR_TOL

FIR low-pass - tolerance [mm / inch]

MD32404 $MA_CALCFIR_SELECT = 1 or 2

FIR low-pass - Calculation for the selected filter lad-

der

Note

Only one variant of the type "FIR low-pass" is permitted in a position setpoint filter chain.

⇒ Additional actions:

• Use the "Change" softkey to adjust the parameters of the jerk filter.

• Use "Reset (po)" to activate the filter type in the following axis machine data:

- MD32402 $MA_AX_JERK_MODE = x5 in the 1st position setpoint filter ladder

- MD32402 $MA_AX_JERK_MODE = 5x in the 2nd position setpoint filter ladder

• The "Cancel" softkey discards the entries.

• Use the "Accept" softkey to activate the entries for the jerk filter.

Double moving average calculation

Enter the time constants for the smoothing effect for the selected axis.

The following machine data is set active with the "Accept" softkey:

MD32400 $MA_AX_JERK_ENABLE = 1

Axial jerk limitation

MD32410 $MA_AX_JERK_TIME

Axial jerk limitation: Time constant [s]

MD32411 $MA_AX_JERK_TIME_ADD

Axial jerk limitation: Time constant [s] for the filter

type double moving average calculation

Use the "Change" softkey to adjust the parameters of the jerk filter.

Use "Reset (po)" to activate the filter type in the following axis machine data:

MD32402 $MA_AX_JERK_MODE = x4 in the 1st position setpoint filter ladder

MD32402 $MA_AX_JERK_MODE = 4x in the 2nd position setpoint filter ladder

⇒ Additional actions:

• Press the "Cancel" softkey to cancel the inputs.

• Use the "Accept" softkey to accept the entries for the jerk filter.

Moving average calculation

Enter the time constant for the smoothing effect for the selected axis.

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8.7 Jerk filter

The following machine data is set active with the "Accept" softkey:

MD32400 $MA_AX_JERK_ENABLE = 1

Axial jerk limitation

MD32410 $MA_AX_JERK_TIME

Axial jerk limitation: Time constant [s]

Use the "Change" softkey to adjust the parameters of the jerk filter.

The filter type is activated in the following axis machine data using a "Reset (po)":

MD32402 $MA_AX_JERK_MODE = x2 in the 1st position setpoint filter ladder

MD32402 $MA_AX_JERK_MODE = 2x in the 2nd position setpoint filter ladder

⇒ Additional actions:

• Press the "Cancel" softkey to cancel the inputs.

• Use the "Accept" softkey to accept the entries for the jerk filter.

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8.8 Diagnosis → System utilization

8.8

Diagnosis → System utilization

System utilization

The channel-specific system utilization is displayed in the "Diagnostics" → Menu forward key →

"System utilization" operating area:

Total system utilization in milliseconds [ms]: MD10050 $MN_SYSCLOCK_CYCLE_TIME (system

base cycle)

Component

Current value display

Position controller

Position-control cycle time display: MD10061 $MN_POSTCTRL_CY-

CLE_TIME

Interpolator

Interpolation cycle display: MD10071 $MN_IPO_CYCLE_TIME

Synchronized actions

To display the time required for synchronized actions, activate

MD11510 $MN_IPO_MAX_LOAD. Enter the proportion of the interpola-

tor cycle in %.

Preprocessing

The factor for the interpolator cycle can be set in

MD10070 $MN_IPO_SYSCLOCK_TIME_RATIO.

NC load from position control-

MD10185 $MN_NCK_PCOS_TIME_RATIO = 90 (default setting)

ler and interpolator

The average current load should not exceed 50%.

In order to have sufficient reserves for the program processing, the max-

imum load in typical operations should not exceed 75%.

Interpolator buffer level

The channel-specific filling level is displayed in

MD28060 $MC_MM_NUM_IPO_BUFFER_SIZE, and indicates whether

block preparation for block processing can commence.

Jerky machining in continuous-path mode, if for instance a number of

short traversing blocks have been programmed in succession, is a typical

indicator of the interpolator buffer idling.

Observe the settings for isochronous operation: (Page 66)

The SINUMERIK Operate Online Help provides more detailed, context-related infor-

mation about the machine data.

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9.1

Introduction

Commissioning of PLC-controlled drives

The following tools support the commissioning of PLC-controlled drives:

• SINUMERIK Operate:

- Guided commissioning (Page 109) with the drive wizard for drive objects.

- Manual commissioning (Page 136) performed by experienced commissioning engineers.

• Access to the parameters of all drive objects in the "Commissioning" → "Machine data"

operating area.

• Support for the series commissioning of the PLC-controlled drives, because the parameters

are contained in the commissioning archive.

• Topology views, including a list of all drive units of this type that have been found.

• Diagnostics (Page 161) with alarms from those PLC drives whose time stamp is synchronized

with the system.

Note

PLC axes with special functions

Guided commissioning, e.g. for vector control, is not provided by the wizard in SINUMERIK

Operate. To do this, the STARTER commissioning software appropriate for the version can be

used.

PLC axes can only be used with the "basic positioning" (EPOS) function module if commissioning

takes place via STARTER.

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9.2 Configuration via PROFIBUS

9.2

Configuration via PROFIBUS

9.2.1

Supplementary conditions for PLC-controlled drives

Supported versions

Note

The SINUMERIK CNC software V4.9x supports the following Control Units with SINAMICS

firmware V5.2:

• CU310-2 DP / CU310-2 PN

• CU320-2 DP / CU320-2 PN

The following applies to PLC-controlled drives:

• Controlled directly from the PLC program.

