S 3.11.
2003
Workshop mold & die 11/2003
These script is not a start-up manual but only a presentation which is completed in the workshop!!
B. Optimization of the feedforward control:
1. OPTIMIZATION OF THE SPEED FEEDFORWARD CONTROL (FFW-MODE 3): 2
1.1. Circularity test: 7
1.2. Varying the shape of the circle (circularity test): 8
1.3. Contour error with the different settings: 10
2. TORQUE (ACCELERATION) FEEDFORWARD CONTROL (FFW-MODE 4) 12
2.1. Contour precision on the example 'rhombus': 15
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With the help of the feedforward control a very high leading Kv factor (very low following error) and a very high
accuracy and contour precision can be obtained. Mainly at dynamically high quality machines with high natural
frequencies and good damping parameters it is possible to reduce the following error extremely also at very
high speed.
A second type of machines who sometimes need feedforward control are (mostly) big machines with low axis
natural frequencies, bad damping and therefore very low reachable Kv factors (0.1 .. 2) in the axis. In this case it
is necessary, to use the feedforward control to reach a suitable contour precision.
The machine application requirements define the need for activating feed forward. Depending on the highest
possible KV factor, when high contour accuracy is required at high velocities, feed forward can be considered.
When feed forward is activated, the servo response becomes very dynamic, thus, jerk limited acceleration is
always necessary to smooth the dynamic response. The user must weigh the benefits of the higher contour
accuracy when feed forward is active with the possible increased overall acceleration time when jerk limited
acceleration is used. As lower the max. allowed Jerk is as longer will be the processing time for a workpiece.
• It is therefore of particular importance to proof if it is necessary to use of a feedforward control.
In software version > 5 some mechanism are established who allow a very good contour precision with a very
reduced excitation intensity of the axis, already with a Kv factor of about 2 m/min/mm and without feedforward
control (only with active compressor or milling applications).
However, if highest precision are demanded, the feedforward control is necessary.
Attention: In software version > 5 or higher only the feedforward modes 3 (speed feedforward) or 4 (Current
/Torque feedforward) should be used. The old modes 1 (speed feedforward old) or 2 (Current/Torque feedfor-
ward old) should be no longer in use.
1. Optimization of the speed feedforward control (FFW-Mode 3):
Requirement: Current-, speed- and position controller are already optimized.
The following parameters are relevant:
32620 FFW_MODE 0
32810 EQUIV_SPEEDCTRL_TIME 0.0
10050 SYSCLOCK_CYCLE_TIME 0.001000
10060 POSCTRL_SYSCLOCK_TIME_RATIO 1
10082 CTRLOUT_LEAD_TIME 0.0
----------------------------------- ------
33000 FIPO_TYPE 3
32610 VELO_FFW_WEIGHT 1.0
32910 DYN_MATCH_TIME 0.000500
32900 DYN_MATCH_ENABLE 0
----------------------------------- ------
32402 AX_JERK_MODE 2
32400 AX_JERK_ENABLE 0
32410 AX_JERK_TIME 0.030000
The easiest way to optimize the feedforward control is to make a position step. Therefore the position setpoint
and the position at the active encoder has to be traced with the servo trace. Then the machine data must be
varied until the position behavior (i.e. the last 50 µm when the axis goes into desired position) is satisfactory.
• The practice shows that a driving range of approx. 50 mm and a velocity of 5 m/min is very useful.
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The following NC-program can be used:
FFWON
SOFT
ANF:
G01 X10 F10000
G04 F0.5
$AA_SCTRACE[X]=1 ;Trigger for Servo-Trace
G01 X60
G04 F0.5
GOTOB ANF
M30
At first the positioning behavior without feedforward must be analyzed.
These parameters are set:
32200 POSCTRL_GAIN 3.80
1407 SPEEDCTRL_GAIN_1 5.50
1409 SPEEDCTRL_INTEGRATOR_TIME_1 10.0
1414 SPEEDCTRL_REF_MODEL_FREQ 0.0
1500 NUM_SPEED_FILTERS 0
32610 VELO_FFW_WEIGHT 1.0
32620 FFW_MODE 0
32810 EQUIV_SPEEDCTRL_TIME 0.0
32431 MAX_AX_JERK 80
32620 FFW_MODE 0
Positioning without feedforward.
