1. 611U drive control profile
611U is a universal-type control panel, It can accept analog volume control, you can also receive a digital volume control (via profibus) .611 U control panel control panel is divided into two kinds of uniaxial and biaxial control panel.
--- 2-axis for sin / cos 1Vpp encoder
--- 2-axis for resovler
--- 1-axis for resovler
2. 611U control mode
Speed / torque mode (speed / torque mode)
In this way, 611U control panel can be used for speed control and torque control. Speed control mode 611U control panel does not have a position control function.
Position mode (position control mode) In this way, 611U control panel can have up to 64 position control statements. Each one can freely define and programming. Including position, velocity, acceleration and other parameters to define. 611U-bit control panel also has speed control functions.
3. 611U can be connected to the motor
1FT6.1FK6.1FK7 Servo Motor (maximum 140NM)
1PH motor (1PH6.1PH7.1PH4.1PH2) Maximum 100KW.
1FN linear motors.
Permanent magnet synchronous motors 1FE1
Standard 1LA induction motor (maximum 100KW)
Without the induction motor encoder
4. 611U can be connected to the measuring system
Resovler, the number of pole pairs 1,2,3,4,5,6
Incremental encoder. Sin / cos 1Vpp maximum pulse number 65535
Absolute Encoder
- Sin / cos 1Vpp
- EnDat
5. 611U range of applications
Textile
Packaging Machinery
Machine
Transmission Line
Woodworking machinery, plastic machinery
Production lines
6. 611U palette
Terminal module
Terminal board a total of 8 inputs and 8 outputs. SW4.1 before the terminal is only assigned to the A axis. SW4.1
This terminal can freely define the future.
Order NO: 6SN1114-0NA00-0AA0
? Profibus-DP module
Profibus communication board, for 611U the profibus communication
Order NO: 6SN1114-0NB01-0AA0
7. 611U and S7 communication
GSD file to import:
GSD file import is to ensure that the correct
Hardware configuration. GSD file in the hardware S7
Or in the random 611U of the TOOL-BOX
Correct choice of Profibus-DP type:
Profibus-DP type depends on the Profibus-DP
Module. Correspondence is as follows:
Profibus-DP1 --- 6SN1114-0NB00-0AA0
Profibus-DP2 --- 6SN1114-0NB00-0AA1
Profibus-DP3 --- 6SN1114-0NB01-0AA0
Parameters and data read and write:
SFC14 ---- read parameters and data
SFC15 ---- write parameters and data
SFC14 and SFC15 the address is hexadecimal, in the
Complete address must be converted. Such as:
Decimal hex
256,100
264,108
SFC14 Example:
CALL SFC 14
LADDR: = W # 16 # 108
RET_VAL: = MW10
RECORD: = P # M 50.0 BYTE 20
LADDR ---- data source starting address
RET_VAL --- error code records
RECORD ---- the start address of stored data
MW50 -
ZSW1 ----
ZSW1.0------ M51.0 ZSW1.8 ------ M50.0
ZSW1.1------ M51.1 ZSW1.9 ------ M50.1
ZSW1.2------ M51.2 ZSW1.10 ------ M50.2
ZSW1.3------ M51.3 ZSW1.11 ------ M50.3
ZSW1.4------ M51.4 ZSW1.12 ------ M50.4
ZSW1.5------ M51.5 ZSW1.13 ------ M50.5
ZSW1.6------ M51.6 ZSW1.14 ------ M50.6
ZSW1.7------ M51.7 ZSW1.15 ------ M50.7
SFC15 Example:
CALL SFC 15
LADDR: = W # 16 # 108
RECORD: = P # M 100.0 BYTE 20
RET_VAL: = MW14
LADDR ---- write data starting address of
RECORD --- user data start address
RET_VAL --- error code records
Write STW1 Example:
MW100 -
STW1 -----
STW1.0------ M101.0 STW1.8 ------ M100.0
STW1.1------ M101.1 STW1.9 ------ M100.1
STW1.2------ M101.2 STW1.10 ------ M100.2
STW1.3------ M101.3 STW1.11 ------ M100.3
STW1.4------ M101.4 STW1.12 ------ M100.4
STW1.5------ M101.5 STW1.13 ------ M100.5
STW1.6------ M101.6 STW1.14 ------ M100.6
STW1.7------ M101.7 STW1.15 ------ M100.7
--- Be free to define the input / output terminals
Terminals are free to define the function. At
simcomU defined in the terminal capabilities.
--- Analog input:
- Speed control 56/14. 24/20
- Torque Control 24/20
--- Analog Output:
- 75/15, 16/15
--10V
- 8-bit D / A Converter
--- Angle encoder (X461/X462)
- P890 = 1 interface as the output
- P890 = 2 interface as input
Spindle Orientation:
- SW5.1 with this function only after
- P0125 = 1 entry into force of spindle orientation function of
- Feature Selection
Terminal choice --- Spindle positioning (28)
Profibus --- STW1 .15
- Location directive statement to complete, if there is no
Specify the statement, the first 0 is the default setting.
Siemens SIMODRIVE 611 power module on the S1 switch settings
SIMODRIVE 611 power module on the S1 switch has the following features: (I / R indicated that feedback from renewable power supply module; UE, said the open-loop power supply module)
S1.1
l OFF:
I / R module into the line voltage = 400VAC ± 10%; DC bus voltage = 600VDC
UE module into the line voltage = 400VAC ± 10%; DC bus voltage = 1.35 × Jin-line voltage
Monitor Threshold: (I / R, UE and monitoring modules)
Pulse Resistance ON = 644VDC (impulse conduction resistance value)
Pulse Resistance OFF = 618VDC (Pulse Resistance off value)
DC bus voltage ≥ 710VDC (DC bus overvoltage value)
l ON:
I / R module into the line voltage = 415VAC ± 10%; DC bus voltage = 625VDC
UE module into the line voltage = 415VAC ± 10%; DC bus voltage = 1.35 × Jin-line voltage
Monitor Threshold: (I / R, UE and monitoring modules)
Pulse Resistance ON = 670VDC (impulse conduction resistance value)
Pulse Resistance OFF = 640VDC (Pulse Resistance off value)
DC bus voltage ≥ 740VDC (DC bus overvoltage value)
S1.2
l OFF:
Ready signal (X111 ready relay)
If the following conditions are met, the relay:
- Power of Internal main contactor closed (terminals NS1-NS2 connected, terminal 48 to enable)
- Enable terminal 63,64
- No Fault is generated (also including the standard interfaces 611A, 611D, and MCU)
- Standard interface or connection into the spin change to the module 611A must be enabled (terminal 663,65)
-NCU/CCU Has been running (SINUMERIK 840D/810D)
-MCU has been running
l ON:
Fault signal (X111 ready relay)
If the following conditions are met, the relay:
- Power of Internal main contactor closed (terminals NS1-NS2 connected, terminal 48 to enable)
- No Fault is generated (also including the standard interfaces 611A, 611D, and MCU)
- Standard interface or connection into the spin change to the module 611A must be enabled (terminal 663,65)
-NCU/CCU Has been running (SINUMERIK 840D/810D)
-MCU has been running
S1.3
l OFF:
Standard setting, regenerative feedback function of the effective
I / R module can be fed into the energy grid
UE module internal resistance of the effective pulse
l ON:
Regenerative feedback function is invalid
I / R module can not be the energy fed into the grid
UE internal pulse resistor module is invalid
Note: This feature is only 10KW following UE module as effective in the 28KW module is invalid
S1.4
l OFF:
When the S1.1 = ON time
l ON:
Jin-line voltage = 480V +6% -10%; DC bus voltage = 1.35 × Jin-line voltage
Monitor Threshold: (I / R, UE and monitoring modules)
Pulse Resistance ON = 744VDC (impulse conduction resistance value)
Pulse Resistance OFF = 718VDC (Pulse Resistance off value)
DC bus voltage ≥ 795VDC (DC bus overvoltage value)
S1.5 This feature is only right I / R power supply module and effective.
l OFF:
Standard setting, power DC bus voltage is controlled
l ON:
DC bus voltage is not controlled DC bus voltage = 1.35 × Jin-line voltage
S1.1 switch settings according to location, in the 600V or 625V power supply when the feed.
S1.6
l OFF:
The square-wave current control loop
l ON:
Standard settings. Closed-loop sinusoidal current control, this feature is only right I / R power supply module and effective.
The following conditions must be met in order to produce sinusoidal current:
n I/R16KW (6SN1145-1BA01-0BA1) HF reactor (6SN1111-0AA00-0BA1) into the line current into the line filter (6SL3000-0BE21-6AA0)
n I/R36KW (6SN1145-1BA02-0CA1) HF reactor (6SN1111-0AA00-0CA1) into the line current into the line filter (6SL3000-0BE23-6AA0)
n I/R55KW (6SN1145-1BA01-0DA1) HF reactor (6SN1111-0AA00-0DA1) into the line current into the line filter (6SL3000-0BE25-5AA0)
n I/R80KW (6SN1145-1BB00-0EA1) HF reactor (6SN1111-0AA00-1EA0) into the line current into the line filter (6SL3000-0BE28-0AA0)
n I/R120KW (6SN1145-1BB00-0FA1) HF reactor (6SN1111-0AA00-1FA0) into the line current into the line filter (6SL3000-0BE31-2AA0)
Tip: with the above list does not match the configuration of the square wave can only be closed-loop current control! ! !
Tuesday, November 24, 2009
Servo-control knowledge
With regard to the three kinds of servo control mode, generally have three kinds of servo-control mode: Speed control mode, torque control mode, position control mode. Want to know is that these three kinds of control mode specific on what basis to choose from?
Speed control and torque control are the analog volume control. Position control is controlled by sending pulses. What is the specific control method used according to customer requirements, to meet to choose what kind of motor function.
If you are the motor speed and position are not required, as long as the output of a constant torque, of course, is to use torque mode.
If you have a certain position and velocity accuracy requirements, while the real-time torque is not very concerned with the torque model is not convenient, with better speed or position modes. If the upper controller has a better closed-loop control functions, with the speed control results will be better. If the request itself is not very high, or, basically no real time requirements of the position control of the upper controller does not have very high demands.
On the servo drive's response rate, the smallest amount of torque mode operation, the drive for the fastest response to control signals; position mode operation the largest, the drive control signals in response to the slowest.
The dynamic performance of the movement has a relatively high demand, we need time to adjust the motor. So, if the controller itself, the computing speed is very slow (eg, PLC, or low-end motion controller), on the location of control of use. If the controller calculation speed is faster, you can use the speed mode, the position loop controller from the drive to reduce the workload of the drive to improve efficiency (such as most of the high-end motion controller); If you have a better control of the Upper device, it can control the torque, the speed loop away from the drive, which is generally only a high-end dedicated controller can be so dry, but this time completely without the use of servo motors.
2. Servo motion control card to connect the general steps to
Have recently seen many people make with the servo motor control card to connect the basic problems, which obviously should be by the control card's technical support staff to answer any questions. Here I give my clients to write the "control card servo motor speed control of the general steps", in order to avoid the ads as much as possible the card does not involve a specific model, and the control card brand model is different from the specific wiring and instructions are also different, and even some of the features do not necessarily support each control card, your reference bar.
1, initialization parameters
In the wiring before initialization parameters.
In the control card: the selected control; PID parameters will be cleared; to control the card by default when you enable signal power off; this state of preservation, ensure the control card again on the power-that is, for this state.
In the servo motor: Set control mode; setting enabled by an external control; encoder signal output of the gear ratio; set control signal and the ratio between the motor speed. In general, it is recommended to make servo work with a maximum design speed of the control voltage corresponding to 9V. For example, Matsushita is set to 1V voltage corresponding to the speed, factory value is 500, if you are only prepared to allow the motor to switch the following work in 1000, then this parameter is set to 111.
2, wiring
The control card power, the connection between the control card and the servo signal line. The following line is the need to take: the control card analog output lines so that it can signal line, servo encoder output signal line. Review wiring without error, the motor and control card (and PC) electricity. At this time motor should not move, and can easily rotate the outside, if not, check the enable signal setup and wiring. External rotation with the motor control card check whether the motor position can accurately detect the changes in, or check the encoder signal wiring and settings
3, test the direction of
For a closed-loop control system, if the feedback signal of the direction is not correct, the consequences will certainly be disastrous. By controlling the card to open servo enable signal. This is the servo should be a lower rate of rotation, which is the legendary "zero drift." General control card will have a zero-drift suppression commands or parameters. Use this command or parameters to see whether the motor speed and direction by this directive (parameter) control. If you can not control, check the wiring and control analog mode parameter settings. Confirmation is given a positive number, the electrical is being transferred, the encoder count increased; given negative, winding back around in circles, the encoder count decreased. If the motor with the load, travel is limited, do not adopt this approach. Test Do not give too much voltage, it is recommended below 1V. If the direction is inconsistent, you can modify the control card or motor parameters, to achieve consistency.
3. Ask: three-loop control principle
1, the first current loop: current loop input is the speed loop PID regulator that after the output, we called the "current loop to the definition of" bar, and then, this is a given current loop and the "feedback current loop" value to compare After the margin of doing in the current loop PID regulator output to the motor, "current loop output" is the motor phase current of each phase, "current loop feedback" is not the encoder feedback but the internal drive installed in each phase Hall elements (magnetic field induced into a current and voltage signals) back to the current loop.
2, speed loop: speed loop PID position loop input is adjusted to set the output as well as the location of the feed-forward value, we call "speed setting", the "speed setting" and "Speed-loop feedback" value to compare After doing the difference in the speed loop PID regulator (mainly the proportional gain and integral processing) after the output is the above mentioned "current loop given." Speed loop feedback from the encoder feedback and the value after "Speed Arithmetic Unit," to get.
3, position loop: Location is the outer ring of the input pulse (usually the case, a direct address to write data to drive the servo exceptions), the external pulse through the smoothing filter processing and electronic gear calculation as a "position of ring settings," setting and the feedback from the encoder pulse counter is calculated through the deviation of the value of the PID position loop after adjustment (proportional gain adjustment, non-integral-differential links) after the output and location of a given feed-forward signal on the combined value the rate mentioned above constitute a ring given. Position loop feedback also came from the encoder.
Encoder mounted on the tail servo motor, it had no connection and current loop, he sampled from the motor rotation rather than the motor current, and the current loop input, output, feedback without any contact. The current loop is formed within the drive, even without the motor, as long as the dummy load is installed on each phase (for example, a light bulb) will be able to form a feedback loop current work. . .
4. For general questions about servo
First of all, I personally think that the most important issue to do servo system is to have a clear concept. A complete set of servo system, should be completed "current loop", "speed ring" and "position loop" control, speed loop and current loop output directly as a given, the output of position loop speed loop as given. Servo drive according to conditions of use of three different settings mode, then the controller should do according to these three modes of the corresponding control. To put it simply, when the servo drive for position mode, its internal needs to adjust all the parameters of the three rings, the upper controller is just a simple given, the controller is open-loop control and, therefore, there is no quality control parameters need to be adjusted. When the servo drive is the speed mode, the controller general to issue-10v voltage as the speed for a given transmitted to the servo drives, while receiving position loop encoder feedback constitutes a closed-loop control, this time controller with adjustable parameters position-dependent control quality parameters, while the servo drive at this time as long as the adjustment speed loop and current loop-related parameter, the drive inside the position loop parameters does not make sense!
You use TRIO controller, which can pulse output, analog output can also be returned at the same time encoder. If you use pulse output, then you need to set the servo drive for position mode, to adjust the position loop, velocity loop and current loop The PID parameters, in addition you want to set the servo drive electronic gear ratio, at this time there is no PID controller parameters need to be adjusted.
If you use analog output increases to return control of the encoder, servo drives is set to speed mode, need to adjust the speed of servo loop parameters related to pid, controller side p_gain, i_gain, d_gain, vff_gain and other parameters needed to be adjusted in order to achieve a good quality control at this time of the position loop servo drive parameters and the electronic gear ratio parameter has no effect. Pid parameter adjustment from the inside out to follow the principle, first adjust current loop parameters, the speed loop parameters, the final position loop parameters, the general situation, you have to set a good servo used within the load ratio, using the recommended parameters can be used, fine-grained control the quality of mediation in the TRIO software, you can turn on the oscilloscope function, you adjust to any changes, can be seen through the oscilloscope, is very convenient!