• Integration in the part program sequence by means of auxiliary functions (H command).

Quantity framework

SINUMERIK 840D sl

Scaling

710.3B PN

720.3B PN

730.3B PN

Drives (drive control DOs) in total²⁾:

• Of which assigned to the NC, maximum²⁾:

• Resulting from this, those not assigned to the

NC, minimum:

• Not assigned to the NC, maximum:

Drive units (DO1) with drive control objects, in to-

tal²⁾:

• Of which at the virtual, integrated PROFIBUS,

maximum³⁾:

• Of which at the virtual, integrated PROFIBUS,

minimum:

• Of which at the DP interface¹⁾ minimum:

• Of which at the DP interface¹⁾ maximum:

X126: PROFIBUS DP of the integrated PLC; X136: PROFIBUS DP/MPI of the integrated PLC

The sum is monitored using alarm 380077

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9.2 Configuration via PROFIBUS

Extending the quantity framework

With MD13160 $MN_SINAMICS_MAX_SLAVE_ADDRESS >0, all SINAMICS drives whose bus

address or device number (n +1) is greater than the entered value (n) are operated on the PLC

as standard slaves according to the PROFIdrive profile and are not included in the NC quantity

framework according to the above table. This address can be set individually for each bus.

MD13160 $MN_SINAMICS_MAX_SLAVE_ADDRESS[i]

Highest address for each bus type:

$MN_SINAMICS_MAX_SLAVE_ADDRESS[0]

PROFIBUS DP1 (X126)

$MN_SINAMICS_MAX_SLAVE_ADDRESS[1]

PROFIBUS DP2 (X136)

$MN_SINAMICS_MAX_SLAVE_ADDRESS[2]

PROFIBUS DP3 integrated

$MN_SINAMICS_MAX_SLAVE_ADDRESS[3]

PROFINET (X150)

A distinction is made between the following scenarios:

• The default setting MD13160 $MN_SINAMICS_MAX_SLAVE_ADDRESS[i] = 0 means that all

connected and configured drives are included in the quantity framework.

• If $MN_SINAMICS_MAX_SLAVE_ADDRESS[i] > 0, all SINAMICS drives with a bus address or

device number greater than the entered value are not included in the quantity framework,

and can be used, for example, for further PLC axes.

Example:

So that all the drives connected via PROFINET, do not have to be taken into account in the NC

quantity framework, MD13160 $MN_SINAMICS_MAX_SLAVE_ADDRESS[3] must be = 1 (= n)

and must be configured in HW Config as the lowest device number 2 (= n+1).

Supplementary conditions

The extended operator control options for the PLC drives produce the following supplementary

conditions:

• Because the PLC drives create an additional communication load, the number of these drive

objects (DO) is limited depending on the NCU ⇒ observe the quantity framework:

• Alarm 380077 "PROFIBUS/PROFINET: Too many DOs: currently %2, maximum %3 in DO group

%1"

• Depending on the versions used, the texts displayed for the SINAMICS parameters and

messages may be incomplete.

• If the drives are assigned to the NC and distributed across several buses, such as DP and DP

integrated, then it must be ensured that each isochronous bus has the same cycle clock

settings. It is also true for the time of day synchronization via NC with telegram 390 that the

cycle settings match for each isochronous bus.

• A DO1 drive unit is required for the internal virtual PROFIBUS DP3 for access to the onboard

I/O including probe.

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9.2 Configuration via PROFIBUS

Note

PROFIBUS DP (X126)

The following should be observed for all drive units connected to an external PROFIBUS DP:

• In the configuration, the user must take into account the supply as well as the switch-on and

switch-off behavior in interaction with the other axes and their supply.

• For the terminal wiring, observe the "Machine Configuration Guidelines" System Manual. In

the simplest case, the feedback signal of the Line Module must be connected to the PLC-

controlled drives (see also: Terminal assignment (Page 103)).

9.2.2

Example: Configuration of the drive components

Overview

The SINAMICS drive system for PLC-drives communicates with the PLC via the PROFIBUS DP X126

interface. The commissioning described in this chapter orientates itself on the following

example configuration of the SINAMICS drive line-up:

6,180(5,.

6,180(5,. RSHUDWRU SDQHO IURQW ZLWK 7&8

6,180(5,.

3&8

,QGXVWULDO (WKHUQHW

352),%86 , 2

'5,9( &/L4

6,180(5,.

' VO

6,1$0,&6 6

ZLWK 6,1$0,&6 6

• • •

3RZHU VXSSO\

6HUYRPRWRUV

0DLQ VSLQGOH PRWRU

Figure 9-1

Configuration via PROFIBUS

Already commissioned are:

• NCU and NX15.3 with additional components.

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9.2 Configuration via PROFIBUS

In this section, the following will be put into operation:

• CU320-2 DP with an infeed (Line Module) and a Double Motor Module.

9.2.3

Commissioning the PLC

Overview

The following steps are carried out when commissioning drives controlled from a PLC for the

first time:

1. PLC commissioning

2. Creating a PLC program

3. Commissioning drives controlled from a PLC

4. Commissioning NC ⇔ drive communication

Precondition

• You have connected the PG/PC to the PLC (see Connect PG/PC with PLC (Page 47)).

• You have started the SIMATIC Manager and created a project (see

SIMATIC S7 project overview (Page 48)).

• You have inserted a SIMATIC Station-300 in the project (see

Adding SINUMERIK NCU to the HW Config (Page 49)).

