Control Theory

SINUMERIK 840D with

SIMODRIVE 611D

SIMOTION / SINAMICS

Gerhard Forster I DT MC R&D 2

Mechatronic Support

© Siemens AG 2012. All Rights Reserved.

 Fourier series of a square-wave signal

Introduction to
mechanical System
Â/1*sin(1ωt)
Dynamics

1.5
Speed and Position
Controller
1

Speed Feed Forward

0.5

Acceleration Limitation
0 Â/1*sin(1ωt)
0 50 100 150 200 250 300 350 400
Jerk Limitation
-0.5
Assessment of Accuracy
at Axes with different n= 1, 3, 5,
Dynamics (Circular Test) -1 ∞

Overview of the -1.5

Procedure of an
Optimization
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 Fourier series of a square-wave signal

Introduction to
mechanical System
Dynamics

Speed and Position

Controller

Speed Feed Forward

Acceleration Limitation

Jerk Limitation

Assessment of Accuracy
at Axes with different
Dynamics (Circular Test)
n = 99
Overview of the
Procedure of an
Optimization
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 Identification of the Characteristics of the Simplified Model

fT , DT
Linear scale
(DMS)
Introduction to Encoder Table (Load)
mechanical System Coupling

Dynamics Motor Nut

Ball screw

Speed and Position

Machine bed
Controller

Speed Feed Forward

Noise Response to the noise

Acceleration Limitation

Jerk Limitation
Numerical Control 840D

Assessment of Accuracy
at Axes with different
Dynamics (Circular Test) Re sponse to noise
Transfer function s = jw = Frequency response =
noise

Overview of the
Procedure of an
Optimization Presentation of the result in a Bode diagram
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 Identification of the Characteristics of the Simplified Model

xLoad
Introduction to AdB
mechanical System xMot
Dynamics

0-dB-Line
Speed and Position
Controller

Speed Feed Forward

Acceleration Limitation

Jerk Limitation

Assessment of Accuracy
Locked rotor frequency » 20 Hz
at Axes with different
Dynamics (Circular Test)
xMot xLoad | xLoad |
A[dB ] = 20 Log
Overview of the | xMotor |
Procedure of an
Optimization
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 Linear Amplitude Factor = f(dB)

Introduction to 100
mechanical System 100

Dynamics

Speed and Position

10
Controller

Speed Feed Forward Alin = f(dB) Significant Values:

1 0 db = 1
Acceleration Limitation 3 db » 1.4
10 dB » 3.16
Jerk Limitation 20 dB = 10
0.1
-3 dB » 0.7
Assessment of Accuracy -10 dB » 0.316
at Axes with different
Dynamics (Circular Test) -20 dB = 0.1
0.01 0.01
40 30 20 10 0 10 20 30 40
- 40 dB 40
Overview of the
Procedure of an
Optimization
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 Relation Between Frequency Response and Time Response

x Load
A = 14 dB
Introduction to
mechanical System
x Mot »5
Dynamics

Speed and Position

Controller

Speed Feed Forward j » -22 °

Acceleration Limitation

Jerk Limitation
Attention! Scale changed in
the following diagrams
XLoad
Assessment of Accuracy
at Axes with different
Dynamics (Circular Test)

Overview of the
XMot
Procedure of an
Optimization
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Time (sec)
Industry Sector
 Relation Between Frequency Response and Time Response

x Load
A = 22 dB
Introduction to
mechanical System
x Mot » 12.6
Dynamics

Speed and Position

Controller

j » -90 °
Speed Feed Forward

Acceleration Limitation

Jerk Limitation
XLoad
15
Assessment of Accuracy 10
at Axes with different
5
Dynamics (Circular Test)
0

-5
Overview of the
Procedure of an -10 XMot
Optimization -15
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Time (sec)
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 Relation Between Frequency Response and Time Response

x Load
Introduction to x Mot
mechanical System
Dynamics

A = -6.6 dB
Speed and Position » 0.47
Controller

Speed Feed Forward

j » -180 °

Acceleration Limitation

Jerk Limitation

XLoad
Assessment of Accuracy
at Axes with different
Dynamics (Circular Test)