Accordingly, only when you use the trio controller analog output plus the location of the encoder feedback closed-loop manner, only open-loop control of position loop controller, say, when the servo = 0, the controller is open-loop control, this when the motion commands do not work, only play a role DAC this directive, DAC is a direct analog output instructions, the direct output-10v to 10v voltage to control the servo speed. (In a manner somewhat like the controlled inverter) their descriptions to help you look carefully. When the servo = 1, the position loop closed-loop control, motion commands to be effective.
In the TRIO has a direct connection servo controller enables the output of the relay-type nodes. When the wdog = 1, the output is ON, so that servo enabled, when the wdog = 0, the disconnect servo enabled. WDOG and open loop does not matter. When the controller in operation process, the system failure, which will automatically wdog = 0!
5. Universal CNC servo and dedicated servo What is the difference
Simply put: NC dedicated servo is the servo and CNC systems are closed, NC dedicated servo you can not be applied in other host computer (such as hair pulse, analog command) occasions. And universal servo (talk UTV servo more professional) can only accept pulse or analog command upper machine, you are no way servo universal application of the NC with dedicated servo systems. an example. Siemens 802C (or S) is a general-purpose servo band, and However, 810,840 to fail you have to use it to their own dedicated servo can not. As for the CNC system made in China or Taiwan production of NC system, which control commands are generally issued by pulse or analog (pulse-fat is probably the most simplest of NC ), so they are (only) with a common servo.
Complex point say: NC-specific servo is a servo power after the class. Servo-driven, and numerical control system has many parts made of one of its signals are PWM signals, mounted on the external drive is only one part of the power supply and power amplifier only. The general-purpose servo is different, its various circuits (such as position, velocity, current) and computing all done in the drive. including motor parameters.
To make a few practical application of the distinction it: dedicated servo parameter adjustment is generally to debug the system in NC, while the general-purpose servo servo drives need to debug.
Some special-purpose type servo motor encoder feedback directly back to numerical control system (due to an external power supply and amplifier is just one only), while the general-purpose servo is necessary to take back part of the drive.
Dedicated servo motor encoder number of lines, many of the millions of lines may be poor but far from universal type, and generally that is 2500 and 17BIT (a million used there? Who can receive too come?)
In high-speed high-precision machine tool applications, have to use special-purpose servo and NC can not be, Taiwan and China-made CNC system plus general-purpose servo do not (at least not now). Of course, much cheaper. Something is not how high-end, The Well is that you apply to any occasion. However, in CNC industry, use of special-purpose servo is a trend.
This is why high-end CNC systems with dedicated servo (too many advantages. Does not say), Mitsubishi and General CNC servo two points are also easy to understand.
6. "Location", "Speed," "Torque"
"Position", "Speed," "Torque" is the servo system from the outside to the inside of the three closed-loop control mode.
Position control methods are to complete all of the three closed-loop servo control, the computer need only send a pulse train to the servo unit can be, the computer does not require the completion of the side of the PID control algorithm;
Using the speed control mode, the servo speed and torque to complete (current) two closed-loop control, the computer needs to send analog servo unit, the computer side of the need to complete PID position control algorithm, and then D / A output;
In general, we need to position control system can either use the servo position control mode, you can also use the speed control mode, only the handling of different host computer. In addition, it was considered less susceptible to interference position control mode.
Torque control method is a servo system only for closed-loop torque control, ie a current control, host computer algorithms are simple, just need to send to the servo unit a target torque value, is an analog quantity. Multi-torque control in a single occasion, such as printing system, a motor with the speed or position control methods used to determine the printing location, and the other motor for torque control method is used to form a constant tension.
7. Servo three kinds of control mode
If you are the motor speed and position are not required, as long as the output of a constant torque, of course, is to use torque mode.
If you have a certain position and velocity accuracy requirements, while the real-time torque is not very concerned with the torque model is not convenient, with better speed or position modes. If the upper controller has a better closed-loop control functions, with the speed control results will be better. If the request itself is not very high, or, basically no real time requirements of the position control of the upper controller does not have very high demands.
On the servo drive's response rate, the smallest amount of torque mode operation, the drive for the fastest response to control signals; position mode operation the largest, the drive control signals in response to the slowest.
The dynamic performance of the movement has a relatively high demand, we need time to adjust the motor. So, if the controller itself, the computing speed is very slow (eg, PLC, or low-end motion controller), on the location of control of use. If the controller calculation speed is faster, you can use the speed mode, the position loop controller from the drive to reduce the workload of the drive to improve efficiency (such as most of the high-end motion controller); If you have a better control of the Upper device, it can control the torque, the speed loop away from the drive, which is generally only a high-end dedicated controller can be so dry, but this time completely without the use of servo motors.
8. Will the servo and inverter What is the difference
1, the two things in common:
AC servo technology itself is a draw and the application of frequency conversion technology, in the DC motor servo control based on the way through the conversion of the PWM DC Motor Control imitation to achieve, that is bound to variable frequency AC servo motor, this links: Frequency is the frequency of the 50,60 HZ AC into DC first rectifier, and then can control the gate of the various types of transistors (IGBT, IGCT, etc.) through the carrier frequency and PWM inverter for adjustable frequency adjustable waveform similar to the are cosine pulse of electricity, due to frequency is adjustable, so the speed of AC motor of the adjustable (n = 60f / p, n speed, f the frequency, p the number of pole pairs)
Second, talk about the converter:
A simple inverter can adjust the speed of AC motor, then you can open-loop can be closed-loop control mode and the inverter depending on the setting, which is in the traditional sense of the V / F control mode. Now many of the conversion have been adopted to establish the mathematical model, the AC motor's stator magnetic field UVW3 phase transformation that can control motor speed and torque of the two current components, and now most of the torque control can be carried out well-known brand of inverter are adoption of such control the torque, UVW output of each phase to be Jia Huoer effects of current detection device, the sampling constitutes a closed-loop feedback and current negative feedback loop PID regulator; ABB variable frequency also proposed and such a different way of direct torque control technique , specifically requested access to relevant information. This can not only control the motor speed control motor torque and speed control accuracy of better than v / f control, encoder feedback can also be added from time increases, plus when the control accuracy and response characteristics much better.
Speed control and torque control are the analog volume control. Position control is controlled by sending pulses. What is the specific control method used according to customer requirements, to meet to choose what kind of motor function.
If you are the motor speed and position are not required, as long as the output of a constant torque, of course, is to use torque mode.
If you have a certain position and velocity accuracy requirements, while the real-time torque is not very concerned with the torque model is not convenient, with better speed or position modes. If the upper controller has a better closed-loop control functions, with the speed control results will be better. If the request itself is not very high, or, basically no real time requirements of the position control of the upper controller does not have very high demands.
On the servo drive's response rate, the smallest amount of torque mode operation, the drive for the fastest response to control signals; position mode operation the largest, the drive control signals in response to the slowest.
The dynamic performance of the movement has a relatively high demand, we need time to adjust the motor. So, if the controller itself, the computing speed is very slow (eg, PLC, or low-end motion controller), on the location of control of use. If the controller calculation speed is faster, you can use the speed mode, the position loop controller from the drive to reduce the workload of the drive to improve efficiency (such as most of the high-end motion controller); If you have a better control of the Upper device, it can control the torque, the speed loop away from the drive, which is generally only a high-end dedicated controller can be so dry, but this time completely without the use of servo motors.
2. Servo motion control card to connect the general steps to
Have recently seen many people make with the servo motor control card to connect the basic problems, which obviously should be by the control card's technical support staff to answer any questions. Here I give my clients to write the "control card servo motor speed control of the general steps", in order to avoid the ads as much as possible the card does not involve a specific model, and the control card brand model is different from the specific wiring and instructions are also different, and even some of the features do not necessarily support each control card, your reference bar.
1, initialization parameters
In the wiring before initialization parameters.
In the control card: the selected control; PID parameters will be cleared; to control the card by default when you enable signal power off; this state of preservation, ensure the control card again on the power-that is, for this state.
In the servo motor: Set control mode; setting enabled by an external control; encoder signal output of the gear ratio; set control signal and the ratio between the motor speed. In general, it is recommended to make servo work with a maximum design speed of the control voltage corresponding to 9V. For example, Matsushita is set to 1V voltage corresponding to the speed, factory value is 500, if you are only prepared to allow the motor to switch the following work in 1000, then this parameter is set to 111.
2, wiring
The control card power, the connection between the control card and the servo signal line. The following line is the need to take: the control card analog output lines so that it can signal line, servo encoder output signal line. Review wiring without error, the motor and control card (and PC) electricity. At this time motor should not move, and can easily rotate the outside, if not, check the enable signal setup and wiring. External rotation with the motor control card check whether the motor position can accurately detect the changes in, or check the encoder signal wiring and settings
3, test the direction of
For a closed-loop control system, if the feedback signal of the direction is not correct, the consequences will certainly be disastrous. By controlling the card to open servo enable signal. This is the servo should be a lower rate of rotation, which is the legendary "zero drift." General control card will have a zero-drift suppression commands or parameters. Use this command or parameters to see whether the motor speed and direction by this directive (parameter) control. If you can not control, check the wiring and control analog mode parameter settings. Confirmation is given a positive number, the electrical is being transferred, the encoder count increased; given negative, winding back around in circles, the encoder count decreased. If the motor with the load, travel is limited, do not adopt this approach. Test Do not give too much voltage, it is recommended below 1V. If the direction is inconsistent, you can modify the control card or motor parameters, to achieve consistency.
3. Ask: three-loop control principle
1, the first current loop: current loop input is the speed loop PID regulator that after the output, we called the "current loop to the definition of" bar, and then, this is a given current loop and the "feedback current loop" value to compare After the margin of doing in the current loop PID regulator output to the motor, "current loop output" is the motor phase current of each phase, "current loop feedback" is not the encoder feedback but the internal drive installed in each phase Hall elements (magnetic field induced into a current and voltage signals) back to the current loop.
2, speed loop: speed loop PID position loop input is adjusted to set the output as well as the location of the feed-forward value, we call "speed setting", the "speed setting" and "Speed-loop feedback" value to compare After doing the difference in the speed loop PID regulator (mainly the proportional gain and integral processing) after the output is the above mentioned "current loop given." Speed loop feedback from the encoder feedback and the value after "Speed Arithmetic Unit," to get.
3, position loop: Location is the outer ring of the input pulse (usually the case, a direct address to write data to drive the servo exceptions), the external pulse through the smoothing filter processing and electronic gear calculation as a "position of ring settings," setting and the feedback from the encoder pulse counter is calculated through the deviation of the value of the PID position loop after adjustment (proportional gain adjustment, non-integral-differential links) after the output and location of a given feed-forward signal on the combined value the rate mentioned above constitute a ring given. Position loop feedback also came from the encoder.
Encoder mounted on the tail servo motor, it had no connection and current loop, he sampled from the motor rotation rather than the motor current, and the current loop input, output, feedback without any contact. The current loop is formed within the drive, even without the motor, as long as the dummy load is installed on each phase (for example, a light bulb) will be able to form a feedback loop current work. . .
4. For general questions about servo
First of all, I personally think that the most important issue to do servo system is to have a clear concept. A complete set of servo system, should be completed "current loop", "speed ring" and "position loop" control, speed loop and current loop output directly as a given, the output of position loop speed loop as given. Servo drive according to conditions of use of three different settings mode, then the controller should do according to these three modes of the corresponding control. To put it simply, when the servo drive for position mode, its internal needs to adjust all the parameters of the three rings, the upper controller is just a simple given, the controller is open-loop control and, therefore, there is no quality control parameters need to be adjusted. When the servo drive is the speed mode, the controller general to issue-10v voltage as the speed for a given transmitted to the servo drives, while receiving position loop encoder feedback constitutes a closed-loop control, this time controller with adjustable parameters position-dependent control quality parameters, while the servo drive at this time as long as the adjustment speed loop and current loop-related parameter, the drive inside the position loop parameters does not make sense!
You use TRIO controller, which can pulse output, analog output can also be returned at the same time encoder. If you use pulse output, then you need to set the servo drive for position mode, to adjust the position loop, velocity loop and current loop The PID parameters, in addition you want to set the servo drive electronic gear ratio, at this time there is no PID controller parameters need to be adjusted.
If you use analog output increases to return control of the encoder, servo drives is set to speed mode, need to adjust the speed of servo loop parameters related to pid, controller side p_gain, i_gain, d_gain, vff_gain and other parameters needed to be adjusted in order to achieve a good quality control at this time of the position loop servo drive parameters and the electronic gear ratio parameter has no effect. Pid parameter adjustment from the inside out to follow the principle, first adjust current loop parameters, the speed loop parameters, the final position loop parameters, the general situation, you have to set a good servo used within the load ratio, using the recommended parameters can be used, fine-grained control the quality of mediation in the TRIO software, you can turn on the oscilloscope function, you adjust to any changes, can be seen through the oscilloscope, is very convenient!
Accordingly, only when you use the trio controller analog output plus the location of the encoder feedback closed-loop manner, only open-loop control of position loop controller, say, when the servo = 0, the controller is open-loop control, this when the motion commands do not work, only play a role DAC this directive, DAC is a direct analog output instructions, the direct output-10v to 10v voltage to control the servo speed. (In a manner somewhat like the controlled inverter) their descriptions to help you look carefully. When the servo = 1, the position loop closed-loop control, motion commands to be effective.
In the TRIO has a direct connection servo controller enables the output of the relay-type nodes. When the wdog = 1, the output is ON, so that servo enabled, when the wdog = 0, the disconnect servo enabled. WDOG and open loop does not matter. When the controller in operation process, the system failure, which will automatically wdog = 0!
5. Universal CNC servo and dedicated servo What is the difference
Simply put: NC dedicated servo is the servo and CNC systems are closed, NC dedicated servo you can not be applied in other host computer (such as hair pulse, analog command) occasions. And universal servo (talk UTV servo more professional) can only accept pulse or analog command upper machine, you are no way servo universal application of the NC with dedicated servo systems. an example. Siemens 802C (or S) is a general-purpose servo band, and However, 810,840 to fail you have to use it to their own dedicated servo can not. As for the CNC system made in China or Taiwan production of NC system, which control commands are generally issued by pulse or analog (pulse-fat is probably the most simplest of NC ), so they are (only) with a common servo.
Complex point say: NC-specific servo is a servo power after the class. Servo-driven, and numerical control system has many parts made of one of its signals are PWM signals, mounted on the external drive is only one part of the power supply and power amplifier only. The general-purpose servo is different, its various circuits (such as position, velocity, current) and computing all done in the drive. including motor parameters.
To make a few practical application of the distinction it: dedicated servo parameter adjustment is generally to debug the system in NC, while the general-purpose servo servo drives need to debug.
Some special-purpose type servo motor encoder feedback directly back to numerical control system (due to an external power supply and amplifier is just one only), while the general-purpose servo is necessary to take back part of the drive.
Dedicated servo motor encoder number of lines, many of the millions of lines may be poor but far from universal type, and generally that is 2500 and 17BIT (a million used there? Who can receive too come?)
In high-speed high-precision machine tool applications, have to use special-purpose servo and NC can not be, Taiwan and China-made CNC system plus general-purpose servo do not (at least not now). Of course, much cheaper. Something is not how high-end, The Well is that you apply to any occasion. However, in CNC industry, use of special-purpose servo is a trend.
This is why high-end CNC systems with dedicated servo (too many advantages. Does not say), Mitsubishi and General CNC servo two points are also easy to understand.
6. "Location", "Speed," "Torque"
"Position", "Speed," "Torque" is the servo system from the outside to the inside of the three closed-loop control mode.
Position control methods are to complete all of the three closed-loop servo control, the computer need only send a pulse train to the servo unit can be, the computer does not require the completion of the side of the PID control algorithm;
Using the speed control mode, the servo speed and torque to complete (current) two closed-loop control, the computer needs to send analog servo unit, the computer side of the need to complete PID position control algorithm, and then D / A output;
In general, we need to position control system can either use the servo position control mode, you can also use the speed control mode, only the handling of different host computer. In addition, it was considered less susceptible to interference position control mode.