• You have started HW Config.

• On the integrated PROFIBUS you have configured an NCU and NX15.3.

Interfaces

The PLC must be notified about the PROFIBUS interfaces of SINAMICS. You generate a SIMATIC

S7 project using the SIMATIC Manager.

To do this, perform the following steps:

• Insert an S120 CU320-2 DP in HW Config.

• Configure the properties of the PROFIBUS interface.

• Compile the configuration and then download it to the PLC.

Note

The SINUMERIK Toolbox must be installed.

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9.2 Configuration via PROFIBUS

3. After releasing the mouse key, configure the properties of the SINAMICS PROFIBUS interface:

4. Confirm with "OK".

5. In the "Version" selection box, select the firmware version of the Control Unit.

Note

The firmware version must match the version of the CompactFlash card on the CU320-2 DP.

Refer to the upgrade instructions for the versions that have been released for PLC-controlled

drives.

6. Confirm with "OK".

7. In the PROFIBUS DP master system (SINUMERIK NCU) under "Properties" → "Network

settings" → "Options" and under the "Equidistance" tab activate the option "Activate

equidistant bus cycle".

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9.2 Configuration via PROFIBUS

8. In the "DP Slave Properties" of the CU320-2 DP under the "Clock synchronization" tab, activate

the option "Synchronize drive to equidistant DP cycle".

9. In the "DP Slave Properties" dialog box, select the "Configuration" tab.

10.Select in the "Overview" the telegrams required for the individual objects (axes and

CU320-2 DP):

- "Siemens telegram 2, PZD-4/4" for example, for speed-controlled axes

- "Siemens telegram 390, PZD-2/2" for CU320-2 DP

Note

SIEMENS telegram 390 is required for the time stamp of alarms from the PLC.

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9.3 Creating a PLC program

9.3

Creating a PLC program

Requirements

This chapter describes the configuration of PLC drives that are not to be operated as NC axes. The

following expansions of the function blocks are required in the PLC program: You will need

additional S7 function blocks from the SINAMICS toolbox ≥ V2.1. This Zip file contains a manual

in several languages.

The SINAMICS Toolbox is available in the Internet at the following link: SINAMICS Toolbox V2.1

(http://support.automation.siemens.com/WW/view/en/25166781 )

Signals "WR_PZD" and "RD_PZD"

The "WR_PZD" and "RD_PZD" signals for FC70 in the example have the following meaning:

Signal

Typ

Range of values

Remark

WR_PZD

Any

P#Mm.n byte x

Target range for process data, master → slave (control words / set-

points)

P#DBno.DBXm.n byte x

Here, generally the axis DB is used, i.e. in the pointer, the same DB

number must be specified as formal parameter "NR_ACHS_DB".

The length of the pointer is 30 bytes for Siemens telegram 136.

RD_PZD

Any

P#Mm.n byte x

Target range for process data, slave → master (status words / actual

values)

P#DBno.DBXm.n byte x

Here, generally the axis DB is used, i.e. in the pointer, the same DB

number must be specified as formal parameter "NR_ACHS_DB".

The length of the pointer is 38 bytes for Siemens telegram 136.

Example with constant speed (fan, pump)

Procedure:

1. You have already created a project and find yourself on the main screen of the SIMATIC

Manager.

2. Select the "File" → "Open" menu and then click the "User projects" tab.

3. Open the example project and copy the FB283, FC70, DB70 and DB283 blocks as well as all

UDT300xx into your existing project.

4. As the DB70 could be used by another PLC program, rename DB70 as DB111!

5. Create a new FC73. Do not use the FC73 from the SINAMICS toolbox.

In the example, 4000_hex corresponds to the rated speed in drive parameter p2000.

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9.3 Creating a PLC program

Edit the OB1, FC70 and FC73 blocks in accordance with the following examples.

Example of OB1:

…

CALL FC70

CALL FC73

…

Example of FC70:

CALL FB283, DB283

NR_ACHS_DB := 111

LADDR := 272

//Logical I/O address

LADDR_DIAG := 8186

//Diagnostic addresses

WR_PZD := P#DB111.DBX172.0 Byte 8

//Source range for outputs

RD_PZD := P#DB111.DBX212.0 Byte 8

//Target range for inputs

CONSIST := TRUE

RESTART := FALSE

AXIS_NO := B#16#3

//Number of the drive object

Example of FC73:

UN E30.0

//E.g. switch for the enable signal

SPB frei

L W#16#47E

//All enables set

T DB111.DBW172

U E3.7

//MCP reset

= DB111.DBX173.7

//Reset fault memory

BEA

frei:

L W#16#47E

//All enable signals except ON/OFF1

T DB111.DBW172

L W#16#4000

//Rated speed in drive parameter p2000

T DB111.DBW174

//Set speed high

You have now finished programming the PLC program. Load the project to the PLC (Page 87).

To synchronize the PLC and NC, a system reset (po) is required:

- NCU: RUN LED is continuously lit green.

- NCU: Status display shows a "6" with a flashing dot.

- SINAMICS CU320-2 DP: LED RDY flashes slowly green (0.5 Hz)

⇒ PLC and NC are in cyclic operation.

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9.5 Checking the communication to the drive

9.5

Checking the communication to the drive

Check configuration

The PLC alarms of the drives must have an identical time stamp with the NC.

For the configuration in the hardware configuration, define the associated Siemens telegram

390 for the SINAMICS CU. The corresponding logical input and output addresses of this

communication interface are entered in the following machine data item:

• MD13120[n] CONTROL_UNIT_LOGIC_ADDRESS

• MD13120[1]...[5] are reserved for NX expansion modules.