Resolution: 5 µm/div.
Without feedforward no overshoot is
acceptable at all velocities.
Now, the feedforward control must be activated with 32620 FFW_MODE = 3. The equivalent speed control time is
switched off first (32810 EQUIV_SPEEDCTRL_TIME = 0). When the machine data 10082 CTRLOUT_LEAD_TIME = 0 , i.e.
switched off, in the some cases a balancing of the feedforward control with the MD 32810
EQUIV_SPEED_CTRL_TIME is not necessary. In this case the NC makes the balancing internal and there is nothing
else to do.
In some other cases (like this) it must be done some additional actions.
The optimal EQUIV_SPEEDCTRL_TIME depends on the mechanic and some time constants in the controller loops of
an axis. So it is possible that different axis with the same EQUIV_SPEEDCTRL_TIME show different positioning be-
havior.
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Positioning with feedforward control:
Resolution: 5 µm/div.
Feedforward control with too big bal-
ancing time constant:
It is to recognize that the actual value
shows a 'crawling' behavior on the
last 10 µm. In this case the
EQUIV_SPEEDCTRL_TIME must be de-
creased.
With SW>5 it is possible to set nega-
32610 VELO_FFW_WEIGHT 1.0
tive EQUIV_SPEEDCTRL_TIME. 32620 FFW_MODE 3
32810 EQUIV_SPEEDCTRL_TIME 0.003
32431 MAX_AX_JERK 80
Jerk limitation active!
Resolution: 5 µm/div.
Feedforward control with too small
balancing time constant:
In this case a overshoot occurs when
the axis drive into position, so the
EQUIV_SPEEDCTRL_TIME must be in-
creased.
32610 VELO_FFW_WEIGHT 1.0
32620 FFW_MODE 3
32810 EQUIV_SPEEDCTRL_TIME 0.002
32431 MAX_AX_JERK 80
Jerk limitation active!
To show that the reason for this 'crawling' or overshoot behavior on the last 10 µm is the balancing of the feed-
forward control, the position controller can be switched off (Kv = 0). Then the positioning looks like as follows:
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Positioning without position controller
(Kv =0):
Resolution: 5 µm/div.
Without position controller the axis
runs nearly perfect into position. The
remaining position deviation exists
because the position controller is
switched off and the axis drives only
with feedforward signals. The peak at
reaching position comes from the
mechanic and can be eliminated with
a stronger jerk limitation if necessary.
32200 POSCTRL_GAIN 0.0
32610 VELO_FFW_WEIGHT 1.0 Has no effect when Kv = 0
32620 FFW_MODE 3
32810 EQUIV_SPEEDCTRL_TIME 0.002
32431 MAX_AX_JERK 80
Positioning without position controller Natural frequency (≈ 30 Hz)
with too high jerk:
Resolution: 5 µm/div.
In this picture the value of the jerk
limitation (MAX_AX_JERK) is increased
to show the overshoot resp. the oscil-
lation of the mechanic. This oscilla-
tion can only come from the me-
chanic and not form the position con-
troller or a possibly wrong
EQUIV_SPEEDCTRL_TIME. Remove this
oscillation by decreasing the
MAX_AX_JERK. 32200 POSCTRL_GAIN 0.0
32610 VELO_FFW_WEIGHT 1.0
32620 FFW_MODE 3
32810 EQUIV_SPEEDCTRL_TIME 0.002
32431 MAX_AX_JERK 150
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Please remember: Max. allowed Jerk in dependence of the natural frequency:
speed feedforward control : Max. Jerk [m/s³] at X_Delta = ...µ
10000.0
1000.0
100.0
100 µ
10 µ
1µ
10.0
1.0
0.1
1 10 100 1000
Natural frequency [Hz]
Reference: Dr. Tröndle, A&D MC RD55, Siemens AG
Positioning with feedforward control and active position controller.
Resolution: 5 µm/div.
Very good positioning behavior when
the feedforward control is exactly
balanced.