Torque control method is a servo system only for closed-loop torque control, ie a current control, host computer algorithms are simple, just need to send to the servo unit a target torque value, is an analog quantity. Multi-torque control in a single occasion, such as printing system, a motor with the speed or position control methods used to determine the printing location, and the other motor for torque control method is used to form a constant tension.
7. Servo three kinds of control mode
If you are the motor speed and position are not required, as long as the output of a constant torque, of course, is to use torque mode.
If you have a certain position and velocity accuracy requirements, while the real-time torque is not very concerned with the torque model is not convenient, with better speed or position modes. If the upper controller has a better closed-loop control functions, with the speed control results will be better. If the request itself is not very high, or, basically no real time requirements of the position control of the upper controller does not have very high demands.
On the servo drive's response rate, the smallest amount of torque mode operation, the drive for the fastest response to control signals; position mode operation the largest, the drive control signals in response to the slowest.
The dynamic performance of the movement has a relatively high demand, we need time to adjust the motor. So, if the controller itself, the computing speed is very slow (eg, PLC, or low-end motion controller), on the location of control of use. If the controller calculation speed is faster, you can use the speed mode, the position loop controller from the drive to reduce the workload of the drive to improve efficiency (such as most of the high-end motion controller); If you have a better control of the Upper device, it can control the torque, the speed loop away from the drive, which is generally only a high-end dedicated controller can be so dry, but this time completely without the use of servo motors.
8. Will the servo and inverter What is the difference
1, the two things in common:
AC servo technology itself is a draw and the application of frequency conversion technology, in the DC motor servo control based on the way through the conversion of the PWM DC Motor Control imitation to achieve, that is bound to variable frequency AC servo motor, this links: Frequency is the frequency of the 50,60 HZ AC into DC first rectifier, and then can control the gate of the various types of transistors (IGBT, IGCT, etc.) through the carrier frequency and PWM inverter for adjustable frequency adjustable waveform similar to the are cosine pulse of electricity, due to frequency is adjustable, so the speed of AC motor of the adjustable (n = 60f / p, n speed, f the frequency, p the number of pole pairs)
Second, talk about the converter:
A simple inverter can adjust the speed of AC motor, then you can open-loop can be closed-loop control mode and the inverter depending on the setting, which is in the traditional sense of the V / F control mode. Now many of the conversion have been adopted to establish the mathematical model, the AC motor's stator magnetic field UVW3 phase transformation that can control motor speed and torque of the two current components, and now most of the torque control can be carried out well-known brand of inverter are adoption of such control the torque, UVW output of each phase to be Jia Huoer effects of current detection device, the sampling constitutes a closed-loop feedback and current negative feedback loop PID regulator; ABB variable frequency also proposed and such a different way of direct torque control technique , specifically requested access to relevant information. This can not only control the motor speed control motor torque and speed control accuracy of better than v / f control, encoder feedback can also be added from time increases, plus when the control accuracy and response characteristics much better.
Monday, November 23, 2009
Siemens Numerical Control System Debugging Tools Sinumerik 840D
1. DOConCD
Siemens SINUMERIK CNC system, SIMODRIVE / SINAMICS drives, 1FT/1FK7/1PH7/1FN3/1FW6 such as motor complete CD-ROM data, including operation, installation, commissioning, and so all the contents, of course, there will be updated every year, but preferable to retain the old version better CD-ROM.
DOConCD: 6FC5298-0CD00-0BG0
2. STEP7 and programming cable
SINUMERIK810D/840D the PLC debugging software, running on the computer, through a programming cable to connect to the system. Of course, there are installed on the PCU50 on STEP7 version.
STEP7 software: 6ES7 810-4CC08-0YA5
Programming Cable: 6GK1 551-2AA00
For PCU50 the STEP7 software: 6FC5252-0AY00-0AG0
3. Toolbox
Including the PLC, the basic procedures and some examples of PLC (knife database management, HHU, etc.), as well as the system is compatible with the table.
The current version of the Toolbox: 6FC5252-0AX21-0AB0
4. Start-up tool for 611D
If the system configuration is MMC100/MMC100.2/PCU20 etc. PC hard drive unit without the need to use this software to debug and optimize the drivers (software installed on the computer).
See SinuCom
5. U Disk
PCU50 support the use of U disk, the file copy for debugging very convenient.
Siemens 512M U Disk: 6ES7648-0DC20-0AA0
6. Cable
PCU50 have ready-made network interface, debugging more convenient to use, such as copying files or modify the INI files, and so. Finally, after a good overall debugging, recommended the adoption of network cable to the hard disk as a whole to be a backup PCU50!
7. CF Card
Typically used in PCU20, as a processing program memory expansion.
Siemens 512M CF card: 6FC5313-4AG00-0AA1
8. Ghost
PCU50 on GHOST software for hard disk partition the entire disk with backups.
9. SinuCom
It is composed of several software, which SinuCom ARC software can open NC system backup files (that is, the file suffix named ARC).
CD-ROM: 6FC5250-0AY00-0AG0
10. PCIN
RS232 communication software, but slowly being U disk, network and other means of transmission replaced.
Siemens SINUMERIK CNC system, SIMODRIVE / SINAMICS drives, 1FT/1FK7/1PH7/1FN3/1FW6 such as motor complete CD-ROM data, including operation, installation, commissioning, and so all the contents, of course, there will be updated every year, but preferable to retain the old version better CD-ROM.
DOConCD: 6FC5298-0CD00-0BG0
2. STEP7 and programming cable
SINUMERIK810D/840D the PLC debugging software, running on the computer, through a programming cable to connect to the system. Of course, there are installed on the PCU50 on STEP7 version.
STEP7 software: 6ES7 810-4CC08-0YA5
Programming Cable: 6GK1 551-2AA00
For PCU50 the STEP7 software: 6FC5252-0AY00-0AG0
3. Toolbox
Including the PLC, the basic procedures and some examples of PLC (knife database management, HHU, etc.), as well as the system is compatible with the table.
The current version of the Toolbox: 6FC5252-0AX21-0AB0
4. Start-up tool for 611D
If the system configuration is MMC100/MMC100.2/PCU20 etc. PC hard drive unit without the need to use this software to debug and optimize the drivers (software installed on the computer).
See SinuCom
5. U Disk
PCU50 support the use of U disk, the file copy for debugging very convenient.
Siemens 512M U Disk: 6ES7648-0DC20-0AA0
6. Cable
PCU50 have ready-made network interface, debugging more convenient to use, such as copying files or modify the INI files, and so. Finally, after a good overall debugging, recommended the adoption of network cable to the hard disk as a whole to be a backup PCU50!
7. CF Card
Typically used in PCU20, as a processing program memory expansion.
Siemens 512M CF card: 6FC5313-4AG00-0AA1
8. Ghost
PCU50 on GHOST software for hard disk partition the entire disk with backups.
9. SinuCom
It is composed of several software, which SinuCom ARC software can open NC system backup files (that is, the file suffix named ARC).
CD-ROM: 6FC5250-0AY00-0AG0
10. PCIN
RS232 communication software, but slowly being U disk, network and other means of transmission replaced.
Knowledge of Siemens 840D
SIEMENS PLC system Siemens SIMATIC MAGAGER used for PLC programming to carry out state control machine tool components, it mainly consists of power supply module, CPU module, input and output module, its interface with, RS232 interface, PROFIBUS Interface , MPI cable interfaces. Through the X122, MPI jack, so that the computer with the NCU connected PLC.
Hardware Configuration
Hardware configuration: tell the PLC hardware structure of the process of
Baud Rate: MPI 187.5kbps
OPI 1.5Mbps
Process: to build the project - → Jianzhan - → Configuration Hardware
? Auto Configuration: The Cable Construction PLC and 840D connected to an automatic configuration automatic identification (upload station) will be transmitted PLC computer:
PLC-→ UPLOAD-→ select MPI Address = 2, if the Address = 3, will include the PLC and the NCU
If the backup PLC, then the process is:
New Project-→ plc-→ upload station, so the hardware will be backed up.
End station building, there even folders: hardware and cpu.CPU folder under the S7 program.
S7 program there are three directories:
(1) symbols such as I40.1 symbol table for the first 40 bytes of the first one
(2) BLOCKS function block
? Manual Configuration:
Process: Open the S7-→ New File - → INSERT-→ STATION-→ SIMATIC 300 - → double-HARDWARE-→ appear Box - → INSERT-→ HARDWARE COMPONENT-→ PROFILE-→ STANDARD-→ S300-→ RACK300
Select the appropriate position (to be set bits in the table), then the corresponding module on the right side double-click on modules will be chosen, selected and then download the
Programming
PLC programming course, the can use the following three forms:
Ladder Logic (LAD):
Statement List (STL):
Function Block Diagram (FBD):
Statement List programming instructions commonly used:
And instruction: A normally open AN NC
Or to order: O Normally open ON NC
Output instructions: =
Call instruction: CALL FCXX
FP: rising edge detection instruction
FN: falling edge detection instruction
After the FP must register with the middle of
CLR operation results, Clear
SET set a
S Set 1
R Clear
Block
? STEP7 There are several commonly used BLOCK Main: OB tissue mass, FC function blocks, FB function blocks, DB data blocks, etc.
OB: function blocks, equivalent to the main program, often are OB1 and OB100;
FC, FB: Function Block, which is equivalent subroutine
Subroutine in the compilation finished, you must call the subroutine in the main program in the PLC after power-OB100 is the first execution, is executed only once; OB1 is the PLC CPU cycles implementation process. After the first implementation of the power-OB100, and then the implementation of OB1 (repeated implementation; OB100 call FB1 (Siemens compiled good)
FB1 is the system bus connection PCU with OPI and MCP, the control panel Definition:
(1) control panel starting address of the input address
(2) the number of control panel
(3) The control panel's output addresses starting address
Control Panel MPI Address: MCPIBUSADR = 6
? OB1 block
FC2: Basic NCK and PLC communications NCK ← → PLC
FC2 must be OB1 the beginning of FC2 ---- "gp_hp"
FC10: dealing with alarm information FC10 ---- "AL-MSG"
PLC generated alarm, passed NCK, NC to take measures, while MMC displays alarm text called FC10, there are two parameters must be set
TouserIF = TRUE (equivalent to 1) and FALSE (equivalent to 0)
Quit: = I3.7 (warning text). Alarm Reset button (RESET) addresses I3.7
FC19: Machine control panel main program FC19 ---- "MCP-IFM"
BAGNO (mode group number) = B # 16 # 1 (B - B hex 16-16 hex)
CHANNO (channel number) = B # 16 # 1
SPINDLEIFNO: = B # 16 # 4 (spindle number)
FEEDHOLD = M100.0 (feed suspended)
SPINDLEHOLD = M100.1 (spindle stop)
? DB block
1. DB module types are:
DBB - Data Module Type
DBW - block word (16 bit)
DBD - block double word (32 bit)
2. Data Type:
DOUBLE: real or integer number, input range ± 4.19 × 10-307 ----± 1.67 × 10308
DWORD: integer number, ranging from -2.147 × 109 ---- 2.147 × 109
BOOLEAN: 0 be a
BYTE: integer, range digital -128 ---- 127
STRING: a maximum of 16-bit string
3. Common data block feature
DB2: alarm interface signals. The signal from the PLC to the NCK, in the PLC set the corresponding bit in the MMC will be able to generate a corresponding alarm number (seven at the beginning of the alarm is set by machine field assumption)
DB10: Show NCU state, used to exchange NCK fast I / O interface to the state, there are a number of the state of the signal NCK
DB11: mode group signal interface
DB19: Operation panel signal interface
DB21-DB30: channel signal interface
DB31-DB61: shaft / spindle interface signals
4. Debugging a common data block mainly by:
DBX6.0: feed to be able to prohibit
DBX6.1: read to be able to prohibit
DBX7.0: Start to be able to prohibit PLC → NC
DBX7.7: Channel reset
DBX194.0 --- DBX206.3 NC → PLC
DBX1.5: entry into force of a measurement system
DBX1.6: force measurement system 2
DBX2.1: Control enabled
DBX21.7: Pulse enable (if not, compared to the free end)
DBX4.3: Axis Stop PLC → NC
DBX12.0: the hard-axis negative limit
DBX12.1: the hard-axis positive limit
DBX12.7: back to zero deceleration
DBX61.7: current loop effective
DBX61.6: speed loop effective
DBX61.5: Position Loop Effective
DBX61.4: axial static
DBX83.5: spindle speed setting within the framework of
SIEMENS PLC system Siemens SIMATIC MAGAGER used for PLC programming to carry out state control machine tool components, it mainly consists of power supply module, CPU module, input and output module, its interface with, RS232 excuse, PROFIBUS excuse , MPI cable interfaces. Through the X122, MPI jack, so that the computer with the NCU connected PLC.
Hardware Configuration
Hardware configuration: tell the PLC hardware structure of the process of
Baud Rate: MPI 187.5kbps
OPI 1.5Mbps
Process: to build the project - → Jianzhan - → Configuration Hardware
* Auto-configuration: The construction of PLC and 840D cable connected to an automatic configuration of automatic identification (upload station) will be transmitted PLC computer:
PLC-→ UPLOAD-→ select MPI Address = 2, if the Address = 3, will include the PLC and the NCU
If the backup PLC, then the process is:
New Project-→ plc-→ upload station, so the hardware will be backed up.
End station building, there even folders: hardware and cpu.CPU folder under the S7 program.
S7 program there are three directories:
(1) symbols such as I40.1 symbol table for the first 40 bytes of the first one
BLOCKS function block
* Manual configuration:
Process: Open the S7-→ New File - → INSERT-→ STATION-→ SIMATIC 300 - → double-HARDWARE-→ appear Box - → INSERT-→ HARDWARE COMPONENT-→ PROFILE-→ STANDARD-→ S300-→ RACK300
Select the appropriate position (to be set bits in the table), then the corresponding module on the right side double-click on modules will be chosen, selected and then download the
Programming
PLC programming course, the can use the following three forms:
Ladder Logic (LAD):
Statement List (STL):
Function Block Diagram (FBD):
Statement List programming instructions commonly used:
And instruction: A normally open AN NC
Or to order: O Normally open ON NC
Output instructions: =
Call instruction: CALL FCXX
FP: rising edge detection instruction
FN: falling edge detection instruction
After the FP must register with the middle of
CLR operation results, Clear
SET set a
S Set 1
R Clear
Block
BLOCK main · STEP7 There are several commonly used: OB tissue mass, FC function blocks, FB function blocks, DB data blocks, etc.