Note

You can view these logical addresses in the HW configuration when configuring the

properties of SINAMICS components under "Details".

Procedure:

1. Check the logical address for SINAMICS CU in the "Commissioning" → "Machine data" →

"General MD" operating area and enter, for example, the following value:

MD13120[6] = 288

2. Press the "Reset (po)" softkey to accept the changed machine data.

This completes the commissioning of the PLC drives.

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9.6 Safety functions for PLC drives

9.6

Safety functions for PLC drives

Introduction

This section only partially describes how a PLC drive can be integrated in a safety-related

application. In this case, the published supplement of the PROFIdrive profile that includes drive-

based safety functions via the PROFIsafe supplement with telegram 30 is used.

Basic procedure

The following steps are necessary to integrate drive-based safety functions:

• Configuration with SIMATIC Manager under HW Config.

• Embedding in safe programmable logic (SPL).

Further information

The following Function Manuals for Safety Integrated are binding when it comes to

implementing a safety-related design:

• Chapter "Control via PROFIsafe" in the SINAMICS S120 Safety Integrated (FHS) (https://

support.industry.siemens.com/cs/ww/en/view/109771806) Function Manual

• Product announcement (https://support.industry.siemens.com/cs/de/en/view/109748675 )

- SINUMERIK 840D sl Safety Integrated Function Manual

- SINUMERIK 840D sl Safety Integrated plus Commissioning Manual

9.6.1

Configuring PROFIsafe

Requirement

In order to configure PROFIsafe, it is necessary that the "S7 Configurations Pack" option is

installed.

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9.6 Safety functions for PLC drives

4. To change the "F_Dest_Add" parameter, select "F_Dest_Add" in the "Parameter Name"

column and click the "Change value ..." button.

5. Check the following values/settings:

- The value of the "F_Dest_Add" parameter must be entered as a hexadecimal value in

p9610 and p9810 of the corresponding drive (e.g. 200_dec corresponds to C8_hex).

- The value of the "F_Source_Add" must match the other used PROFIsafe modules and also

be entered in MD10385 $MN_PROFISAFE_MASTER_ADRESS.

- It must be ensured that the same source address is set for all PROFIsafe modules.

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9.6 Safety functions for PLC drives

NC machine data

The SPL PROFIsafe configuration for the basic safety functions STO without SSI are then shown:

Archive excerpt

Comment

CHANDATA(1)

N10385 $MN_PROFISAFE_MASTER_ADDRESS='H50007d2'

N10386 $MN_PROFISAFE_IN_ADDRESS[0]='H50000c8'

;=> entry from HW Config

N10387 $MN_PROFISAFE_OUT_ADDRESS[0]='H50000c8'

;=> entry from HW Config

N10390 $MN_PROFISAFE_IN_ASSIGN[0]=9011

;=> INSE[9] for S_STW1.0 No Safe Torque Off

;=> INSE[10] for S_STW1.1 No Safe Stop 1

;=> INSE[11] for S_STW1.7 INTERNAL_EVENT_ACK

; No extended functions

N10400 $MN_PROFISAFE_OUT_ASSIGN[0]=9011

;=> OUTSE[9] for S_ZSW1.0 Power removed

;=> OUTSE[10] for S_ZSW1.1 Safe Stop 1 not active

;=> OUTSE[11] for S_ZSW1.7 INTERNAL_EVENT

; No extended functions

N13300 $MN_PROFISAFE_IN_FILTER[0]='H83'

N13320 $MN_PROFISAFE_OUT_FILTER[0]='H83'

Drive machine data

Values that have been added as a result of telegram 30:

• p9601=p9801=0x8

• p9610=p9810=0xC8

"safe.SPF" file:

Program example

Comment

IDS = 40 DO $A_OUTSE[09] = $A_INSE[2]

;If the cover is locked then deselect STO

IDS = 41 DO $A_OUTSE[10] = $A_INSE[2]

;If the cover is locked then deselect SS1

PLC program extension:

Program example

Comment

"SPL".SPL_DATA.INSEP[2];

// => cover switch locked?

"SPL".SPL_DATA.OUTSEP[9];

// $A_OUTSE[9] =1 => Deselect STO

"SPL".SPL_DATA.OUTSEP[10];

// $A_OUTSE[10] =1 => Deselect SS1

//Enable signal OFF1 set:

"SPL".SPL_DATA.INSEP[9];

// => No STO?

"SPL".SPL_DATA.INSEP[10];

// => No SS1?

0.0;

// only if OFF1 is also requested via switch

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Drive tuning

10.1

Tuning procedure

Precondition

Once the drives have been commissioned and the axes assigned, you must start tuning the

particular machine or a machine type.

• The commissioning of the drives has been completed.

• The topology has been checked and is OK.

Tuning procedure

Depending on the requirements, the following tuning procedure is recommended: Procedure

when tuning axes and drives (Page 34)

Especially efficient procedure: Tuning, utilizing all default settings of the automatic servo tuning:

• Example: This is how you tune the X axis (Page 272)

• Example: This is how you tune the Y axis (Page 276)

• Example: How to start the path interpolation (Page 281)

Procedure for experts:

• Tuning using the automatic servo tuning with manual parameter settings:

Example for experts: Axis tuning (Page 285)

• Tuning using measuring functions and manual parameter settings of the position controller,

speed controller and current controller:

- Example: Setting the filter for the following error (speed control loop) (Page 296)

- Examples for the measuring methods (position control loop) (Page 299)

- Example, function generator: Speed setpoint after the filter (Page 303)

The SINUMERIK Operate Online Help provides more detailed, context-related infor-

mation on the parameterization of the "Automatic Servo Tuning".