32200 POSCTRL_GAIN 3.800000
32610 VELO_FFW_WEIGHT 1.0
32620 FFW_MODE 3
32810 EQUIV_SPEEDCTRL_TIME 0.0025
If the equivalent time constant of the speed control loop 32810 EQUIV_SPEEDCTRL_TIME is already too big with the
value 0 you can use a negative EQUIV_SPEEDCTRL_TIME.
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1.1. Circularity test:
Normally the actual radius (mean radius) is too big, when feedforward control is set active. With the help of the
dynamic response adaptation 32910 DYN_MATCH_TIME or the Ax_Jerk_Time 32410 AX_JERK_TIME the mean radius
can be adjusted very well.
All circles with SOFT and FFWON.
Circle 1:
Circle with balanced feedforward control, without any
additional actions: Mean radius 16 µm too large.
Axis 1 Axis 2
32200 POSCTRL_GAIN 3.800 3.800
1407 SPEEDCTRL_GAIN_1 5.500 5.0
1409 SPEEDCTRL_INTEGRATOR_TIME_1 10.0 10.0
1414 SPEEDCTRL_REF_MODEL_FREQ 400.0 400.0
1500 NUM_SPEED_FILTERS 0 0
32610 VELO_FFW_WEIGHT 1.0 1.0
32620 FFW_MODE 3 3
32810 EQUIV_SPEEDCTRL_TIME 0.0025 0.0025
32900 DYN_MATCH_ENABLE 0 0
32400 AX_JERK_ENABLE 0 0
Circle 2:
Radius adjusted with dynamic response adaptation:
Axis 1 Axis 2
32200 POSCTRL_GAIN 3.800 3.800
1407 SPEEDCTRL_GAIN_1 5.500 5.0
1409 SPEEDCTRL_INTEGRATOR_TIME_1 10.0 10.0
1414 SPEEDCTRL_REF_MODEL_FREQ 400.0 400.0
1500 NUM_SPEED_FILTERS 0 0
32610 VELO_FFW_WEIGHT 1.0 1.0
32620 FFW_MODE 3 3
32810 EQUIV_SPEEDCTRL_TIME 0.0025 0.0025
32910 DYN_MATCH_TIME 0.0062 0.0062
32900 DYN_MATCH_ENABLE 1 1
32400 AX_JERK_ENABLE 0 0
Circle 3:
Adjusting the radius is also possible with the
Ax_Jerk_Time:
Axis 1 Axis 2
32200 POSCTRL_GAIN 3.800 3.800
1407 SPEEDCTRL_GAIN_1 5.500 5.0
1409 SPEEDCTRL_INTEGRATOR_TIME_1 10.0 10.0
1414 SPEEDCTRL_REF_MODEL_FREQ 400.0 400.0
1500 NUM_SPEED_FILTERS 0 0
32610 VELO_FFW_WEIGHT 1.0 1.0
32620 FFW_MODE 3 3
32810 EQUIV_SPEEDCTRL_TIME 0.0025 0.0025
32900 DYN_MATCH_ENABLE 0 0
32402 AX_JERK_MODE 2 2
32400 AX_JERK_ENABLE 1 1
32410 AX_JERK_TIME 0.023 0.023
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1.2. Varying the shape of the circle (circularity test):
If the shape of the circle doesn't fit (e.g. skew Ellipse) so this can additional be adjusted with the dynamic re-
sponse adaptation.