OB: function blocks, equivalent to the main program, often are OB1 and OB100;
FC, FB: Function Block, which is equivalent subroutine
Subroutine in the compilation finished, you must call the subroutine in the main program
OB100 is a PLC after power-first execution, is executed only once; OB1 is the PLC CPU cycles implementation process. After the first implementation of the power-OB100, and then the implementation of OB1 (repeated implementation; OB100 call FB1 (Siemens compiled good)
FB1 is the system bus connection PCU with OPI and MCP, the control panel Definition:
(1) control panel starting address of the input address
(2) the number of control panel
(3) The control panel's output addresses starting address
Control Panel MPI Address: MCPIBUSADR = 6
· OB1 block
FC2: Basic NCK and PLC communications NCK ← → PLC
FC2 must be OB1 the beginning of FC2 ---- "gp_hp"
FC10: dealing with alarm information FC10 ---- "AL-MSG"
PLC generated alarm, passed NCK, NC to take measures, while MMC displays alarm text
Call FC10, there are two parameters must be set
TouserIF = TRUE (equivalent to 1) and FALSE (equivalent to 0)
Quit: = I3.7 (warning text). Alarm Reset button (RESET) addresses I3.7
FC19: Machine control panel main program FC19 ---- "MCP-IFM"
BAGNO (mode group number) = B # 16 # 1 (B - B hex 16-16 hex)
CHANNO (channel number) = B # 16 # 1
SPINDLEIFNO: = B # 16 # 4 (spindle number)
FEEDHOLD = M100.0 (feed suspended)
SPINDLEHOLD = M100.1 (spindle stop)
· DB block
1. DB module types are:
DBB - Data Module Type
DBW - block word (16 bit)
DBD - block double word (32 bit)
2. Data Type:
DOUBLE: real or integer number, input range ± 4.19 × 10-307 ----± 1.67 × 10308
DWORD: integer number, ranging from -2.147 × 109 ---- 2.147 × 109
BOOLEAN: 0 be a
BYTE: integer, range digital -128 ---- 127
STRING: a maximum of 16-bit string
3. Common data block feature
DB2: alarm interface signals. The signal from the PLC to the NCK, in the PLC set the corresponding bit in the MMC will be able to generate a corresponding alarm number (seven at the beginning of the alarm is set by machine field assumption)
DB10: Show NCU state, used to exchange NCK fast I / O interface to the state, there are a number of the state of the signal NCK
DB11: mode group signal interface
DB19: Operation panel signal interface
DB21-DB30: channel signal interface
DB31-DB61: shaft / spindle interface signals
4. Debugging a common data block mainly by:
DBX6.0: feed to be able to prohibit
DBX6.1: read to be able to prohibit
DBX7.0: Start to be able to prohibit PLC → NC
DBX7.7: Channel reset
DBX194.0 --- DBX206.3 NC → PLC
DBX1.5: entry into force of a measurement system
DBX1.6: force measurement system 2
DBX2.1: Control enabled
DBX21.7: Pulse enable (if not, compared to the free end)
DBX4.3: Axis Stop PLC → NC
DBX12.0: the hard-axis negative limit
DBX12.1: the hard-axis positive limit
DBX12.7: back to zero deceleration
DBX61.7: current loop effective
DBX61.6: speed loop effective
DBX61.5: Position Loop Effective
DBX61.4: axial static
DBX83.5: spindle speed setting within the framework of
Common Maintenance Failure Analysis
1. Machine operating mode and channel of choice:
As the NCK function continuously strengthened, a NCK can complete multiple systems to complete the original work, which can have multiple channels, a channel rather with an independent NC, 840D can have up to 10 channels, each channel has its own zero over the set, tool compensation and R parameters, but the program area is shared, each channel has its own working methods, if the work of several channels have been the same, then this constitutes a method group. the 840D on the , mode is way switch to select, access is key to W1 ... n to choose.
2. Tools and zero-bias
Because different tools have different geometric shapes and geometry, while the program is subject to the workpiece size and therefore require compensation tool, each with its own knife, there is a corresponding geometric shape of the tool types, such as drills, milling cutters. Each of the knife can have more than a knife fill size to D, to mark the
Like with the tool, processing of different parts require different zero, so there is zero bias, in the 840D using G54 to G57 to select, if necessary, the number of zero-bias can also be used to expand the machine parameters.
3.840D system maintenance
* Maintenance of liquid crystal displays
LCD display life of 30,000 hours. While the backlight tube life is time 10000 - 20,000 hours.
Replacement backlight tube methods: a. Open the protective cover b. monitor the installation of loose screws, disconnect the power supply and display backlight control signal cable, remove the display c. replace the backlight tube d. above steps to install the opposite
* Replacement of the battery
A total of 840 system, two batteries, one in MMC above, the main information to save CMOS, and its lifetime is at least ten years, it is generally no need to replace. NCU BOX also a battery inside, and fans together, it's life generally three years or so, to save the NCK inside the programs and data, because of the protection of capacitor charging, you can replace the battery after the NCK full power, but time can not be more than 15 minutes
This is the same as two battery models. Model: 6FC5247-0AA18-0AA0
(Note: the replacement battery it is best to make a few NCK and the PLC, data backup, Siemens 840C battery in the CSB board, must be the case of electricity in the system to replace!)
4.840D system data backup
840D system data are many, including NCK data, PLC data and MMC data, which NCK and PLC data is by the battery to maintain, and it directly affects the loss of the normal operation of NC, while the data is stored in the MMC MMC hard disk (MMC103), or Flash EPROM inside (MMC100.2), which under normal circumstances, the loss of NC data only affect the display and input.
System data backup methods are the following three
(1) backup to MMC's hard disk (only MMC103 adaptation), it is recommended best MMC, NCK and the PLC's data separately for backup, the file name is best to use the system default file name plus the date.
(2) backup to a floppy disk or through the RS232 port on the backup to an external computer.
(3) back to the NCK above the PCMCIA card, the card is an NC system, installed programs 8M of Flash EPROM card. It is about 5M or so of space can be used to store backup data. This feature is only in the MMC software version 5.0 and above to be used. Such data without a hard drive backup methods particularly suitable for the MMC100.2.
5. MMC103 file structure
· MMC103's hardware is actually a band MPI (OPI) interface PC. Software is running on the WINDOWS operating system on a man-machine interface software. As the MMC version of the software not the same as its operation, the operating system are not the same, there are early WIN32, the mid-WIN95 and now WINNT, to run in WIN95 environment MMC Ver5.3 example shows the file structure MMC.
· MMC103 hard disk is divided into two partitions, C: drive and D: drive, where D is mainly used to store the hard disk drive and partition number of backup files, including several versions of the system brought about by MMC system backup, but also used to install software to use as a temporary storage area. C drive is mainly stored WINDOWS operation of the system files, MMC's system files, machine tool manufacturers developed a number of add-on software and user programs and data.
· C drive under the directory structure:
C drive has the following directories under the main
MMC2: Siemens, is mainly used to store system files, Siemens there are also some standard configuration files in this directory, the directory the file is best not to modify the. Windows storage running Windows system files and other documents under Windows environment,
Add_on: Siemens add-on products, such as remote diagnostics. OEM used to store tools on their own development
Products.
USER: storing the user's own profile, not the same as all the standard configuration files are stored in this directory, such as alarm settings for the service.
DH: used to store data associated with the NCK, NCK its file structure and file structure, have a piece subdirectories, the workpiece main program directory, a subdirectory subroutine, the standard fixed-cycle subdirectory, the user such as a fixed cycle of subdirectories. User alarm texts are generally the existence of the directory the following subdirectories inside MB.
These are the MMC103's file structure, in general, the user's own files are stored in the back of four directories inside, so MMC data backup is mainly a backup four directories and files.
Note: MMC earlier version of the user's own configuration files and system configuration files are stored in the system files directory.
· MMC103 alarm server configuration
MMC103 configuration are mostly. INI file for the suffix to achieve, such as knives library display, all kinds of operating mode password level required to operate, as well as alarm settings for the server, the following set up to alert the server to home shows the configuration file changes.
MMC is responsible for the display of alarm text, alarm text stored in MMC2 and DH the following subdirectories inside the MB, the file name format Alxx_xx.com, of which the first two XX said alarm contents of the text, followed by two XX said that the language of the text alert . For example ALP_UK.COM said yes PLC alarm text, language is English. And the relevant alarm display settings are stored in MBDDE.INI file.
Note: The user directory the following configuration files covering MMC2 directory configuration files. WINDOWS system configuration files of all the sum can not exceed 60KB.
6.611 series of drives and motors works
* 611 series AC variable speed drive is a device that by controlling the power supply, the frequency of AC motor to achieve speed control purposes. The main part is from a DC to AC into the rectifier and the DC into an AC variable frequency inverter component. Due to the different interface signals,
The characteristics of servo motor
Because of the motion control, CNC machine tools demanding, and requires a good dynamic characteristics, a large speed range and accurate position control precision, and therefore it requires a special servo motor drive systems generally use the Siemens synchronous servo motor, spindle is Precision induction motor, its principles and general principles of the same squirrel-cage motors, synchronous servo motor and induction motors The biggest difference is not the same as the structure of the rotor. synchronous motors have a staggered distribution of the rotor pole, and therefore require a corresponding test rotor position detection component, replacement of components when these tests also need to re-adjust, the following is commonly used in three kinds of motor Siemens distinction:
· 1FT5 and 1FT6/1FK6 difference between motor
Both the motor is basically the same principle, but not the same as the structure and detection devices, 1FT5 AC servo motor used in the system, while 1FT6 motors are used in the digital servo system.
Stator winding structure is different, 1FT6 motor stator winding structure allows the motor current is much closer to being the cosine waveforms
1FT5 motor tachometer generator is used to detect the speed of the motor with the sharing circle on the Hall element to detect the relative position of the rotor, and 1FT6 motor is used to detect a position encoder motor speed, the motor encoder in addition the conventional A, B, and R phase are cosine signals, there are two C phase and D phase is cosine signals to detect the rotor position.
1FK6 1FT6 motors, like principles, only a little difference in the mechanical structure, 1FK6 more 1FT6 economy.
l Note: The replacement of the motor encoder should pay attention to the encoder zero position, replace the encoder to ensure that when you replace the front and rear rotor is not moving when the encoder wheel on a shell on the signs on signs and the relative position of the same, if the This relative position has changed only through the oscilloscope to adjust. the location of the encoder does not affect the motor is running, such as not running smoothly, the current is too large, and even affect the motor life.
7. Servo motor and spindle motor of the difference between
Rotor structure is different, the spindle motor rotor and squirrel cage rotor motor, like the absence of magnetic poles, which does not require the corresponding rotor position detection signal, 1PH7 spindle motor encoder model ERN1381, 1FT6/1FK6 the motor encoder type To ERN1387, the main difference is that ERN1381 no additional C-phase and D believe that number, and therefore do not need to re-adjust the replacement of the encoder, ERN1387 can be used in 1PH motors, but in turn ERN1381 can not be used in the feed motor.
Spindle motor power of a great general, and thus the motor structure of cooling demand is higher.
Not the same scope of work, servo motor operates at the lowest speed and rated speed constant torque between the areas, while the spindle motor operates at rated speed and maximum speed constant power between the areas, because to achieve a great speed range of spindle the motor rated speed is generally very low
Common repair techniques
ERN1387 Encoder Replacement Method
1. Unloading open motor rear cover, rear cover encoder
2. Release encoder mounting screws
3. Rotating rotor shaft, so that the encoder rotor encoder on the signs and marks on the shell overlap
4. Remove encoder, attention to handling the time out to make use of a special screw top to avoid damage to the encoder
5. Rotation of new encoders, so that the two signs coincide encoder
6. According to the above reverse order to install the encoder
Note: In the process of installing the encoder, to ensure that the rotor different, otherwise they will lose the relative position of the rotor, if the loss of the relative position of the old motor will need to use the oscilloscope to adjust the installation position of the encoder, the new motor can be based on a sign of rotor shaft to adjust the encoder to determine the installation location, which can be mechanical adjustments, you can also adjust the drive parameters MD1016 to set an offset value, but the method can only be used in the 840D, through this method to adjust the motor change to other machine tool use may be due to the different driving parameters can not work properly.
* Zero adjustment
Adjustment steps are as follows: startup - → machine data - → Axis MD - → parameter adjustments: 34100 (axis coordinate value in the reference power) Amendment, if the change finished, now and in the original difference of 10mm, will be adjusted parameters 34100 to 10.
Can also 34090 (reference point offset) to modify: It is now zero difference with the original zero, the number.
* A simple power module detection method:
As the power module is the main parts of high-power tubes, with the following methods can be broadly detect power tube is good or bad:
Multimeter hit resistance profile, with a multimeter is the table T received a power module DC voltage input terminals P600, the land received a three-phase power tube power output U2, V2, W2, the time should be infinite resistance, exchange multimeter two tables T, the resistance should be rare. the multimeter pen received the M600 on a table, repeat the above process, the results should be, and above just the opposite.
Motor temperature alarm processing
Motor which is equipped with thermal resistance of the signal through the signal cable back to the driver control panel inside, when the temperature reaches alarm value, the system to produce alarm, end feedback can be detected when the corresponding resistance value, the alarm if you need to shield , the 611D can be in the driving parameters MD1608 (the control panel of the 611A is a parameter MD64) to set a value of less than 100, you can mask the alarm, the method can only be used in diagnosis.
611A spindle encoder alarm control unit shield
Driver control panel connected encoder can be monitored, if there is an exception, then generate a corresponding alarm, 611A spindle control panel can be the parameter MD P-90 bit 2 set a screen of the alarm.
611D-driven V / F control
Sometimes, in order diagnostic, drivers need to be open-loop frequency control, this method can only be used for diagnostic purposes, and the speed can not be set too high. MD1014 is a set driving parameters shall be open-loop frequency control
Driven optimization
CNC driven by the current loop, velocity loop and position loop composed of the optimization in general from the inside and outer layers of optimization, but because of current loop parameters of the motor and power module model is established with the factory default parameter, the general does not require optimization, it is optimization optimize the speed of the first ring, and then you can optimize the position loop.
Speed loop optimization, generally related to the speed loop gain and speed loop time constant, the speed loop time constant and gain the greater the lower the speed loop and more stable, but the accuracy and dynamic characteristics of the worse, in general, the speed loop time constant is located in 10ms, while the speed loop and speed loop gain adjustment in making the order is about to respond to a 20-40 overshoot.
Position loop optimization involves the position loop gain and acceleration, before adjustment can reduce the acceleration value, and further increase the value of position loop gain to ensure the system is stable, and then increase the acceleration at an appropriate value, and to adapt the mechanical properties of machine tools, pay attention to the same group of interpolation axis position loop gain to be consistent, otherwise it will affect the machining accuracy.
Axis shield deal
Sometimes the need for a single axis shield, concrete steps are as follows:
Parameters in the corresponding axis, the set MD13030 and MD13024 0
In the drive configuration menu, find the corresponding module, set to "no active" can be, when the shaft on the virtual axis, the corresponding module and the motor can be removed, if you want to restore to the above parameters The value can be back to the original.
Axis load processing: Sometimes because of the need for machine tools should be dismantled or loading of the shaft, such as rotary indexing head, this time to plug the encoder and motor power outlet, Ran do not want the operator to change the above parameters, this time to PARKING temporary set to the shaft axis, the specific method is also reset the axis DB3X.DBX1.5 and 1.6 can.
.. If your tool change is through subroutine calls. You can change the position of spindle orientation. SPOS =** (is that you transfer a good position. Either plus or minus. Either entered directly. According to the current value of SPOS to decide, SPOS There are some of these: SPOS = "AC" () SPOS = "ACP" () and other programming reference manual.
2. If it is executed by T * M6. You can view the parameters 10715 / 10716 subroutine parameter to see what Nago. And then change the subroutine also in SPOS =** (value). If you find inside a subroutine, The SPOS = 0. you can change the 34090 [1] or 34080 [1] to complete you want to change the angle.
Access to 1,071,510,716 parameters. You can STARTUP inside MACHINE DATA Lane GENERAL MD. Which can be found. Take a look at what is subroutine. On the inside subroutines or procedures set inside the user program. But it is best not to change. By changing the 34080 [1] or 34090 [1] to be completed.
After the completion of spindle orientation in general. You can manually transferred to the spindle tool changing position of the quasi-stop. And in DIAGNOSIS inside view inside SERVICE DISPLY spindle CURRENT MEASURING SYSTEM 2 look. Spindle position. And then be modified.
There. Change Machine factory according to the specific methods, the general set of values there are upper and lower limits. If - 0.5 degrees according to circumstances.
SM up to 8 modules
A maximum of four
Power supply module (PS) for the PLC and the NC to provide power supply 24V and 5V.
Interface Module (IM) is used for the interconnection between class.
Signal modules (SM) using the machine PLC input / output modules, there are two kinds of input type and output type.
二. Hardware Interface
840D System Interface
840D system, MMC, HHU, MCP through an MPI cable hanging in the NCU above, MPI is the Siemens PLC, a multi-point communication protocol, and therefore the agreement is open, but OPI is the 840D system for NC part of the components of a special The communication protocol is MPI, a special case, does not have open, than the traditional MPI communications faster, MPI communication speed is 187.5K baud rate, while the OPI is 1.5M.
In addition to an OPI port NCU above, there is a MPI, a Profibus interface, Profibus interface can access all of the equipment with a Profibus communications capabilities. Profibus communications cable and MPI cable, are both a dual-core shielded cable.