Further information can be found in:

• "Axes and Spindles (https://support.industry.siemens.com/cs/document/109766213 )"

Function Manual

• "Monitoring and Compensating (https://support.industry.siemens.com/cs/document/

109766213)"

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10.2 Function overview for the tuning

10.2

Function overview for the tuning

Commissioning → Tuning/test

The following functions are available to support the commissioning:

• Automatic servo tuning

• Measuring functions (Page 288) (current control loop, speed control loop, position control

loop)

• Function generator (Page 301)

• Circularity test (Page 306)

• Characteristic curves for the hydraulic module (if present)

• Active filters (Page 305)

Figure 10-1

Example: "Automatic servo tuning"

Diagnosis → Trace

With the "Trace (Page 147)" function, you select the NC variables, PLC variables or drive variables

whose signal chart is to be visualized:

• Trace for PLC/NC//servo variables

Recording and graphical representation of the signal values with respect to time, such as

actual position value, following error, etc.

• Trace for drive variables

Recording and graphical representation of the signal values with respect to time from the

drive system, such as e.g. speed actual value, current actual value etc.

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10.3 Automatic servo tuning

10.3

Automatic servo tuning

Which functions are available?

The following options are available for automatically tuning an axis:

• Selection of an individual axis for tuning

• Selection of a strategy from many options

• Reconfiguration of measurement conditions

• Chart display and activity log for tuning process

• Display of the measured frequency responses (speed control system) and the calculated

frequency responses (open circuit, closed control loop)

• Checking and processing the tuning results for speed and position controller: The response

of the control loop is simulated on the basis of the frequency response and displayed in the

bode diagram.

• Accept or reject the results of the tuning

The function "Automatic servo tuning" is started in the operating area "Commissioning"

→ "Automatic servo tuning", and can be used for all servo and direct drives.

Interpolation axes

For axes which make up an interpolation group, additional tuning steps should be undertaken,

e.g.:

• Path interpolation with the automatic servo tuning.

• Circularity test (Page 306)

• Adjust servo gain factor.

• When using feedforward control, transfer equivalent time constants of the slowest axis

(highest value) in all interpolating axes.

10.3.1

Setting the options for the measurement procedure

Options in JOG mode

In the first step, press the "Options" softkey to set the general behavior for automatic servo

tuning.

For a predominantly automatic sequence in the JOG mode the following selection is

recommended, utilizing all automatic sequences and settings:

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10.3 Automatic servo tuning

Condition for AUTO mode

Software option

In order to use this function a license is required for the following option: "Call AST

from the part program" (6FC5800-0_S10-0YB0)

With the option "Assign this HMI for "Call AST from the part program"", you select SINUMERIK

Operate to perform the automatic servo tuning in the AUTO mode:

•

☑ If this option is selected, the current SINUMERIK Operate performs the automatic servo

tuning.

•

☐ If this option is not selected, a different SINUMERIK Operate performs the automatic servo

tuning.

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10.3 Automatic servo tuning

Sequence in AUTO mode

As a result of the changing load, for direct drives (e.g. torque motors) it may be necessary to tune

the axis involved for each new workpiece size or clamping device.

Standard cycles (CYCLE751...759) are available, that machine OEMs can use in a manufacturer

cycle. The automatic servo tuning can be parameterized and started using the cycles. The

previous settings and results from the automatic servo tuning can be employed, using

SINUMERIK Operate. The machine manufacturer provides the machine operator with a

manufacturer's cycle, which includes the appropriate commands. This means that after

retuning, an end user can insert a manufacturer's cycle in his part program, which performs the

tuning and selects the appropriate data sets. The part program does not have to be interrupted

for the retuning.

The following settings must be made by the machine manufacturer so that the cycle call for the

automatic servo tuning from the part program functions at the end user.

• The instance of SINUMERIK Operate on which the cycles are executed has been selected.

• The XML files with the appropriate tuning settings for the respective axis, which are required

by the cycles, are available.

• The manufacturer cycles are available, and when required a parameter set switchover is set

up.

Additional information about the cycles and a description of the syntax are provided in Chapter

"Automatic Retuning" in the "Axes and Spindles (https://support.industry.siemens.com/cs/

document/109766213)" Function Manual.

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10.3 Automatic servo tuning

10.3.2

Selecting the tuning strategy

Default setting for "Axis" strategy

For a predominantly automatic sequence in the JOG mode the following selection is

recommended: Select a tuning strategy for axis, speed controller and position controller using

softkey "Select strategy >". The recommended strategies are 102, 303 and 203.

Figure 10-2

Strategy: Axis example

For the "Axis" strategy, select which controller should be tuned. When doing this, the tuned,

closed control loop can be measured to check the results.

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10.3 Automatic servo tuning

The most important settings are: Tuning aggressiveness and minimum integral time Tn.

•

Tuning aggressiveness:

This parameter determines the setting of Kp and Tn based on stability limits. The phase

margin and amplitude margin values are pre-assigned according to this setting.

- Default setting = 0.5

- Min = 0 [maximum stability]

- Max = 1 [maximum aggressiveness]

•

Minimum integral time Tn:

This parameter prevents automatic servo tuning from setting the integrator time of the

speed control loop too low. If the automatic servo tuning sets a value lower than this

parameter has set, the actual value used will be limited to the value set by the minimum

integral time Tn.