Example:
Variation of the DYN_MATCH_TIME:
Axis 1 Axis 2
32200 POSCTRL_GAIN 3.800 3.800
1407 SPEEDCTRL_GAIN_1 5.500 5.0
1409 SPEEDCTRL_INTEGRATOR_TIME_1 10.0 10.0
1414 SPEEDCTRL_REF_MODEL_FREQ 400.0 400.0
1500 NUM_SPEED_FILTERS 0 0
32610 VELO_FFW_WEIGHT 1.0 1.0
32620 FFW_MODE 3 3
32810 EQUIV_SPEEDCTRL_TIME 0.0025 0.0025
32910 DYN_MATCH_TIME 0.0035 0.0036
32900 DYN_MATCH_ENABLE 1 1
32400 AX_JERK_ENABLE 0 0
Variation of the DYN_MATCH_TIME:
Axis 1 Axis 2
32200 POSCTRL_GAIN 3.800 3.800
1407 SPEEDCTRL_GAIN_1 5.500 5.0
1409 SPEEDCTRL_INTEGRATOR_TIME_1 10.0 10.0
1414 SPEEDCTRL_REF_MODEL_FREQ 400.0 400.0
1500 NUM_SPEED_FILTERS 0 0
32610 VELO_FFW_WEIGHT 1.0 1.0
32620 FFW_MODE 3 3
32810 EQUIV_SPEEDCTRL_TIME 0.0025 0.0025
32910 DYN_MATCH_TIME 0.0035 0.0037
32900 DYN_MATCH_ENABLE 1 1
32400 AX_JERK_ENABLE 0 0
Variation of the DYN_MATCH_TIME:
Axis 1 Axis 2
32200 POSCTRL_GAIN 3.800 3.800
1407 SPEEDCTRL_GAIN_1 5.500 5.0
1409 SPEEDCTRL_INTEGRATOR_TIME_1 10.0 10.0
1414 SPEEDCTRL_REF_MODEL_FREQ 400.0 400.0
1500 NUM_SPEED_FILTERS 0 0
32610 VELO_FFW_WEIGHT 1.0 1.0
32620 FFW_MODE 3 3
32810 EQUIV_SPEEDCTRL_TIME 0.0025 0.0025
32910 DYN_MATCH_TIME 0.0035 0.004
32900 DYN_MATCH_ENABLE 1 1
32400 AX_JERK_ENABLE 0 0
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Variation of the DYN_MATCH_TIME:
Axis 1 Axis 2
32200 POSCTRL_GAIN 3.800 3.800
1407 SPEEDCTRL_GAIN_1 5.500 5.0
1409 SPEEDCTRL_INTEGRATOR_TIME_1 10.0 10.0
1414 SPEEDCTRL_REF_MODEL_FREQ 400.0 400.0
1500 NUM_SPEED_FILTERS 0 0
32610 VELO_FFW_WEIGHT 1.0 1.0
32620 FFW_MODE 3 3
32810 EQUIV_SPEEDCTRL_TIME 0.0025 0.0025
32910 DYN_MATCH_TIME 0.0035 0.003
32900 DYN_MATCH_ENABLE 1 1
32400 AX_JERK_ENABLE 0 0
Variation of the speed filter:
Axis 1 Axis 2
32200 POSCTRL_GAIN 3.800 3.800
1407 SPEEDCTRL_GAIN_1 5.500 5.0
1409 SPEEDCTRL_INTEGRATOR_TIME_1 10.0 10.0
1414 SPEEDCTRL_REF_MODEL_FREQ 400.0 400.0
1500 NUM_SPEED_FILTERS 0 0
32610 VELO_FFW_WEIGHT 1.0 1.0
32620 FFW_MODE 3 3
32810 EQUIV_SPEEDCTRL_TIME 0.0025 0.0025
32910 DYN_MATCH_TIME 0.0035 0.0035
32900 DYN_MATCH_ENABLE 1 1
32400 AX_JERK_ENABLE 0 0
1500 NUM_SPEED_FILTERS 2 0
1503 SPEED_FILTER_2_TIME 3.0 0.0
With the speed filter the equivalent time constant of the position controller loop did not change from the point of
view of the Interpolator. The speed filter lift only the amplitude of the position controller frequency response and
therefore the radius of the circle. With the Dynamic match time filter the equivalent time constant of the position
controller loop change, the phase relation changes, the circle changes to a ellipse or a ellipse will be corrected
to a circle.
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1.3. Contour error with the different settings:
• Contour error at the workpiece with balanced feedforward control without any further actions (parameters
like picture 'Circle 1', mean radius 16µm to large):
Axis 1 Axis 2
32200 POSCTRL_GAIN 3.800 3.800
1407 SPEEDCTRL_GAIN_1 5.500 5.0
1409 SPEEDCTRL_INTEGRATOR_TIME_1 10.0 10.0
1414 SPEEDCTRL_REF_MODEL_FREQ 400.0 400.0
1500 NUM_SPEED_FILTERS 0 0
32610 VELO_FFW_WEIGHT 1.0 1.0
32620 FFW_MODE 3 3
32810 EQUIV_SPEEDCTRL_TIME 0.0025 0.0025
32900 DYN_MATCH_ENABLE 0 0
32400 AX_JERK_ENABLE 0 0
Scale: 15 µm/div.