Overview of the
Procedure of an
Optimization
XMot © Siemens AG 2012. All Rights Reserved.
Time (sec)
Industry Sector
 Evaluation of the control property (closed control loop)

Amplitude [ dB ] The gain peak (max. 3 dB) defines the overshoot

Introduction to
mechanical System Amplitude-
Dynamics 0 margin
- 3dB

Speed and Position -20 Natural frequency as high as possible

Controller
Gain peak to a maximum of +3dB

-40 At a phase more negative than -180 degree

Speed Feed Forward à amplitude < 0 dB
(amplitude reserve required)

Acceleration Limitation
Phase [ Grad ]

Jerk Limitation

Assessment of Accuracy 0
at Axes with different
Dynamics (Circular Test)
-90
resonance frequency
Overview of the
(at gain peak)
Procedure of an -180
Optimization
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The natural frequency AG 2012.
(-3 dB) defines theAll Rights
rise time Reserved.
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 Freq. Resp. of the Speed Controller plant:

Introduction to Reference Freq. Resp. of closed Position Control

mechanical System Loop
Dynamics Xact / Xset
Reference Freq. Resp. of closed Speed Control Loop
Ref. Freq. Resp. of Mechanics
nact / nset
nact,DMS / nact,MMS
Speed and Position Speed Controller Plant
Controller nact / iact
Mechanics
xset nset iset iact xact,MMS xact,DMS
Speed Feed Forward

Acceleration Limitation nact

Jerk Limitation

Assessment of Accuracy
at Axes with different Linear scale (direct MS)
Dynamics (Circular Test)
Motor measurement system
(indirect MS)

Overview of the
Procedure of an
Optimization
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 2-Mass-Oscillator (Motor and Load Mass)

c
Introduction to FMot mMot mLoad
mechanical System
Dynamics
xMot D=0,02 xLoad
Speed and Position ·
vMot(t) = xMot(t)
Controller

Transfer Function of the Speed Controller plant:

Speed Feed Forward GSpeedControllerPlant(s) = VMot(s)/ FMot(s)

Bode-Diagram
Acceleration Limitation Resonance
Frequency:
Amplitude [dB]

Pole 1 c c
fP = × +
2 ×p mMot mLoad
Jerk Limitation

Zero
Assessment of Accuracy Locked Rotor Freq.:
at Axes with different
1 c
Dynamics (Circular Test) fZ = ×
Phase [deg]

2 × p mLoad

Overview of the
Procedure of an
Optimization c: [N/m]
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m: [kg]
Industry Sector
 actual speed motor
Freq. Resp. of the Speed Controller Plant: actual torque motor

Introduction to Reference Freq. Resp. of closed Position Control Loop

mechanical System Xact / Xset
Dynamics
Reference Freq. Resp. of closed Speed Control Loop
nact / nset Ref. Freq. Resp. of Mechanics
nact,DMS / nact,MMS
Speed and Position Speed Controller Plant
Controller nact / iact
Mechanics
xset nset iset iact xact,MMS xact,DMS
Speed Feed Forward

nact
Acceleration Limitation

Jerk Limitation

Assessment of Accuracy
at Axes with different Linear scale (direct MS)
Dynamics (Circular Test)
Motor measurement system
(indirect MS)

Overview of the
Procedure of an
Optimization
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 Mass und Stiffness Distribution of a Linear Machine Axis:

fT , DT
Linear scale
(DMS)
Introduction to Encoder Table (Load)
mechanical System Coupling
Dynamics
Motor Nut
Ball screw

Speed and Position

Controller Machine bed

Speed Feed Forward

Tacho Table (Load)