A higher integral time ensures a more rugged closed-loop control if changes to the weight or

the moment of inertia are expected. This is recommended for direct drives and main spindles

of turning machines.

- Default setting = 10 ms

- Min = 0.5 ms

- Max = 100 ms

•

Pole/zero point identification as from frequency:

This parameter sets the lower limit value of the frequency range, through which the

automatic servo tuning searches for natural frequency modes: Pole and zero points on the

controlled system. This parameter is intended to prevent measurement noise in the low

frequency range being incorrectly marked as the pole or zero position. The frequencies

identified as pole or zero positions play a role in the estimation of the total inertia of the axis.

For this reason, it is important that the lowest natural frequency of the axis is correctly

identified by the automatic servo tuning.

On large machines with low frequency vibration modes, it may be necessary to reduce the

15 Hz default value of this parameter. The reduction of this parameter may have to be

accompanied by a reduction in the bandwidth of the measurement of the speed-controlled

system.

Default setting: 15 Hz

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10.3 Automatic servo tuning

Example for "Position": Strategy 203

Figure 10-5

Strategy: Position control loop - example

The value for reducing the servo gain factor and its upper limit depends on the selected tuning

objective.

• Reduce servo gain factor

The maximum servo gain factor is calculated from the automatic servo tuning; in the process,

no overshoot is allowed with the position controller. The maximum servo gain factor is the

value that does not result in any overshoot. The maximum servo gain factor can be reduced

to increase ruggedness against mechanical changes. A reserve of 40% is set for the tuning

objective "moderate responsiveness". Furthermore, the servo gain factor is limited to 4 mm/

min.

- Default setting = 0.6

- Min = 0.1

- Max = 1 (no reduction)

• Feedforward control mode: Torque feedforward control is recommended.

When telegram 136 is used, the torque feedforward control allows the highest contour

precision to be achieved.

Tuning objective

The default settings for speed and position controllers are adapted by selecting the tuning

objective.

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10.3 Automatic servo tuning

• Maximum responsiveness:

The speed and position controller gain (servo gain factor) is tuned with maximum values and

minimum ruggedness.

Application: High-speed machining with maximum suppression of all disturbing forces such

as friction, teeth of the drive belt, strong cutting forces, when machining titanium, for

example. Recommended for high-speed machining with linear motors.

Precondition: The machine must have a rigid design; the dynamic masses do not change

significantly.

• Moderate responsiveness (= default):

This controller dynamic response is sufficient for the majority of machines and applications.

The setting is more rugged than "Maximum responsiveness".

Application: The inertia or the load mass of the axes does not change much and therefore this

setting is suitable for numerous applications.

• Conservative/robust responsiveness:

Only weak control gains are selected in order to ensure as high a level of ruggedness as

possible.

The speed controller is tuned so that it achieves maximum damping to prevent oscillations

and to achieve good position controller gain.

Application: Recommended for machines on which the mechanical axis system or the load

mass can change significantly. Also suitable for axes that respond with oscillations, e.g. main

spindles on turning machines or large axes with high load mass.

Recommended for applications with low requirements on the machining time.

10.3.3

Example: This is how you tune the X axis

Precondition

This example shows how to tune the X1 axis using the "Automatic servo tuning" function. In this

case, the following machine configuration is assumed:

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10.3 Automatic servo tuning

WARNING

Avoiding unwanted axis movements

Automatic servo tuning is based on the analysis of measurements. These measurements

require the axis to move.

Carefully ensure that all axes are in a safe position and no collisions will occur during the

traversing motion that is required.

Number of measurements

For tuning purposes, the following measurements are taken with the speed controller:

Speed controlled system:

• Overall bandwidth: Preliminary measurement in both directions

• Overall bandwidth: Measurement in both directions

• Reduced bandwidth: Preliminary measurement in both directions

• Reduced bandwidth: Measurement in both directions

Mechanical system motor to DMS:

• Measurement in both directions

Tuning the X axis

Procedure:

1. Softkey "Options >", to select options when performing the measurements.

2. Softkey "Select strategy >", to select a strategy: Default setting 102, 203, 303.

3. Check that the tuning objective "Moderate responsiveness" is selected

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10.3 Automatic servo tuning

7. Follow the instructions by pressing <NC START>. After the measurements have been

successfully made, the tuned values of the parameters are output:

8. Softkey "Accept", to activate the parameters and exit tuning.

9. OR: Enter suitable values in column "Manual" and confirm using softkey "Accept", to activate

the parameters and exit tuning:

10.After completion of the measurement, you can display the complete tuning log: "Tuning log"

softkey.

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10.3 Automatic servo tuning

Procedure:

1. The options and strategies that have been set remain valid.

2. In dialog "Axis selection" select the Y axis:

3. Start the measurement with the "Tune" softkey.

4. Confirm the "Axis park position" with "OK". Two measurements are performed.

5. Follow the instructions by pressing <NC START>. After the measurements have been

successfully made, the tuned values of the parameters are output:

6. Softkey "Accept", to activate the parameters and exit tuning.

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10.3 Automatic servo tuning

10.3.5

Spindle tuning sequence

Benefits

The automatic spindle tuning function supports you in the following scenarios:

• Controller tuning in the various modes: axis mode and spindle mode.

The speed controller, position controller, and feedforward control are optimized.