X101 control panel interface (OPI)
X102 PROFIBUS Interface
X112 aside Interface (NCU and NCU communication)
X111 SIMATIC Interface (IM361)
X122 PC MPI Interface (MPI)
X121 I / O interface (cable distribution box)
H1/H2 error and status lights
H3 7 segment display
S1/S2 Reset / NMI button
S3 NCK Start Switch
S4 PLC Switch Start
X130A SIMODRIVE 611D Interface
X130B digital module I / O expansion interface (only NCU573)
X172 Device Bus Interface
X173 PCMCIA slot (X173)
In MPI, OPI, and Profibus communications cable must be received at both ends of the terminal resistance, resistance is the 220 in Europe, all the good or bad if you want to test cable can be seen in NCU-side open socket cover, the amount of A, B between the two lines resistance, under normal circumstances should be 110 Europe.
二. 611 Series driver and interface composition of
1.611 series of drives into analog 611A, the number 611D and the common type 611U. Are the modular structure, mainly in the following modules:
? Power Module Power Supply Module is to provide the drive and numerical control system power, including the maintenance of normal work of the system weak and supply of 600V power module using DC voltage. According to DC voltage control mode, which in turn are divided into open-loop control, closed-loop control of UE modules and I / R module, UE module does not supply the feedback system, its normal for the DC voltage of about 570V, and when braking energy is large, voltage can be as high as more than 640 volts. I / R module voltage has remained at around 600V
? Control module control module to achieve the speed of the servo axes ring and closed-loop control of current loop
? Power module to the servo motor to provide variable frequency and voltage AC power supply
? Monitoring module is mainly weak supply capacity of the power module to add.
? Filter module for filtering the power role.
? Reactance voltage play a steady role.
2.611 Power Module Interface Signals
611 module interface signals are the following groups:
(1) Power Interface
U1 V1 W1 main control loop three-phase power input port
X181 Power Supply input port, use is often associated with the main power supply shorted, and some systems the power to make machines work properly after the driver is also available for some time, the terminal voltage of 600V and P500 M500 terminals shorted, such as 600V voltage not immediately discharge is completed, but also the maintenance of normal work-driven control panel for some time. P600M600 is a 600V DC voltage output terminal.
(2) Control Interface
64 control the enable input, the signal to all connected modules at the same time effective, the signal is removed, all the speed of the shaft for a given voltage is zero, axis with the greatest acceleration parking. After a certain time delay, cancel pulse enable 63-pulse enable input, the signal to all connected modules at the same time effective, the signal after the abolition of all the shaft power cancellation axis movement in the form of free parking.
48 main circuit relay, the signal off, the main control circuit power supply disconnect the main relay.
112 debug or standard mode, the signal tends to be used in transmission-line debugging in general, on the receiving system, 24V.
X121 module ready signal and the module overheating signal. No. ready signal and the module DIP switch settings on, when the S1.2 = ON, the module fails, ready to signal cancellation, and S1.2 = OFF, the module has failures and to make energy (63,64) signal cancellation, will be ready to cancel the signal, so when the replacement of the module to check the top of the module DIP switch settings, otherwise the module may not work correctly. All modules connected to motor overload and overheat alarm output will be triggered by overheating.
NS1/NS2 the main relay closure enabled, only the signal is high, the main power relay is possible too. Relay the signal used to decide in closed-chain conditions.
AS1/AS2 the main relay state, the main relay the signal to reflect the closed state, the main relay is closed when high.
9/19/R 9 is a 24V output voltage, 19 is a 24V ground, R alarm reset signal for the module.
(3) Other auxiliary interface
X351 device bus, for connecting the module behind the power to use.
X141-voltage detection terminal, used for diagnostic and other purposes.
7: P24, +24 V 45: P15, +15 V 44: N15,-15V
10: N24,-24V 15: M, 0V
Power supply module has six lights above, respectively, directed modules fault and working condition. Under normal circumstances, said green light enable signal loss (63 and 64), yellow light signals that the module is ready, when 600V DC voltage has reached the allowable value of the system work properly.
Power supply module to enable normal work conditions:
48,112,63,64 then high, NS1 and NS2 shorted, appears as a yellow light, other lights are not bright. DC bus voltage should be 600V or so.
3.611 drive control module interface signals
(1) 611D drive control module interface signals
611D CNC control module and the system is mainly through a data bus connected to the basic there is not much of interface signals.
X431: axis pulse enable, the signal is low, the shaft power to withdraw, generally the signal directly with the shorted 24V
X432: BERO terminal, the interface used for BERO switch signal input port.
X34, X35 analog output ports, including two analog port (X1, X2) as a diagnostic test module, which can be used to track the amount of some figures, such as speed, voltage and current, etc. and put it into a 0 to 5V analog voltage output, the specific output signal through the numerical control system selection, Ir analog output port is fixed and the output motor current in phase R analog value.
X411: Motor encoder interface, input the motor encoder signals, as well as the motor thermistor, in which the motor thermistor value is through the socket 13 and 25 pin input, the thermal resistance at room temperature under 580 Europe , 155 degrees, more than 1200 in Europe, then control panel off the power and generate electrical power machines overheating alarm. (1PH7 motor temperature detection signal connected to the same 1FT6/1FK6 motor)
X411: direct measurement of system input port, enter the direct position measurement signal, generally positive cosine voltage signals
* 611D control panel of the speed loop and current loop inside the parameters set in the NCK, so no need to replace the control panel to reset the parameters.
. 840D System Operation
SINUMERIK840D/810D or SINUMERIK FM-NC is the machine's CNC control systems, CNC control system through the control panel perform the following basic functions:
• Develop and modify the part program
* Implementation of the part program
* Manual control
* Read in / read out the part program and data
* Edit the program data
* Cancel alarm display and alarm
* Edit the machine data
In an MMC or MMC, or between a few or several NC 1 NC to establish communication links between the (M: N, m-MMC devices and n-NCK/PLC devices)
User interface include:
* Display components, such as monitoring devices, LED, etc.;
* Operating components, such as keys, switches, hand-lun. q
840D system with CNC machine tools with automatic, manual, programming, back to a reference point, manual data entry and other functions.
Manual: Manual is mainly used to adjust the machine tool, manual and step manual with continuous manual, and sometimes need to go to a certain length, you can choose the variable INC mode, enter the length of run can be.
Automatic: 840D procedure is generally where the implementation of NCK of RAM, so MMC103 or PCU50, it was necessary should first program loaded into the NCK years, but for a particularly long process, you can choose the hard disk where the implementation of specific operational method To: Select processing, the program outline, use the cursor to select the implementation of the program, select from the hard drive the implementation of both. in automatic mode, if the MMC with SINDNC software, you can also run programs from a network hard drive.
MDA: MDA with the almost automatic, except that it paragraph by paragraph, the procedures can be input, not necessarily a complete program that exists NCK inside a fixed buffer MDA, the MDA buffer can be stored in the program directory program, district can also be transferred from a procedural program to MDA buffer.
REPOS: re-positioning capabilities, and sometimes in the program run automatically when you need to stop and test the tool away parts, and then followed by the implementation of procedures, require re-positioning capabilities, methods of operation mode in the automatic suspension of program execution, go to the manual, remove the corresponding the shaft, to re-execute the program, go to the re-positioning mode, press the corresponding axial movement button to return to the program a breakpoint, press start button process to continue. Note that in this process can not press the reset button.
Program to simulate: 840D to support the program before running a formal graphical simulation program in order to reduce the failure rate, but because of the different MMC systems, simulation of the method is not, as in MMC103, the program to simulate entirely on the implementation of the MMC, so the simulation does not NCK will have an impact, but in MMC100.2 on the program to simulate the NCK inside the implementation, and procedures for the practical implementation of the case, so be sure to simulate the selection process before the tests, but also to improve simulation speed, you can also choose to run empty.
二. System connection and commissioning
(A) the hardware connection
SINUMERIK810D/840D the system's hardware to connect in two ways:]
First, according to their interface requirements, first CNC and drive unit, MMC, PLC of three parts are connected to the right:
Source Module X161 kinds of 9,112,48 connection; drive the bus and device bus; the far right terminal resistor module (CNC and drive unit).
(2) MMC and the MCP polarity of the 24V power supply should be careful (MMC).
(3) PLC Module attention to the power line connection; bearing in mind the SM connection.
Second, the hardware of the three parts are interconnected, the connection should pay attention to:
PI, and OPI bus wiring must be correct.
CU or NCU and S7 of the IM module connection.
2. Check
In the correct completion of all mechanical and electrical installation work can be carried out electricity and commissioning work; while the first thing to do is to start the preparatory work, it can ensure that the control system and its components to start normally, and to meet the EMC test conditions
Full system connection is completed the necessary examination needs to be done, as follows:
* Shield: (1) to ensure that the cables used in line with Siemens to provide the wiring diagram of the requirements;
(2) to ensure that the signal-point field shielding at both ends connected with the rack or chassis.
For external devices (such as printers, programmers, etc.), the standard single-ended shielded cable can also be used. But once the control system for normal operation, it should not answer any of these external devices is appropriate; if we must access at both ends of the connecting cable should be shielded.
· EMC (Electromagnetic Compatibility) test conditions:
The signal line and power lines as far as possible separated from a bit further;
Departure from the NC or the PLC to the NC or the PLC may live cables should be used to provide cable SIEMENS;
Signal lines should not be too close to the external strong electromagnetic fields (such as point machines and transformers);
HC / HV pulse circuit cables must be completely separated from all other cable laying;
If the signal line can not be separated from other cables, it should take the shield threading pipe (metal);
The following distance should be as small as possible:
- The signal line and signal line
- Signal line side pre-supplementary equipotential
- And other potential clients and PE (come together)
* Protection ESD (Electromaqnetic Sensitive Device) components test conditions:
Dealing with a static module, should ensure that its normal grounding;
Such as avoiding electronic modules can not take office, then please do not touch the module components, pins or other conductive parts;
Touch the components must ensure that the human body through the electrostatic discharge device (wrist strap, or shoes) and the earth connection;
Module should be designed to conductive surface on the north (put-static packaging materials such as conductive rubber, etc.);
Modules should not be close to the VDU, monitor or TV (Away from the screen, and 10cm);
Modules Do not rechargeable electrical insulation material contact (such as plastics and fabrics);
A prerequisite for measuring
- Measuring equipment grounding
- Insulation instrument measuring the first pre-let electrical
Coordinates
1. Workpiece Coordinate System
Workpiece zero is the original origin of workpiece coordinate system
Cartesian coordinates: The coordinates of the point reached to determine the coordinates of the point
Polar coordinates: The radius and angle to measure the workpiece or part of the workpiece
2. Absolute coordinates: All positional parameters associated with the current effective starting point that will be accessible location tool
Incremental Coordinates: If the size is not the key to the origin, but relative to the other points on the workpiece, it is necessary to use an incremental coordinates. The incremental coordinates to determine the size and dimensions of these conversions can be avoided. Incremental coordinates refer to the previous power position data for the tool movement is used to describe the tool moving distance
3. Plane: The two axes to determine a plane, the first three axis perpendicular to that plane and determine the direction of the tool cross-section. Programming, to determine the processing surface in order to facilitate control system can accurately calculate the tool offset value.
Identify the direction of plane cross-section
G17 X / Y Z
G18 Z / X Y
G19 Y / Z X
4. Zero position
In the NC machine tool can determine the origin and reference point for the different position of these reference points:
* For the machine tool positioning
• The size of the workpiece program
They are:
M = Machine 12:00
A = chuck 12:00, age spots coincide with the workpiece (value for lathes)
W = Workpiece 12:00 12:00 = Program
B = starting point, you can give each program to determine the starting point, the starting point is the first tool a starting place for processing
R = reference point, with the cam and measurement systems to determine the location, you must first know the distance to the machine zero, so as to accurately set the axis position:
Establish coordinate system R
1. Of machine tools with machine zero M coordinates X B
2. Base coordinate system (also can make the workpiece coordinate system W)
3. The workpiece with the workpiece coordinate system W 12:00
4. Band is currently one know how to zero Wa of the workpiece
The current workpiece coordinate system M A W Z
The establishment of axes
When programming is usually used in the following axes:
Machine shaft: You can set the data in the machine tool axis identifier, identifier: X1, Y1, Z1, A1, B1, C1, U1, V1, AX1, AX2, etc.;
Channel axis: all in a mobile channel axis identifier: X, Y, Z, A, B, C, U, V
Geometric axis: major axis, generally have X, Y, Z;
A specific axis: no need to determine the geometric relationship between a particular axis, such as the turret position of U, Tailstock V;
The path axis: determine the path and tool movement, the path is programmed feed rate and effective, in the NC program using FGROUP to determine the path axis;
Synchronization axis: mean from the programming point of origin to destination mobile synchronization axis;
Positioning axis: Typical positioning shaft from the parts carrying, unloading the loader, knives library / turret, etc. identifier: POS, POSA, POSP, etc.
Directive axis (axis synchronized movement): the instruction is generated by the synchronized movement directive axis, they can be positioned to start and stop can be completely synchronized with the workpiece program. Axis is an independent interpolation instruction, each instruction has its own shaft axis interpolation and feed rate
Connecting shaft: NCU box refers to the connection with another real axis, their position will be subject to the control of the NCU, the connection shaft can be dynamically assigned to different channels of NCU
PLC-axis: The specific features of the PLC with the PLC axes to move, their movements with all the other all of the axes are not synchronized, moving the movement arises from the path and synchronized campaigns are nothing to do;
* Geometric axes, synchronization and positioning axes are the axes can be programmed.
* According to the movement commands are programmed with a feed rate of F, so that shaft produces movement.
* Synchronizing shaft axis synchronized movement with the path and use the same move all the time path of axes.
* Positioning axis movement and all other axes asynchronous, these mobile campaigns has nothing to do with the path and synchronized movement.
* PLC by the PLC control shaft, and produce all the other axes are not synchronized with the movement of mobile movement has nothing to do with the path and synchronized campaigns
Programming Language
* Programming address and the meaning of
Address the meaning of
Program numbered addresses N
10 program segment number
G Preparatory Function
X, Y, Z position data interpolation parameters
F Feed
S spindle speed
T Tool number
D Tool offset number
M Miscellaneous Functions
H Accessibility
* Data Type
Type of meaning range of values
INT unsigned integer ± (231-1)
REAL real numbers (with decimal points) ± (10-300 ... 100 300)
BOOL code is determined by a ASSCII characters 0 ... 255
STRING string, in [...] in the string sequence of values 0 ... 255
Up to 200 characters
AXIS Axis name (axis address) channel on the name of an arbitrary axis
FRAME translation, rotation, scale and image of the geometrical parameters
* Directive:
1. G command
· G90: origin of reference coordinate system retaining wall, in the workpiece coordinate system in the preparation of tools to run point program.
G91: near the point of reference date, the preparation of tools to run from the program.
GO: fast-moving so fast tool positioning, movement around the workpiece near the tool change point, or
G1: Tool along with the shaft, slash or any other space orientation parallel to the line of mobile home.