Acceleration Limitation Motor Nut

Ballscrewl
Coupling
Jerk Limitation

Assessment of Accuracy
at Axes with different J_Tacho= J_Motor= J_M1= J_M2= J_M3= J_M4=
Dynamics (Circular Test) c_Tacho= c_Motor= c_M1_M2= c_M2_M3= c_M3_M4=
J_Tacho= Jmot_ges= J_coup/2= J_coup/2+Js Jbscr/2= JT=
p/2=
0,0000025 0,00085 0,0001 0,00028 0,00018 0,00127
Overview of the kgm² C_Tacho= kgm² Cmot= kgm² C_coup= kgm² Cblscr= kgm² Caxial= kgm²
Procedure of an 2800 31600 10314 2604,4416 74,4400533
Nm/rad Nm/rad Nm/rad Nm/rad Nm/rad
Optimization
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 Freq. Resp. of the Speed Controller plant: actual Speed Motor
Multiple Body System actual Torque Motor

Introduction to Bode-Diagram
mechanical System
Dynamics
e.g. Torsion
Ball screw e.g. Res. Freq. of the
Amplitude [dB]

Speed and Position Coupling

Controller

Speed Feed Forward

e.g. locked rotor. Freq. of the Table

Acceleration Limitation e.g. Res. Freq of the first half of the

coupling with motor shaft

Jerk Limitation
Phase [deg]

Assessment of Accuracy
at Axes with different
Dynamics (Circular Test)

Overview of the
Procedure of an
Frequency [Hz]
Optimization
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 actual Speed Motor
Freq. Resp. of Closed Speed Control Loop: commanded Speed Motor

Bode-Diagram
Introduction to
mechanical System
Dynamics

Speed and Position

Controller

Speed Feed Forward

Acceleration Limitation

Jerk Limitation

Assessment of Accuracy
at Axes with different
Dynamics (Circular Test)

Overview of the
Procedure of an Kp = 0,2 Nms/rad
Optimization Tn = 100 ms
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 Freq. Resp. of Closed Speed Control Loop: actual Speed Motor
Kp even more increased! commanded Speed Motor

Bode-Diagram
Attention:
Introduction to Attention:
Vibration tendency!
mechanical System Vibration tendency!
Dynamics

Speed and Position

Controller

Speed Feed Forward

Acceleration Limitation

Jerk Limitation

Assessment of Accuracy
at Axes with different
Dynamics (Circular Test)

Overview of the
Procedure of an Kp = 1 Nms/rad
Optimization Tn = 100 ms
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 Evaluation of the filter criteria

Notch frequency
Introduction to
mechanical System
Dynamics

Speed and Position

Controller
Notch depth
50%
Speed Feed Forward

Acceleration Limitation
Bandwidth

Jerk Limitation 50%

Assessment of Accuracy
at Axes with different
Dynamics (Circular Test)

Overview of the
Procedure of an
Optimization
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 Freq. Resp. of the Closed Speed Control Loop Including the
Current Setpoint Filters: With Kp = 1 Stabile und Reserve

Bode-Diagram
Introduction to Filter active!
mechanical System Result:
Dynamics

Speed and Position

Controller

Speed Feed Forward

Acceleration Limitation

Jerk Limitation

Assessment of Accuracy
at Axes with different
Dynamics (Circular Test)
Kp = 1Nms/rad Band stop 1: f = 590 Hz, BW = 590 Hz, BW_num = 200 Hz
Overview of the Tn = 100 ms Band stop 2: f = 1100 Hz, BW = 1100 Hz, BW_num = 400 Hz
Procedure of an
Optimization
© Siemens AG 2012. All Rights Reserved.
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 Freq. Resp. of the Closed Speed Control Loop Including the
Current Setpoint Filters: Kp increased

Bode-Diagram
Introduction to
mechanical System
Dynamics

Speed and Position

Controller

Speed Feed Forward

Acceleration Limitation

Jerk Limitation

Assessment of Accuracy
at Axes with different
Dynamics (Circular Test)

Kp = 1,4 Nms/rad Band stop 1: f = 590 Hz, BW = 590 Hz, BW_num = 200 Hz
Overview of the
Procedure of an Tn = 100 ms Band stop 2: f = 1100 Hz, BW = 1100 Hz, BW_num = 400 Hz
Optimization
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 active actual Position
Freq. Resp. of the Closed Position Controller commanded position