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• Contour error at the workpiece with balanced feedforward control and adjusted radius with dynamic re-
sponse adaptation (parameters like picture 'Circle 2'):
Max. deviation: 7 µm
32200 POSCTRL_GAIN 3.800 3.800
1407 SPEEDCTRL_GAIN_1 5.500 5.0
1409 SPEEDCTRL_INTEGRATOR_TIME_1 10.0 10.0
1414 SPEEDCTRL_REF_MODEL_FREQ 400.0 400.0
1500 NUM_SPEED_FILTERS 0 0
32610 VELO_FFW_WEIGHT 1.0 1.0
32620 FFW_MODE 3 3
32810 EQUIV_SPEEDCTRL_TIME 0.0025 0.0025
32910 DYN_MATCH_TIME 0.0062 0.0062
32900 DYN_MATCH_ENABLE 1 1
32400 AX_JERK_ENABLE 0 0
Scale: 15 µm/div.
Contour precision at a rhombus (max. deviation ca. ± 5 µm)
Scale: 3.2 µm/div.
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2. Torque (acceleration) feedforward control (FFW-Mode 4)
Advantage of the torque feedforward control: very high contour precision, very low following error, very low de-
pendence on velocity.
Disadvantage of the torque feedforward control: Possibly stronger stimulation of the mechanic and therefore a
higher tendency to oscillation marks on the surface.
The machine application requirements define the need for activating feed forward. When feed forward is acti-
vated, the servo response becomes very dynamic, thus, jerk limited acceleration is always necessary to smooth
the dynamic response. The user must weigh the benefits of the higher contour accuracy when feed forward is
active with the possible increased overall acceleration time when jerk limited acceleration is used. Because of
the use of jerk limitation it is probable that the contour deviation is already quite low during acceleration with
speed feed forward activated and therefore it may be that there is only a small benefit from using acceleration
feed forward.
One problem can be any changes in axis inertia. During acceleration feed forward the system anticipates the
amount of current required using MD 32650 Ax_Inertia, therefore if the axis inertia changes this will be wrong.
Therefore acceleration feed forward is more advantageous where the axis inertia does not change e.g. on a
fixed base style of machine, or you have to make a compromise by using the mass of a typical test piece and
fixture on a moving table style of machine.
Requirement: Current-, speed and position controller are already optimized. Positioning behavior with pure
position control must be completely without overshoot.
The following parameters must be adapted:
32620 FFW_MODE 4
32610 VELO_FFW_WEIGHT 1.0
32800 EQUIV_CURRCTRL_TIME 0.0
32650 AX_INERTIA 0.0
32652 AX_MASS 0.0
1424 SPEED_FFW_FILTER_TIME 0.0
1425 SPEED_FFW_DELAY 0.0
1004 CTRL_CONFIG 1001 H (=Bit 12 and Bit 0)
The following parameters have an influence on the adjustment:
32930 POSCTRL_OUT_FILTER_ENABLE 0
32940 POSCTRL_OUT_FILTER_TIME 0.0
32200 POSCTRL_GAIN 3.800000
1407 SPEEDCTRL_GAIN_1 5.500000
1409 SPEEDCTRL_INTEGRATOR_TIME_1 10.0
1414 SPEEDCTRL_REF_MODEL_FREQ 0.0
1500 NUM_SPEED_FILTERS 0
1503 SPEED_FILTER_2_TIME 3.0
1117 MOTOR_INERTIA 0.004800
32610 VELO_FFW_WEIGHT 1.0
32910 DYN_MATCH_TIME 0.006200
32900 DYN_MATCH_ENABLE 0
32402 AX_JERK_MODE 2
32400 AX_JERK_ENABLE 0
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The torque feedforward control can be optimized in the same way as the speed feedforward control with a posi-
tion step (Detail look at speed feedforward control).