G2: the arc in a clockwise direction on a track to run
G3: anti-clockwise on the circular track to run
G4: pause time effect (F ... in seconds; S ... used to determine the number of spindle rotation time)
G17: No tool radius compensation
G18: Cutter Radius Compensation to the contours of the left side
G19: Cutter Radius Compensation to the contours of the right side of
G40: lift the tool radius compensation
G41: active tool radius compensation, tool machining direction along the contour to run to the right side of
G42: active tool radius compensation, tool machining direction along the contour to run to the left of
G53: Non-modal access, including the programmed bias
G54 ... G57: Call No. 1 to No. 4 can be set to zero bias
G94: linear feed rate in mm / min, inches / min
G95: rotating feed rate mm / turn, inch / turn
2. M command
M0: Programming Stop
M1: choose to stop
M2: main program entry procedure at the beginning of the end of
M30: end of the process
M17: Subroutine end
M3: active spindle clockwise rotation
M4: Active spindle counterclockwise rotation
M5: Active Spindle Stop
M6: ATC instructions
3. Other
F: Feed Rate
S: active spindle speed (unit: rev / min)
T: Call Tool
D: Tool offset number (range: 1 ... 32000)
If it is grating back to zero, please refer to the following the following methods:
If your foot is the grating with a distance of coded reference point of grating ruler, then mark (usually behind the Heidenhain grating ruler marked with C have this function), return a reference point do not need to switch back to zero, the parameter set as follows:
1,34200 = 3 using the type of optical grating
2,34300 [1] = 20mm linear grating-foot grid spacing mark a reference point (LS486C to 20mm)
3,34060 [1] = 40 return to reference point distance = 2 times the largest mobile linear grating-foot grid spacing of the reference point mark
4,34000 = 0 do not use feed cam shaft to return a reference point, that is, without a reference point return deceleration switch signal (DB31.DBX12.7)
5,34090 = XXX to return a reference point offset value
6,34310 [1] = 0.020 signal optical grating pitch (LS486C to 0.020mm)
Hardware Configuration
Hardware configuration: tell the PLC hardware structure of the process of
Baud Rate: MPI 187.5kbps
OPI 1.5Mbps
Process: to build the project - → Jianzhan - → Configuration Hardware
? Auto Configuration: The Cable Construction PLC and 840D connected to an automatic configuration automatic identification (upload station) will be transmitted PLC computer:
PLC-→ UPLOAD-→ select MPI Address = 2, if the Address = 3, will include the PLC and the NCU
If the backup PLC, then the process is:
New Project-→ plc-→ upload station, so the hardware will be backed up.
End station building, there even folders: hardware and cpu.CPU folder under the S7 program.
S7 program there are three directories:
(1) symbols such as I40.1 symbol table for the first 40 bytes of the first one
(2) BLOCKS function block
? Manual Configuration:
Process: Open the S7-→ New File - → INSERT-→ STATION-→ SIMATIC 300 - → double-HARDWARE-→ appear Box - → INSERT-→ HARDWARE COMPONENT-→ PROFILE-→ STANDARD-→ S300-→ RACK300
Select the appropriate position (to be set bits in the table), then the corresponding module on the right side double-click on modules will be chosen, selected and then download the
Programming
PLC programming course, the can use the following three forms:
Ladder Logic (LAD):
Statement List (STL):
Function Block Diagram (FBD):
Statement List programming instructions commonly used:
And instruction: A normally open AN NC
Or to order: O Normally open ON NC
Output instructions: =
Call instruction: CALL FCXX
FP: rising edge detection instruction
FN: falling edge detection instruction
After the FP must register with the middle of
CLR operation results, Clear
SET set a
S Set 1
R Clear
Block
? STEP7 There are several commonly used BLOCK Main: OB tissue mass, FC function blocks, FB function blocks, DB data blocks, etc.
OB: function blocks, equivalent to the main program, often are OB1 and OB100;
FC, FB: Function Block, which is equivalent subroutine
Subroutine in the compilation finished, you must call the subroutine in the main program in the PLC after power-OB100 is the first execution, is executed only once; OB1 is the PLC CPU cycles implementation process. After the first implementation of the power-OB100, and then the implementation of OB1 (repeated implementation; OB100 call FB1 (Siemens compiled good)
FB1 is the system bus connection PCU with OPI and MCP, the control panel Definition:
(1) control panel starting address of the input address
(2) the number of control panel
(3) The control panel's output addresses starting address
Control Panel MPI Address: MCPIBUSADR = 6
? OB1 block
FC2: Basic NCK and PLC communications NCK ← → PLC
FC2 must be OB1 the beginning of FC2 ---- "gp_hp"
FC10: dealing with alarm information FC10 ---- "AL-MSG"
PLC generated alarm, passed NCK, NC to take measures, while MMC displays alarm text called FC10, there are two parameters must be set
TouserIF = TRUE (equivalent to 1) and FALSE (equivalent to 0)
Quit: = I3.7 (warning text). Alarm Reset button (RESET) addresses I3.7
FC19: Machine control panel main program FC19 ---- "MCP-IFM"
BAGNO (mode group number) = B # 16 # 1 (B - B hex 16-16 hex)
CHANNO (channel number) = B # 16 # 1
SPINDLEIFNO: = B # 16 # 4 (spindle number)
FEEDHOLD = M100.0 (feed suspended)
SPINDLEHOLD = M100.1 (spindle stop)
? DB block
1. DB module types are:
DBB - Data Module Type
DBW - block word (16 bit)
DBD - block double word (32 bit)
2. Data Type:
DOUBLE: real or integer number, input range ± 4.19 × 10-307 ----± 1.67 × 10308
DWORD: integer number, ranging from -2.147 × 109 ---- 2.147 × 109
BOOLEAN: 0 be a
BYTE: integer, range digital -128 ---- 127
STRING: a maximum of 16-bit string
3. Common data block feature
DB2: alarm interface signals. The signal from the PLC to the NCK, in the PLC set the corresponding bit in the MMC will be able to generate a corresponding alarm number (seven at the beginning of the alarm is set by machine field assumption)
DB10: Show NCU state, used to exchange NCK fast I / O interface to the state, there are a number of the state of the signal NCK
DB11: mode group signal interface
DB19: Operation panel signal interface
DB21-DB30: channel signal interface
DB31-DB61: shaft / spindle interface signals
4. Debugging a common data block mainly by:
DBX6.0: feed to be able to prohibit
DBX6.1: read to be able to prohibit
DBX7.0: Start to be able to prohibit PLC → NC
DBX7.7: Channel reset
DBX194.0 --- DBX206.3 NC → PLC
DBX1.5: entry into force of a measurement system
DBX1.6: force measurement system 2
DBX2.1: Control enabled
DBX21.7: Pulse enable (if not, compared to the free end)
DBX4.3: Axis Stop PLC → NC
DBX12.0: the hard-axis negative limit
DBX12.1: the hard-axis positive limit
DBX12.7: back to zero deceleration
DBX61.7: current loop effective
DBX61.6: speed loop effective
DBX61.5: Position Loop Effective
DBX61.4: axial static
DBX83.5: spindle speed setting within the framework of
SIEMENS PLC system Siemens SIMATIC MAGAGER used for PLC programming to carry out state control machine tool components, it mainly consists of power supply module, CPU module, input and output module, its interface with, RS232 excuse, PROFIBUS excuse , MPI cable interfaces. Through the X122, MPI jack, so that the computer with the NCU connected PLC.
Hardware Configuration
Hardware configuration: tell the PLC hardware structure of the process of
Baud Rate: MPI 187.5kbps
OPI 1.5Mbps
Process: to build the project - → Jianzhan - → Configuration Hardware
* Auto-configuration: The construction of PLC and 840D cable connected to an automatic configuration of automatic identification (upload station) will be transmitted PLC computer:
PLC-→ UPLOAD-→ select MPI Address = 2, if the Address = 3, will include the PLC and the NCU
If the backup PLC, then the process is:
New Project-→ plc-→ upload station, so the hardware will be backed up.
End station building, there even folders: hardware and cpu.CPU folder under the S7 program.
S7 program there are three directories:
(1) symbols such as I40.1 symbol table for the first 40 bytes of the first one
BLOCKS function block
* Manual configuration:
Process: Open the S7-→ New File - → INSERT-→ STATION-→ SIMATIC 300 - → double-HARDWARE-→ appear Box - → INSERT-→ HARDWARE COMPONENT-→ PROFILE-→ STANDARD-→ S300-→ RACK300
Select the appropriate position (to be set bits in the table), then the corresponding module on the right side double-click on modules will be chosen, selected and then download the
Programming
PLC programming course, the can use the following three forms:
Ladder Logic (LAD):
Statement List (STL):
Function Block Diagram (FBD):
Statement List programming instructions commonly used:
And instruction: A normally open AN NC
Or to order: O Normally open ON NC
Output instructions: =
Call instruction: CALL FCXX
FP: rising edge detection instruction
FN: falling edge detection instruction
After the FP must register with the middle of
CLR operation results, Clear
SET set a
S Set 1
R Clear
Block
BLOCK main · STEP7 There are several commonly used: OB tissue mass, FC function blocks, FB function blocks, DB data blocks, etc.
OB: function blocks, equivalent to the main program, often are OB1 and OB100;
FC, FB: Function Block, which is equivalent subroutine
Subroutine in the compilation finished, you must call the subroutine in the main program
OB100 is a PLC after power-first execution, is executed only once; OB1 is the PLC CPU cycles implementation process. After the first implementation of the power-OB100, and then the implementation of OB1 (repeated implementation; OB100 call FB1 (Siemens compiled good)
FB1 is the system bus connection PCU with OPI and MCP, the control panel Definition:
(1) control panel starting address of the input address
(2) the number of control panel
(3) The control panel's output addresses starting address
Control Panel MPI Address: MCPIBUSADR = 6
· OB1 block
FC2: Basic NCK and PLC communications NCK ← → PLC
FC2 must be OB1 the beginning of FC2 ---- "gp_hp"
FC10: dealing with alarm information FC10 ---- "AL-MSG"
PLC generated alarm, passed NCK, NC to take measures, while MMC displays alarm text
Call FC10, there are two parameters must be set
TouserIF = TRUE (equivalent to 1) and FALSE (equivalent to 0)
Quit: = I3.7 (warning text). Alarm Reset button (RESET) addresses I3.7
FC19: Machine control panel main program FC19 ---- "MCP-IFM"
BAGNO (mode group number) = B # 16 # 1 (B - B hex 16-16 hex)
CHANNO (channel number) = B # 16 # 1
SPINDLEIFNO: = B # 16 # 4 (spindle number)
FEEDHOLD = M100.0 (feed suspended)
SPINDLEHOLD = M100.1 (spindle stop)
· DB block
1. DB module types are:
DBB - Data Module Type
DBW - block word (16 bit)
DBD - block double word (32 bit)
2. Data Type:
DOUBLE: real or integer number, input range ± 4.19 × 10-307 ----± 1.67 × 10308
DWORD: integer number, ranging from -2.147 × 109 ---- 2.147 × 109
BOOLEAN: 0 be a
BYTE: integer, range digital -128 ---- 127
STRING: a maximum of 16-bit string
3. Common data block feature
DB2: alarm interface signals. The signal from the PLC to the NCK, in the PLC set the corresponding bit in the MMC will be able to generate a corresponding alarm number (seven at the beginning of the alarm is set by machine field assumption)
DB10: Show NCU state, used to exchange NCK fast I / O interface to the state, there are a number of the state of the signal NCK
DB11: mode group signal interface
DB19: Operation panel signal interface
DB21-DB30: channel signal interface
DB31-DB61: shaft / spindle interface signals
4. Debugging a common data block mainly by:
DBX6.0: feed to be able to prohibit
DBX6.1: read to be able to prohibit
DBX7.0: Start to be able to prohibit PLC → NC
DBX7.7: Channel reset
DBX194.0 --- DBX206.3 NC → PLC
DBX1.5: entry into force of a measurement system
DBX1.6: force measurement system 2
DBX2.1: Control enabled
DBX21.7: Pulse enable (if not, compared to the free end)
DBX4.3: Axis Stop PLC → NC
DBX12.0: the hard-axis negative limit
DBX12.1: the hard-axis positive limit
DBX12.7: back to zero deceleration
DBX61.7: current loop effective
DBX61.6: speed loop effective
DBX61.5: Position Loop Effective
DBX61.4: axial static
DBX83.5: spindle speed setting within the framework of
Common Maintenance Failure Analysis
1. Machine operating mode and channel of choice:
As the NCK function continuously strengthened, a NCK can complete multiple systems to complete the original work, which can have multiple channels, a channel rather with an independent NC, 840D can have up to 10 channels, each channel has its own zero over the set, tool compensation and R parameters, but the program area is shared, each channel has its own working methods, if the work of several channels have been the same, then this constitutes a method group. the 840D on the , mode is way switch to select, access is key to W1 ... n to choose.
2. Tools and zero-bias
Because different tools have different geometric shapes and geometry, while the program is subject to the workpiece size and therefore require compensation tool, each with its own knife, there is a corresponding geometric shape of the tool types, such as drills, milling cutters. Each of the knife can have more than a knife fill size to D, to mark the
Like with the tool, processing of different parts require different zero, so there is zero bias, in the 840D using G54 to G57 to select, if necessary, the number of zero-bias can also be used to expand the machine parameters.
3.840D system maintenance
* Maintenance of liquid crystal displays
LCD display life of 30,000 hours. While the backlight tube life is time 10000 - 20,000 hours.
Replacement backlight tube methods: a. Open the protective cover b. monitor the installation of loose screws, disconnect the power supply and display backlight control signal cable, remove the display c. replace the backlight tube d. above steps to install the opposite
* Replacement of the battery
A total of 840 system, two batteries, one in MMC above, the main information to save CMOS, and its lifetime is at least ten years, it is generally no need to replace. NCU BOX also a battery inside, and fans together, it's life generally three years or so, to save the NCK inside the programs and data, because of the protection of capacitor charging, you can replace the battery after the NCK full power, but time can not be more than 15 minutes
This is the same as two battery models. Model: 6FC5247-0AA18-0AA0
(Note: the replacement battery it is best to make a few NCK and the PLC, data backup, Siemens 840C battery in the CSB board, must be the case of electricity in the system to replace!)
4.840D system data backup
840D system data are many, including NCK data, PLC data and MMC data, which NCK and PLC data is by the battery to maintain, and it directly affects the loss of the normal operation of NC, while the data is stored in the MMC MMC hard disk (MMC103), or Flash EPROM inside (MMC100.2), which under normal circumstances, the loss of NC data only affect the display and input.
System data backup methods are the following three
(1) backup to MMC's hard disk (only MMC103 adaptation), it is recommended best MMC, NCK and the PLC's data separately for backup, the file name is best to use the system default file name plus the date.
(2) backup to a floppy disk or through the RS232 port on the backup to an external computer.
(3) back to the NCK above the PCMCIA card, the card is an NC system, installed programs 8M of Flash EPROM card. It is about 5M or so of space can be used to store backup data. This feature is only in the MMC software version 5.0 and above to be used. Such data without a hard drive backup methods particularly suitable for the MMC100.2.
5. MMC103 file structure
· MMC103's hardware is actually a band MPI (OPI) interface PC. Software is running on the WINDOWS operating system on a man-machine interface software. As the MMC version of the software not the same as its operation, the operating system are not the same, there are early WIN32, the mid-WIN95 and now WINNT, to run in WIN95 environment MMC Ver5.3 example shows the file structure MMC.
· MMC103 hard disk is divided into two partitions, C: drive and D: drive, where D is mainly used to store the hard disk drive and partition number of backup files, including several versions of the system brought about by MMC system backup, but also used to install software to use as a temporary storage area. C drive is mainly stored WINDOWS operation of the system files, MMC's system files, machine tool manufacturers developed a number of add-on software and user programs and data.
· C drive under the directory structure:
C drive has the following directories under the main
MMC2: Siemens, is mainly used to store system files, Siemens there are also some standard configuration files in this directory, the directory the file is best not to modify the. Windows storage running Windows system files and other documents under Windows environment,
Add_on: Siemens add-on products, such as remote diagnostics. OEM used to store tools on their own development
Products.
USER: storing the user's own profile, not the same as all the standard configuration files are stored in this directory, such as alarm settings for the service.
DH: used to store data associated with the NCK, NCK its file structure and file structure, have a piece subdirectories, the workpiece main program directory, a subdirectory subroutine, the standard fixed-cycle subdirectory, the user such as a fixed cycle of subdirectories. User alarm texts are generally the existence of the directory the following subdirectories inside MB.
These are the MMC103's file structure, in general, the user's own files are stored in the back of four directories inside, so MMC data backup is mainly a backup four directories and files.
Note: MMC earlier version of the user's own configuration files and system configuration files are stored in the system files directory.
· MMC103 alarm server configuration
MMC103 configuration are mostly. INI file for the suffix to achieve, such as knives library display, all kinds of operating mode password level required to operate, as well as alarm settings for the server, the following set up to alert the server to home shows the configuration file changes.
MMC is responsible for the display of alarm text, alarm text stored in MMC2 and DH the following subdirectories inside the MB, the file name format Alxx_xx.com, of which the first two XX said alarm contents of the text, followed by two XX said that the language of the text alert . For example ALP_UK.COM said yes PLC alarm text, language is English. And the relevant alarm display settings are stored in MBDDE.INI file.