Introduction to Reference Freq. Resp. of closed Position Control Loop

mechanical System Xact / Xset
Dynamics
Reference Freq. Resp. of closed Speed Control Loop
Ref. Freq. Resp. of Mechanics
nact / nset
nact,DMS / nact,MMS
Speed and Position Speed Controller Plant
Controller nact / iact
Mechanics
xset nset iset iact xact,MMS xact,DMS
Speed Feed Forward

nact
Acceleration Limitation

Jerk Limitation

Assessment of Accuracy
at Axes with different Linear scale (direct MS)

Dynamics (Circular Test) Motor measurement system

(indirect MS)

Overview of the
Procedure of an
Optimization
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 Relationship Between Kv-Factor and
Lowest Locked Rotor Freq.

Introduction to
mechanical System
Kv-Factor [1/s] Erreichbarer Kv-Faktor[1000/min]
Attainable Kv-Factor [1000/min]
Dynamics
no delay Position Control
1666,66 100,0
Speed and Position
Controller with DSC (0,125 ms Pos Control
Cycle Time)

1 ms Pos Control Cycle Time

Speed Feed Forward
166,66 10,0
4 ms Pos Control Cycle Time
Acceleration Limitation

Jerk Limitation 16,66 1,0

Assessment of Accuracy
at Axes with different
Dynamics (Circular Test) 1,66 0,1
1

10

100

1000

10000
Overview of the
Procedure of an Minimale
lowest Tilgerfrequenz
Locked Rotor Frequ. [Hz]
[Hz]
Optimization
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Industry Sector
 Freq. Resp. of the Closed Position Controller With Current
Setpoint Filters: Kv Increased

Bode-Diagram
Introduction to
mechanical System
Dynamics

Speed and Position

Controller

Speed Feed Forward

Acceleration Limitation

Jerk Limitation

Assessment of Accuracy
at Axes with different Bandwidth » 34 Hz
Dynamics (Circular Test) Kv = 1,5 m/min/mm (Position Controller Cycle Time 1ms)

Kp = 1,4 Nms/rad Band stop 1: f = 590 Hz, BW = 590 Hz, BW_num = 200 Hz
Overview of the Tn = 8 ms Band stop 2: f = 1100 Hz, BW = 1100 Hz, BW_num = 400 Hz
Procedure of an without Reference model
Optimization
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 History of Siemens synchronous servomotors

Introduction to
mechanical System
Dynamics 2011

1FK7 G2
2010
Spindle
Speed and& Position
Servo
Controller
Motor
2009
1FK7 Hi
Speed Feed Forward
2008
1FT7 CT
Acceleration Limitation
2006 1FT7 HD

Jerk Limitation
2003 1FK7 CT
1FK7 HD
Assessment of Accuracy
at Axes with different
Dynamics (Circular Test) 1FK6
1995
1FK6 HD

Overview of the 1993 1FT6

Procedure of an
Optimization
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1984 1FT5 1FT5
1FT5
Industry Sector
 Servomotor Charicteristic

Introduction to
mechanical System
Dynamics

Spindle
Speed and& Position
Servo
Controller
Motor

Speed Feed Forward

Acceleration Limitation

Jerk Limitation

Assessment of Accuracy
at Axes with different
Dynamics (Circular Test)

Overview of the
Procedure of an
Optimization
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 1PH8 Spindle Motor Overload Factor

Introduction to
mechanical System
Dynamics

Speed
Spindle
and& Position
Servo
Controller
Motor

Speed Feed Forward

Acceleration Limitation

Jerk Limitation

Assessment of Accuracy
at Axes with different
Dynamics (Circular Test)

Overview of the
Procedure of an
Optimization
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Industry Sector
 Spindle motor Charicteristic

Introduction to
mechanical System
Dynamics

Speed
Spindle
and& Position
Servo
Controller
Motor

Speed Feed Forward

Acceleration Limitation

Jerk Limitation

Assessment of Accuracy
at Axes with different
Dynamics (Circular Test)

Overview of the
Procedure of an
Optimization
© Siemens AG 2012. All Rights Reserved.
Industry Sector