• Calibration of the following errors for tapping by means of path tuning

• Calibration of the following errors for axis mode by means of path tuning

The progress of spindle tuning is clearly visible to the machine manufacturer:

• The tuning strategy set for the spindle.

• The suitable default setting of the tuning strategy for the selected use case.

• The mode that must still be optimized and the mode that is already optimized.

• The gear stages that must still be optimized and the ones that are already optimized.

Preconditions

Only one channel is supported: MD20000 $MC_CHAN_NAME

Only one gear stage is supported: MD35090 $MA_NUM_GEAR_STEPS = 1

The gear change is disabled: MD35010 $MA_GEAR_STEP_CHANGE_ENABLE = 0H

Axis mode is only supported for the first gear stage:

MD35014 $MA_GEAR_STEP_USED_IN_AXISMODE = 1

Note

Tuning sequence

Only tune the spindle after completing the tuning of all of the other axes.

At least one optimized geometry axis is necessary to optimize the spindle for the tapping.

Spindle tuning sequence

In operating area "Setup" → "Tuning/Test" → "Automatic servo tuning: Axis selection", select the

spindle for tuning:

①

Axis selection

The "Automatic servo tuning: Axis selection" dialog shows the current status of the axes/spindles:

• Select the spindle.

• Start the spindle tuning with the softkey "Tune >".

②

Parameter

• Select the spindle type: e.g. milling spindle, rotary table.

• Select the spindle mode.

When selecting tapping, in the last step the spindle can be optimized for tapping.

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10.3 Automatic servo tuning

③

Spindle tuning

Tuning of the first gear stage of the spindle.

The tuning result for the axis mode is identical to the tuning result of the spindle mode.

④

Tapping

If the spindle is used for tapping, the spindle mode and parameter set 2 are automatically selected.

The geometry axis used for tapping also switches to parameter set 2 for the tuning procedure.

The respectively correct parameter set for the spindle and for the geometry axis are selected for path

interpolation.

The tuning status of the parameter sets is displayed in the last step of tuning:

not optimized

axis-optimized

axis-optimized (for spindles only)

path-optimized

Tuning strategy

Different tuning strategies are applied, depending on the operating range of the spindle:

• Spindle for milling machines:

Tuning aggressiveness = 0.3

K_P is lower and T_N is higher than with a linear axis.

• Spindles for turning machines or grinding machines:

Tuning aggressiveness = 0.2

K_P is lower and T_N is higher than with a milling spindle.

• The spindle is used as a rotary table.

Tuning aggressiveness = 0.5

K_P and T_N behave identically to a linear axis.

• If the preset strategy does not meet the requirements, select a different strategy or "Custom

strategy".

• The same tuning strategy that was selected for the path axes is selected for the axis mode.

• The position controller is always optimized for tapping.

Result

The optimized parameters for the axis are displayed in the "Controller review" dialog.

The optimized parameters of the path interpolation are displayed in the "Interpolation path

review" dialog.

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10.3 Automatic servo tuning

10.3.6

Example: How to start the path interpolation

Strategy selection

Interpolation means that all axes in the channel have the same following error. The controllers

have different settings once all of the individual axes have been tuned. To standardize the

following error, the controllers, including the servo gain factor and feedforward control, are set

corresponding to the axis with the slowest response. The default strategy 1105 is recommended

for this:

Interpolating axes with different dynamic responses can be adapted with a time constant as

dynamic response adaptation to the slowest control loop. The difference between the

equivalent time constants of the slowest control loop and the particular axis should be entered

as time constant for the dynamic response adaptation:

• Different equivalent times after axis tuning are aligned with the time constant (MD32895

$MA_DESVAL_DELAY_TIME).

• The following values are adapted for speed feedforward control: Kp, Tn, reference model and

speed setpoint filter

• The servo gain factor is not adapted for torque feedforward control. The maximum servo gain

factor is adopted after tuning.

• If there is a time constant (MD32895 $MA_DESVAL_DELAY_TIME), then

MD32890 $MA_DESVAL_DELAY_ENABLE =1 is set and the time constant from MD32895 is

used. If there is no time constant, MD32900 $MA_DYN_MATCH_ENABLE = 1 and

MD32910 $MA_DYN_MATCH_TIME are used.

The following strategies are also available:

1102: Adaptation by setting the largest equivalent time constants for all of the path axes and

moderate reduction of the speed control gain factor

1103: Adaptation by setting the largest equivalent time constants for all of the path axes

1104: Interpolation path tuning custom strategy

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10.3 Automatic servo tuning

Axis selection

Procedure:

1. Use the "Select strategies to use" to check the interpolation strategy:

The following parameters are adapted with the recommended Strategy 1105:

- Dynamics matching in MD32900 $MA_DYN_MATCH_ENABLE=1 is active.

- The precontrol set in the MD32620 $MA_FFW_MODE=3 (default) is always enabled.

2. Using the "Adapt strategy" softkey, enable the editing to adapt the selected strategy user-

specifically.

3. Using the "Path interpolation" softkey, select the axes for path interpolation:

4. Start the measurements with the "Tune" softkey.

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10.3 Automatic servo tuning

Path interpolation

Once tuning has been completed, the tuned values are shown for the following parameters:

Softkey ">>", to switch over the vertical softkey bar for further processing:

• Softkey: "Retune"

• Softkey: "Revert to auto tuned"

• Softkey: "Revert to axis opt."

• Softkey "<<", to switch over the vertical softkey bar.

• Softkey "Save to file", to save the tuning data to an xml file.

• Softkey "Generate report", to generate a report in the rtf format.