Note: The user directory the following configuration files covering MMC2 directory configuration files. WINDOWS system configuration files of all the sum can not exceed 60KB.
6.611 series of drives and motors works
* 611 series AC variable speed drive is a device that by controlling the power supply, the frequency of AC motor to achieve speed control purposes. The main part is from a DC to AC into the rectifier and the DC into an AC variable frequency inverter component. Due to the different interface signals,
The characteristics of servo motor
Because of the motion control, CNC machine tools demanding, and requires a good dynamic characteristics, a large speed range and accurate position control precision, and therefore it requires a special servo motor drive systems generally use the Siemens synchronous servo motor, spindle is Precision induction motor, its principles and general principles of the same squirrel-cage motors, synchronous servo motor and induction motors The biggest difference is not the same as the structure of the rotor. synchronous motors have a staggered distribution of the rotor pole, and therefore require a corresponding test rotor position detection component, replacement of components when these tests also need to re-adjust, the following is commonly used in three kinds of motor Siemens distinction:
· 1FT5 and 1FT6/1FK6 difference between motor
Both the motor is basically the same principle, but not the same as the structure and detection devices, 1FT5 AC servo motor used in the system, while 1FT6 motors are used in the digital servo system.
Stator winding structure is different, 1FT6 motor stator winding structure allows the motor current is much closer to being the cosine waveforms
1FT5 motor tachometer generator is used to detect the speed of the motor with the sharing circle on the Hall element to detect the relative position of the rotor, and 1FT6 motor is used to detect a position encoder motor speed, the motor encoder in addition the conventional A, B, and R phase are cosine signals, there are two C phase and D phase is cosine signals to detect the rotor position.
1FK6 1FT6 motors, like principles, only a little difference in the mechanical structure, 1FK6 more 1FT6 economy.
l Note: The replacement of the motor encoder should pay attention to the encoder zero position, replace the encoder to ensure that when you replace the front and rear rotor is not moving when the encoder wheel on a shell on the signs on signs and the relative position of the same, if the This relative position has changed only through the oscilloscope to adjust. the location of the encoder does not affect the motor is running, such as not running smoothly, the current is too large, and even affect the motor life.
7. Servo motor and spindle motor of the difference between
Rotor structure is different, the spindle motor rotor and squirrel cage rotor motor, like the absence of magnetic poles, which does not require the corresponding rotor position detection signal, 1PH7 spindle motor encoder model ERN1381, 1FT6/1FK6 the motor encoder type To ERN1387, the main difference is that ERN1381 no additional C-phase and D believe that number, and therefore do not need to re-adjust the replacement of the encoder, ERN1387 can be used in 1PH motors, but in turn ERN1381 can not be used in the feed motor.
Spindle motor power of a great general, and thus the motor structure of cooling demand is higher.
Not the same scope of work, servo motor operates at the lowest speed and rated speed constant torque between the areas, while the spindle motor operates at rated speed and maximum speed constant power between the areas, because to achieve a great speed range of spindle the motor rated speed is generally very low
Common repair techniques
ERN1387 Encoder Replacement Method
1. Unloading open motor rear cover, rear cover encoder
2. Release encoder mounting screws
3. Rotating rotor shaft, so that the encoder rotor encoder on the signs and marks on the shell overlap
4. Remove encoder, attention to handling the time out to make use of a special screw top to avoid damage to the encoder
5. Rotation of new encoders, so that the two signs coincide encoder
6. According to the above reverse order to install the encoder
Note: In the process of installing the encoder, to ensure that the rotor different, otherwise they will lose the relative position of the rotor, if the loss of the relative position of the old motor will need to use the oscilloscope to adjust the installation position of the encoder, the new motor can be based on a sign of rotor shaft to adjust the encoder to determine the installation location, which can be mechanical adjustments, you can also adjust the drive parameters MD1016 to set an offset value, but the method can only be used in the 840D, through this method to adjust the motor change to other machine tool use may be due to the different driving parameters can not work properly.
* Zero adjustment
Adjustment steps are as follows: startup - → machine data - → Axis MD - → parameter adjustments: 34100 (axis coordinate value in the reference power) Amendment, if the change finished, now and in the original difference of 10mm, will be adjusted parameters 34100 to 10.
Can also 34090 (reference point offset) to modify: It is now zero difference with the original zero, the number.
* A simple power module detection method:
As the power module is the main parts of high-power tubes, with the following methods can be broadly detect power tube is good or bad:
Multimeter hit resistance profile, with a multimeter is the table T received a power module DC voltage input terminals P600, the land received a three-phase power tube power output U2, V2, W2, the time should be infinite resistance, exchange multimeter two tables T, the resistance should be rare. the multimeter pen received the M600 on a table, repeat the above process, the results should be, and above just the opposite.
Motor temperature alarm processing
Motor which is equipped with thermal resistance of the signal through the signal cable back to the driver control panel inside, when the temperature reaches alarm value, the system to produce alarm, end feedback can be detected when the corresponding resistance value, the alarm if you need to shield , the 611D can be in the driving parameters MD1608 (the control panel of the 611A is a parameter MD64) to set a value of less than 100, you can mask the alarm, the method can only be used in diagnosis.
611A spindle encoder alarm control unit shield
Driver control panel connected encoder can be monitored, if there is an exception, then generate a corresponding alarm, 611A spindle control panel can be the parameter MD P-90 bit 2 set a screen of the alarm.
611D-driven V / F control
Sometimes, in order diagnostic, drivers need to be open-loop frequency control, this method can only be used for diagnostic purposes, and the speed can not be set too high. MD1014 is a set driving parameters shall be open-loop frequency control
Driven optimization
CNC driven by the current loop, velocity loop and position loop composed of the optimization in general from the inside and outer layers of optimization, but because of current loop parameters of the motor and power module model is established with the factory default parameter, the general does not require optimization, it is optimization optimize the speed of the first ring, and then you can optimize the position loop.
Speed loop optimization, generally related to the speed loop gain and speed loop time constant, the speed loop time constant and gain the greater the lower the speed loop and more stable, but the accuracy and dynamic characteristics of the worse, in general, the speed loop time constant is located in 10ms, while the speed loop and speed loop gain adjustment in making the order is about to respond to a 20-40 overshoot.
Position loop optimization involves the position loop gain and acceleration, before adjustment can reduce the acceleration value, and further increase the value of position loop gain to ensure the system is stable, and then increase the acceleration at an appropriate value, and to adapt the mechanical properties of machine tools, pay attention to the same group of interpolation axis position loop gain to be consistent, otherwise it will affect the machining accuracy.
Axis shield deal
Sometimes the need for a single axis shield, concrete steps are as follows:
Parameters in the corresponding axis, the set MD13030 and MD13024 0
In the drive configuration menu, find the corresponding module, set to "no active" can be, when the shaft on the virtual axis, the corresponding module and the motor can be removed, if you want to restore to the above parameters The value can be back to the original.
Axis load processing: Sometimes because of the need for machine tools should be dismantled or loading of the shaft, such as rotary indexing head, this time to plug the encoder and motor power outlet, Ran do not want the operator to change the above parameters, this time to PARKING temporary set to the shaft axis, the specific method is also reset the axis DB3X.DBX1.5 and 1.6 can.
.. If your tool change is through subroutine calls. You can change the position of spindle orientation. SPOS =** (is that you transfer a good position. Either plus or minus. Either entered directly. According to the current value of SPOS to decide, SPOS There are some of these: SPOS = "AC" () SPOS = "ACP" () and other programming reference manual.
2. If it is executed by T * M6. You can view the parameters 10715 / 10716 subroutine parameter to see what Nago. And then change the subroutine also in SPOS =** (value). If you find inside a subroutine, The SPOS = 0. you can change the 34090 [1] or 34080 [1] to complete you want to change the angle.
Access to 1,071,510,716 parameters. You can STARTUP inside MACHINE DATA Lane GENERAL MD. Which can be found. Take a look at what is subroutine. On the inside subroutines or procedures set inside the user program. But it is best not to change. By changing the 34080 [1] or 34090 [1] to be completed.
After the completion of spindle orientation in general. You can manually transferred to the spindle tool changing position of the quasi-stop. And in DIAGNOSIS inside view inside SERVICE DISPLY spindle CURRENT MEASURING SYSTEM 2 look. Spindle position. And then be modified.
There. Change Machine factory according to the specific methods, the general set of values there are upper and lower limits. If - 0.5 degrees according to circumstances.
SM up to 8 modules
A maximum of four
Power supply module (PS) for the PLC and the NC to provide power supply 24V and 5V.
Interface Module (IM) is used for the interconnection between class.
Signal modules (SM) using the machine PLC input / output modules, there are two kinds of input type and output type.
二. Hardware Interface
840D System Interface
840D system, MMC, HHU, MCP through an MPI cable hanging in the NCU above, MPI is the Siemens PLC, a multi-point communication protocol, and therefore the agreement is open, but OPI is the 840D system for NC part of the components of a special The communication protocol is MPI, a special case, does not have open, than the traditional MPI communications faster, MPI communication speed is 187.5K baud rate, while the OPI is 1.5M.
In addition to an OPI port NCU above, there is a MPI, a Profibus interface, Profibus interface can access all of the equipment with a Profibus communications capabilities. Profibus communications cable and MPI cable, are both a dual-core shielded cable.
X101 control panel interface (OPI)
X102 PROFIBUS Interface
X112 aside Interface (NCU and NCU communication)
X111 SIMATIC Interface (IM361)
X122 PC MPI Interface (MPI)
X121 I / O interface (cable distribution box)
H1/H2 error and status lights
H3 7 segment display
S1/S2 Reset / NMI button
S3 NCK Start Switch
S4 PLC Switch Start
X130A SIMODRIVE 611D Interface
X130B digital module I / O expansion interface (only NCU573)
X172 Device Bus Interface
X173 PCMCIA slot (X173)
In MPI, OPI, and Profibus communications cable must be received at both ends of the terminal resistance, resistance is the 220 in Europe, all the good or bad if you want to test cable can be seen in NCU-side open socket cover, the amount of A, B between the two lines resistance, under normal circumstances should be 110 Europe.
二. 611 Series driver and interface composition of
1.611 series of drives into analog 611A, the number 611D and the common type 611U. Are the modular structure, mainly in the following modules:
? Power Module Power Supply Module is to provide the drive and numerical control system power, including the maintenance of normal work of the system weak and supply of 600V power module using DC voltage. According to DC voltage control mode, which in turn are divided into open-loop control, closed-loop control of UE modules and I / R module, UE module does not supply the feedback system, its normal for the DC voltage of about 570V, and when braking energy is large, voltage can be as high as more than 640 volts. I / R module voltage has remained at around 600V
? Control module control module to achieve the speed of the servo axes ring and closed-loop control of current loop
? Power module to the servo motor to provide variable frequency and voltage AC power supply
? Monitoring module is mainly weak supply capacity of the power module to add.
? Filter module for filtering the power role.
? Reactance voltage play a steady role.
2.611 Power Module Interface Signals
611 module interface signals are the following groups:
(1) Power Interface
U1 V1 W1 main control loop three-phase power input port
X181 Power Supply input port, use is often associated with the main power supply shorted, and some systems the power to make machines work properly after the driver is also available for some time, the terminal voltage of 600V and P500 M500 terminals shorted, such as 600V voltage not immediately discharge is completed, but also the maintenance of normal work-driven control panel for some time. P600M600 is a 600V DC voltage output terminal.
(2) Control Interface
64 control the enable input, the signal to all connected modules at the same time effective, the signal is removed, all the speed of the shaft for a given voltage is zero, axis with the greatest acceleration parking. After a certain time delay, cancel pulse enable 63-pulse enable input, the signal to all connected modules at the same time effective, the signal after the abolition of all the shaft power cancellation axis movement in the form of free parking.
48 main circuit relay, the signal off, the main control circuit power supply disconnect the main relay.
112 debug or standard mode, the signal tends to be used in transmission-line debugging in general, on the receiving system, 24V.
X121 module ready signal and the module overheating signal. No. ready signal and the module DIP switch settings on, when the S1.2 = ON, the module fails, ready to signal cancellation, and S1.2 = OFF, the module has failures and to make energy (63,64) signal cancellation, will be ready to cancel the signal, so when the replacement of the module to check the top of the module DIP switch settings, otherwise the module may not work correctly. All modules connected to motor overload and overheat alarm output will be triggered by overheating.
NS1/NS2 the main relay closure enabled, only the signal is high, the main power relay is possible too. Relay the signal used to decide in closed-chain conditions.
AS1/AS2 the main relay state, the main relay the signal to reflect the closed state, the main relay is closed when high.
9/19/R 9 is a 24V output voltage, 19 is a 24V ground, R alarm reset signal for the module.
(3) Other auxiliary interface
X351 device bus, for connecting the module behind the power to use.
X141-voltage detection terminal, used for diagnostic and other purposes.
7: P24, +24 V 45: P15, +15 V 44: N15,-15V
10: N24,-24V 15: M, 0V
Power supply module has six lights above, respectively, directed modules fault and working condition. Under normal circumstances, said green light enable signal loss (63 and 64), yellow light signals that the module is ready, when 600V DC voltage has reached the allowable value of the system work properly.
Power supply module to enable normal work conditions:
48,112,63,64 then high, NS1 and NS2 shorted, appears as a yellow light, other lights are not bright. DC bus voltage should be 600V or so.
3.611 drive control module interface signals
(1) 611D drive control module interface signals
611D CNC control module and the system is mainly through a data bus connected to the basic there is not much of interface signals.
X431: axis pulse enable, the signal is low, the shaft power to withdraw, generally the signal directly with the shorted 24V
X432: BERO terminal, the interface used for BERO switch signal input port.
X34, X35 analog output ports, including two analog port (X1, X2) as a diagnostic test module, which can be used to track the amount of some figures, such as speed, voltage and current, etc. and put it into a 0 to 5V analog voltage output, the specific output signal through the numerical control system selection, Ir analog output port is fixed and the output motor current in phase R analog value.
X411: Motor encoder interface, input the motor encoder signals, as well as the motor thermistor, in which the motor thermistor value is through the socket 13 and 25 pin input, the thermal resistance at room temperature under 580 Europe , 155 degrees, more than 1200 in Europe, then control panel off the power and generate electrical power machines overheating alarm. (1PH7 motor temperature detection signal connected to the same 1FT6/1FK6 motor)
X411: direct measurement of system input port, enter the direct position measurement signal, generally positive cosine voltage signals
* 611D control panel of the speed loop and current loop inside the parameters set in the NCK, so no need to replace the control panel to reset the parameters.
. 840D System Operation
SINUMERIK840D/810D or SINUMERIK FM-NC is the machine's CNC control systems, CNC control system through the control panel perform the following basic functions:
• Develop and modify the part program
* Implementation of the part program
* Manual control
* Read in / read out the part program and data
* Edit the program data
* Cancel alarm display and alarm
* Edit the machine data
In an MMC or MMC, or between a few or several NC 1 NC to establish communication links between the (M: N, m-MMC devices and n-NCK/PLC devices)
User interface include:
* Display components, such as monitoring devices, LED, etc.;
* Operating components, such as keys, switches, hand-lun. q
840D system with CNC machine tools with automatic, manual, programming, back to a reference point, manual data entry and other functions.
Manual: Manual is mainly used to adjust the machine tool, manual and step manual with continuous manual, and sometimes need to go to a certain length, you can choose the variable INC mode, enter the length of run can be.
Automatic: 840D procedure is generally where the implementation of NCK of RAM, so MMC103 or PCU50, it was necessary should first program loaded into the NCK years, but for a particularly long process, you can choose the hard disk where the implementation of specific operational method To: Select processing, the program outline, use the cursor to select the implementation of the program, select from the hard drive the implementation of both. in automatic mode, if the MMC with SINDNC software, you can also run programs from a network hard drive.
MDA: MDA with the almost automatic, except that it paragraph by paragraph, the procedures can be input, not necessarily a complete program that exists NCK inside a fixed buffer MDA, the MDA buffer can be stored in the program directory program, district can also be transferred from a procedural program to MDA buffer.