In contrast to the speed feedforward who is balanced with the MD 32810 EQUIV_SPEEDCTRL_TIME the torque feed-
forward (=current feedforward = acceleration feedforward) is balanced with the MD 32800 EQUIV_CURRCTRL_TIME.
The MD 32810 EQUIV_SPEEDCTRL_TIME has no effect to the torque feedforward.
For correct calculation of the torque feedforward the axis inertia or at linear motors the axis mass has to be pa-
rameterized approximately. For the first test the motor inertia can be used as a starting value for 32650
AX_INERTIA.
For the first test the relevant MD should be set as follows:
32620 FFW_MODE 4
32800 EQUIV_CURRCTRL_TIME 0.0
32650 AX_INERTIA = MD 1117 MOTOR_INERTIA
32652 AX_MASS 0.0 (only for linear motors)
1424 SPEED_FFW_FILTER_TIME 0.0
1425 SPEED_FFW_DELAY 0.0
1004 CTRL_CONFIG 1001 H (=Bit 12 and Bit 0)
Torque feedforward control active, Ax-Inertia = Motor-Inertia:
32620 FFW_MODE 4
32200 POSCTRL_GAIN 3.800000 32610 VELO_FFW_WEIGHT 1.0
1407 SPEEDCTRL_GAIN_1 5.500000 32800 EQUIV_CURRCTRL_TIME 0.0
1409 SPEEDCTRL_INTEGRATOR_TIME_1 10.0 1117 MOTOR_INERTIA 0.0048
1414 SPEEDCTRL_REF_MODEL_FREQ 0.0 32650 AX_INERTIA 0.0048
1500 NUM_SPEED_FILTERS 0 32652 AX_MASS 0.0
32900 DYN_MATCH_ENABLE 0 1424 SPEED_FFW_FILTER_TIME 0.0
32400 AX_JERK_ENABLE 0 1425 SPEED_FFW_DELAY 0.0
The axis shows the same 'crawling' behavior on the last 10 µm like with speed feedforward control.
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First of all the Axis inertia 32650 AX_INERTIA should be increased. Values till ca. 5 * Motor inertia (1117 MO-
TOR_INERTIA) are practical. Higher values can stimulate the mechanic to oscillation.
Then the MD 32800 EQUIV_CURRCTRL_TIME should be optimized in the same way as the speed feedforward
(overhoot -> longer EQUIV_CURRCTRL_TIME, undershoot -> shorter EQUIV_CURRCTRL_TIME).
The MD 1424 SPEED_FFW_FILTER_TIME can be used for fine tuning for the last µm. The range for this filter time is
typically 50 … 300 µs.
Adjustment for best contour precision:
32620 FFW_MODE 4
32200 POSCTRL_GAIN 3.800000 32610 VELO_FFW_WEIGHT 1.0
1407 SPEEDCTRL_GAIN_1 5.500000 32800 EQUIV_CURRCTRL_TIME 0.0006
1409 SPEEDCTRL_INTEGRATOR_TIME_1 10.0 1117 MOTOR_INERTIA 0.0048
1414 SPEEDCTRL_REF_MODEL_FREQ 0.0 32650 AX_INERTIA 0.018
1500 NUM_SPEED_FILTERS 0 32652 AX_MASS 0.0
32900 DYN_MATCH_ENABLE 0 1424 SPEED_FFW_FILTER_TIME 80
32400 AX_JERK_ENABLE 0 1425 SPEED_FFW_DELAY 0.0
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Positioning behavior with too big
AX_INERTIA:
32620 FFW_MODE 4
32610 VELO_FFW_WEIGHT 1.0
32800 EQUIV_CURRCTRL_TIME 0.0
1117 MOTOR_INERTIA 0.0048
32650 AX_INERTIA 0.02
32652 AX_MASS 0.0
1424 SPEED_FFW_FILTER_TIME 0.0
1425 SPEED_FFW_DELAY 0.0
2.1. Contour precision on the example 'rhombus':
Adjustment for best contour precision, MD like in the picture before:
G64
Scale: 3.2 µm/div.
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