A signal indicates that additional measures are required for path interpolation.

The tuned axis data are activated in the associated machine data using softkey "Accept":

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10.3 Automatic servo tuning

Documenting the result

The following reports are available to document the measurement results:

• After each individual axis has been tuned

• After path interpolation for the interpolating axes

The results are available in the following form:

• Softkey "Save to file", to save the tuning data to an xml file.

• Softkey "Generate report", to generate a report in the rtf format. The report includes

parameters as well as diagrams, and is created in the language set for the control system.

The following directory is the default directory for these reports:

user/sinumerik/hmi/log/optimization

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10.3 Automatic servo tuning

10.3.7

Example for experts: Axis tuning

Axis: User-defined strategy (108)

Manual setting of the measurement parameters

The tuning objective can be directly entered in "Speed" or "Position". Alternatively, a predefined

strategy (102, etc.) can be selected, accepted with "Adapt strategy" and then changes can be

made.

By activating the checkbox, the commissioning engineer selects the individual steps for

measuring and tuning. Several steps are interdependent: For instance, the speed-controlled

system must always be measured before tuning the speed controller. All checkboxes which

result in a measurement are marked with an arrow. Additional default settings are available for

each measurement using the "Meas. parameters >" vertical softkey.

Perform preliminary measurement to determine the excitation:

The preliminary measurement to determine the excitation can always be selected or deselected.

The preliminary measurement is always recommended when first commissioning the axis or for

unknown mass relationships (load/motor). The measurement parameters for the following

measurement are automatically determined after the preliminary measurement. User-defined

measurement parameters are then overwritten.

Deactivate controller properties that are not supported in the NC and drive:

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10.3 Automatic servo tuning

The following functions are deactivated if they are used:

• Axis:

MD32220 $MA_POSCTRL_INTEGR_ENABLE = 0

MD32610 $MA_VELO_FFW_WEIGHT = 1.0 (should always be 1)

MD32930 $MA_POSCTRL_OUT_FILTER_ENABLE = 0

• Drive:

If the Advanced Position Control (APC) function module is activated: p3700.0 = 0

Velocity control configuration: p1400.5 = 0

The speed controller adaptation is deactivated.

Speed controller integrator feedback time constant: p1494 = 0.0

Measure smoothed speed setpoint step to create a mechanical model:

At the start of the tuning, the load moment of inertia, the stiffness of the coupling and the

correctness of the current controller setting are unknown. A step response can be measured to

make a first estimate. As a consequence, while measuring the speed-controlled system, it is

easier to automatically determine parameters.

Measure speed-controlled system:

This measurement is required to tune the speed controller.

It is initially performed with the maximum bandwidth (e.g. 4000 Hz)

Measure speed-controlled system with reduced bandwidth:

This measurement is required to tune the speed controller.

This measurement is performed with reduced bandwidth in order to improve the frequency

resolution.

Measure speed control loop for speed controller-controlled system model:

This measurement is necessary if the position control loop (including feedforward control) is to

be automatically tuned, but the speed controller was not tuned with automatic servo tuning.

Tune speed controller:

The parameters for the speed controller (including current setpoint filter) are calculated an the

basis of the measured speed-controlled systems and the specified tuning objective. The

parameters are not transferred into the drive until the axis tuning has been completed, or a

measurement for checking has been performed. The "Speed" settings are applied.

Measure speed control loop for checking:

The closed speed controller is measured with the new parameters. To do this, the new

parameters are written to the drive.

Measure mechanical system:

Measure the transmission link between the motor encoder and direct encoder (e.g. linear scale).

This does not include any influence on the closed-loop control. Using this measurement, the

position control loop can be calculated with closed-loop control on the direct encoder.

Tune position controller: without parameters

Servo gain factor and feedforward control are tuned on the basis of the prior measurements. The

tuning objective is also applied. The "Position" settings are applied. If a second encoder is setup,

then the position control is always calculated as if this second encoder is used for the position

control.

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10.3 Automatic servo tuning

Control measurement position control loop:

The closed position controller is measured with the new parameters. To do this, the new speed

and position control parameters are written to the drive and the NC. The feedforward control

must be disabled for this measurement. Depending on the option setting, this is the reason that

a message is output to press the reset button on the machine control panel. After the

measurement, the feedforward control is reactivated; this why another request for a reset (re)

is issued after the measurement .

⇒ Checking the measurement data quality: without parameters

The software for automatic tuning checks whether the excitation and offset velocity were

sufficient, and then outputs an appropriate message.

⇒ Measurement parameters:

Individual measurement parameters can be entered for each of the following measurements:

• Measure speed setpoint step for the mechanical model

• Measure speed-controlled system

• Measure speed-controlled system with reduced bandwidth

• Measure speed control loop for speed controller-controlled system model

• Measure speed control loop for checking

• Measure mechanical system

• Control measurement position control loop

⇒ Additional actions:

• Press the "Adapt strategy" softkey to adapt the default values to a predefined strategy. The

values of the pre-defined strategy are assigned to the user-defined strategy (108). All

parameters can be set in the "User-defined strategy". The tuning objective "Moderate

responsiveness" is the default setting for the "User-defined strategy".

• Press the "Meas. parameters >" softkey to adapt the parameters for a measurement. This

softkey can only be used when selecting the "User-defined strategy".

• Press the "Speed" and "Position" softkeys to toggle between speed controller and position

controller when selecting a strategy.

• "Cancel" and "OK" softkeys to cancel or accept the new settings.

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