REPOS: re-positioning capabilities, and sometimes in the program run automatically when you need to stop and test the tool away parts, and then followed by the implementation of procedures, require re-positioning capabilities, methods of operation mode in the automatic suspension of program execution, go to the manual, remove the corresponding the shaft, to re-execute the program, go to the re-positioning mode, press the corresponding axial movement button to return to the program a breakpoint, press start button process to continue. Note that in this process can not press the reset button.
Program to simulate: 840D to support the program before running a formal graphical simulation program in order to reduce the failure rate, but because of the different MMC systems, simulation of the method is not, as in MMC103, the program to simulate entirely on the implementation of the MMC, so the simulation does not NCK will have an impact, but in MMC100.2 on the program to simulate the NCK inside the implementation, and procedures for the practical implementation of the case, so be sure to simulate the selection process before the tests, but also to improve simulation speed, you can also choose to run empty.
二. System connection and commissioning
(A) the hardware connection
SINUMERIK810D/840D the system's hardware to connect in two ways:]
First, according to their interface requirements, first CNC and drive unit, MMC, PLC of three parts are connected to the right:
Source Module X161 kinds of 9,112,48 connection; drive the bus and device bus; the far right terminal resistor module (CNC and drive unit).
(2) MMC and the MCP polarity of the 24V power supply should be careful (MMC).
(3) PLC Module attention to the power line connection; bearing in mind the SM connection.
Second, the hardware of the three parts are interconnected, the connection should pay attention to:
PI, and OPI bus wiring must be correct.
CU or NCU and S7 of the IM module connection.
2. Check
In the correct completion of all mechanical and electrical installation work can be carried out electricity and commissioning work; while the first thing to do is to start the preparatory work, it can ensure that the control system and its components to start normally, and to meet the EMC test conditions
Full system connection is completed the necessary examination needs to be done, as follows:
* Shield: (1) to ensure that the cables used in line with Siemens to provide the wiring diagram of the requirements;
(2) to ensure that the signal-point field shielding at both ends connected with the rack or chassis.
For external devices (such as printers, programmers, etc.), the standard single-ended shielded cable can also be used. But once the control system for normal operation, it should not answer any of these external devices is appropriate; if we must access at both ends of the connecting cable should be shielded.
· EMC (Electromagnetic Compatibility) test conditions:
The signal line and power lines as far as possible separated from a bit further;
Departure from the NC or the PLC to the NC or the PLC may live cables should be used to provide cable SIEMENS;
Signal lines should not be too close to the external strong electromagnetic fields (such as point machines and transformers);
HC / HV pulse circuit cables must be completely separated from all other cable laying;
If the signal line can not be separated from other cables, it should take the shield threading pipe (metal);
The following distance should be as small as possible:
- The signal line and signal line
- Signal line side pre-supplementary equipotential
- And other potential clients and PE (come together)
* Protection ESD (Electromaqnetic Sensitive Device) components test conditions:
Dealing with a static module, should ensure that its normal grounding;
Such as avoiding electronic modules can not take office, then please do not touch the module components, pins or other conductive parts;
Touch the components must ensure that the human body through the electrostatic discharge device (wrist strap, or shoes) and the earth connection;
Module should be designed to conductive surface on the north (put-static packaging materials such as conductive rubber, etc.);
Modules should not be close to the VDU, monitor or TV (Away from the screen, and 10cm);
Modules Do not rechargeable electrical insulation material contact (such as plastics and fabrics);
A prerequisite for measuring
- Measuring equipment grounding
- Insulation instrument measuring the first pre-let electrical
Coordinates
1. Workpiece Coordinate System
Workpiece zero is the original origin of workpiece coordinate system
Cartesian coordinates: The coordinates of the point reached to determine the coordinates of the point
Polar coordinates: The radius and angle to measure the workpiece or part of the workpiece
2. Absolute coordinates: All positional parameters associated with the current effective starting point that will be accessible location tool
Incremental Coordinates: If the size is not the key to the origin, but relative to the other points on the workpiece, it is necessary to use an incremental coordinates. The incremental coordinates to determine the size and dimensions of these conversions can be avoided. Incremental coordinates refer to the previous power position data for the tool movement is used to describe the tool moving distance
3. Plane: The two axes to determine a plane, the first three axis perpendicular to that plane and determine the direction of the tool cross-section. Programming, to determine the processing surface in order to facilitate control system can accurately calculate the tool offset value.
Identify the direction of plane cross-section
G17 X / Y Z
G18 Z / X Y
G19 Y / Z X
4. Zero position
In the NC machine tool can determine the origin and reference point for the different position of these reference points:
* For the machine tool positioning
• The size of the workpiece program
They are:
M = Machine 12:00
A = chuck 12:00, age spots coincide with the workpiece (value for lathes)
W = Workpiece 12:00 12:00 = Program
B = starting point, you can give each program to determine the starting point, the starting point is the first tool a starting place for processing
R = reference point, with the cam and measurement systems to determine the location, you must first know the distance to the machine zero, so as to accurately set the axis position:
Establish coordinate system R
1. Of machine tools with machine zero M coordinates X B
2. Base coordinate system (also can make the workpiece coordinate system W)
3. The workpiece with the workpiece coordinate system W 12:00
4. Band is currently one know how to zero Wa of the workpiece
The current workpiece coordinate system M A W Z
The establishment of axes
When programming is usually used in the following axes:
Machine shaft: You can set the data in the machine tool axis identifier, identifier: X1, Y1, Z1, A1, B1, C1, U1, V1, AX1, AX2, etc.;
Channel axis: all in a mobile channel axis identifier: X, Y, Z, A, B, C, U, V
Geometric axis: major axis, generally have X, Y, Z;
A specific axis: no need to determine the geometric relationship between a particular axis, such as the turret position of U, Tailstock V;
The path axis: determine the path and tool movement, the path is programmed feed rate and effective, in the NC program using FGROUP to determine the path axis;
Synchronization axis: mean from the programming point of origin to destination mobile synchronization axis;
Positioning axis: Typical positioning shaft from the parts carrying, unloading the loader, knives library / turret, etc. identifier: POS, POSA, POSP, etc.
Directive axis (axis synchronized movement): the instruction is generated by the synchronized movement directive axis, they can be positioned to start and stop can be completely synchronized with the workpiece program. Axis is an independent interpolation instruction, each instruction has its own shaft axis interpolation and feed rate
Connecting shaft: NCU box refers to the connection with another real axis, their position will be subject to the control of the NCU, the connection shaft can be dynamically assigned to different channels of NCU
PLC-axis: The specific features of the PLC with the PLC axes to move, their movements with all the other all of the axes are not synchronized, moving the movement arises from the path and synchronized campaigns are nothing to do;
* Geometric axes, synchronization and positioning axes are the axes can be programmed.
* According to the movement commands are programmed with a feed rate of F, so that shaft produces movement.
* Synchronizing shaft axis synchronized movement with the path and use the same move all the time path of axes.
* Positioning axis movement and all other axes asynchronous, these mobile campaigns has nothing to do with the path and synchronized movement.
* PLC by the PLC control shaft, and produce all the other axes are not synchronized with the movement of mobile movement has nothing to do with the path and synchronized campaigns
Programming Language
* Programming address and the meaning of
Address the meaning of
Program numbered addresses N
10 program segment number
G Preparatory Function
X, Y, Z position data interpolation parameters
F Feed
S spindle speed
T Tool number
D Tool offset number
M Miscellaneous Functions
H Accessibility
* Data Type
Type of meaning range of values
INT unsigned integer ± (231-1)
REAL real numbers (with decimal points) ± (10-300 ... 100 300)
BOOL code is determined by a ASSCII characters 0 ... 255
STRING string, in [...] in the string sequence of values 0 ... 255
Up to 200 characters
AXIS Axis name (axis address) channel on the name of an arbitrary axis
FRAME translation, rotation, scale and image of the geometrical parameters
* Directive:
1. G command
· G90: origin of reference coordinate system retaining wall, in the workpiece coordinate system in the preparation of tools to run point program.
G91: near the point of reference date, the preparation of tools to run from the program.
GO: fast-moving so fast tool positioning, movement around the workpiece near the tool change point, or
G1: Tool along with the shaft, slash or any other space orientation parallel to the line of mobile home.
G2: the arc in a clockwise direction on a track to run
G3: anti-clockwise on the circular track to run
G4: pause time effect (F ... in seconds; S ... used to determine the number of spindle rotation time)
G17: No tool radius compensation
G18: Cutter Radius Compensation to the contours of the left side
G19: Cutter Radius Compensation to the contours of the right side of
G40: lift the tool radius compensation
G41: active tool radius compensation, tool machining direction along the contour to run to the right side of
G42: active tool radius compensation, tool machining direction along the contour to run to the left of
G53: Non-modal access, including the programmed bias
G54 ... G57: Call No. 1 to No. 4 can be set to zero bias
G94: linear feed rate in mm / min, inches / min
G95: rotating feed rate mm / turn, inch / turn
2. M command
M0: Programming Stop
M1: choose to stop
M2: main program entry procedure at the beginning of the end of
M30: end of the process
M17: Subroutine end
M3: active spindle clockwise rotation
M4: Active spindle counterclockwise rotation
M5: Active Spindle Stop
M6: ATC instructions
3. Other
F: Feed Rate
S: active spindle speed (unit: rev / min)
T: Call Tool
D: Tool offset number (range: 1 ... 32000)
If it is grating back to zero, please refer to the following the following methods:
If your foot is the grating with a distance of coded reference point of grating ruler, then mark (usually behind the Heidenhain grating ruler marked with C have this function), return a reference point do not need to switch back to zero, the parameter set as follows:
1,34200 = 3 using the type of optical grating
2,34300 [1] = 20mm linear grating-foot grid spacing mark a reference point (LS486C to 20mm)
3,34060 [1] = 40 return to reference point distance = 2 times the largest mobile linear grating-foot grid spacing of the reference point mark
4,34000 = 0 do not use feed cam shaft to return a reference point, that is, without a reference point return deceleration switch signal (DB31.DBX12.7)
5,34090 = XXX to return a reference point offset value
6,34310 [1] = 0.020 signal optical grating pitch (LS486C to 0.020mm)
PLC
PLCs were invented in the 60/70's for the automotive manufacturing industry. Since this time, they have developed into one of the most versatile tools used for industrial automation. A working knowledge of PLCs and other microprocessor based control systems are critical to technical personnel who are staying current with technology in industry.
Programmable Logic Controllers or PLC are the hub of many manufacturing processes. These microprocessor based units are used in processes as simple as boxing machines or bagging equipment to controlling and tracking sophisticated manufacturing processes. They are in virtually all new manufacturing, processing and packing equipment in one form or another. Because of their popularity in industry, it becomes increasingly more important to learn skills related to these devices. Click on the buttons to learn more about industrial automation and this invaluable tool.
The microprocessor or processor module is the brain of a PLC system. It consists of the microprocessor, memory
integrated circuits, and circuits necessary to store and retrieve information from memory. It also includes communications ports to other peripherals, other PLC's or programming terminals. Today's processors vary widely in their capabilities to control real world devices. Some control as few as 6 inputs and outputs (I/O) and others 40,000 or more. One processor can control more than one process or manufacturing line. Processors are often linked together in order to provided continuity throughout the process. The number of inputs and outputs PLCs can control are limited by the overall capacity of the PLC system
hardware and memory capabilities. The job of the processor is to monitor status or state of input devices, scan and solve the logic of a user program, and control on or off state of output devices.
RAM or Random Access Memory is a volatile memory that would lose it's information if power were removed..
This is why some processor units incorporate a battery back up. The type of RAM normally used is CMOS or
Complementary Metal Oxide Semiconductor. CMOS RAM is used for storage of the user's program (ladder logic diagrams) and storage memory.
ROM or Read Only Memory is a non-volatile type of memory. This means you don't need an external power source to keep information. In this type of memory, information can be read, but not changed. For this reason the manufacture sometimes calls this firmware. It is placed there for the internal use and operation of processor units.
EEPROM or Electrically Erasable Programmable Read Only Memory is usually an add-on memory module that is used to back up the main program in CMOS RAM of the processor. In many cases, the processor can be programmed to load the EEPOM's program to RAM if RAM is lost or corrupted.
Input Module
There are many types of input modules to choose from. The type of input module used is dependent upon what real world input to the PLC is desired. Some examples of inputs are limit switches, electric eyes, and pushbuttons. DC inputs, such as thumbwheel switches, can be used to enter integer values to be manipulated by the PLC. DC input cards are used for this application. Since most industrial power systems are inherently noisy, electrical isolation is provided between the input and the processor. Electromagnetic interference (EMI) and Radio Frequency Interference (RFI) can cause severe problems in most solid state control systems. The component used most often to provide electrical isolation within I/O cards is called an optical isolator or optocoupler. The wiring of an input is not complex. The object is to get a voltage at a particular point on the card. Typically there are 8 to 32 input points on any one input module. Each point will be assigned a unique address by the processor. Analog input modules are special input cards that use analog to digital conversion (A to D) to sense variables such as temperature, speed, pressure, and position. The external device normally is connected to a controller (transducer) producing an electrical signal the analog input card can interpret. This signal is usually 4 to 20 Ma or a 0 to 10 volt signal.
Output Module
Output modules can be for used for ac or dc devices such as solenoids, relays, contractors, pilot lamps, and LED readouts. Output cards usually have from 6 to 32 output points on a single module. The output device within the card provides the
connection from the user power supply to the load. Usually silicon controlled rectifiers (SCR), triac, or dry contact relays are use for this purpose. Individual outputs are rated most often at 2 to 3 amperes. Output cards, like input cards have electrical
isolation between the load being connected and the PLC. Analog output cards are a special type of output modules that use digital to analog conversion (D to A). The analog output module can take a value stored in a 12 bit file and convert it to an analog signal. Normally this signal is 0 -10 volts dc or 4 to 20 Ma. This analog signal is often used in equipment such as motor operated valves and pneumatic position control devices.
ANALOG
Analog inputs and/or outputs can be 0 to 10V; -10 to +10V; -5v to +5v; 0 to 20mA and 4 to 20mA.
The analog signals are sent to the PLC input where they are read in and converted into a numerical value.
Analog outputs are numerical values in the PLC which are sent to the outputs where they are converted into a variable signal (volts or mA).
The "raw" numerical value from an analog input signal can be processed further for use within the user program.
This raw value is usually scaled before such use to make it easier to process. i.e. a 20mA max signal maybe converted into 1024 units but in the real world 20mA may equate to, say, 600 degrees. It can be seen that if the actual input was 13mA to use the un-scaled value to set min/max alarms in the PLC would be difficult; therefore the user program firsts "scales" the raw values into something more sensible.
For example a sub-routine could scale the raw value to, 1024 units = 600 units, to set min/max alarms now would be easier. i.e.. 300 units = 300 degrees.
E.G.
Process = 0 to 600 degrees
Input = 0 to 20mA (0 degrees = 0 units; 600 degrees = 1024 units)
Raw value = 0 to 1024 units.
Scale = 0 to 600
The sub routine would have to carry some maths to perform the following.
MAX SCALED VALUE / MAX RAW VALUE * ACTUAL RAW VALUE
Max Scaled Value = 600
Max Raw Value = 1024
Actual Raw Value = 700 (variable)
Using the above equation the scaled value would be 410.16 (degrees)
If the actual raw value was 1000 the scaled value would be 585.94 (degrees)
If the actual raw value was 200 the scaled value would be 117.18 (degrees)
Programmable Logic Controllers or PLC are the hub of many manufacturing processes. These microprocessor based units are used in processes as simple as boxing machines or bagging equipment to controlling and tracking sophisticated manufacturing processes. They are in virtually all new manufacturing, processing and packing equipment in one form or another. Because of their popularity in industry, it becomes increasingly more important to learn skills related to these devices. Click on the buttons to learn more about industrial automation and this invaluable tool.
The microprocessor or processor module is the brain of a PLC system. It consists of the microprocessor, memory
integrated circuits, and circuits necessary to store and retrieve information from memory. It also includes communications ports to other peripherals, other PLC's or programming terminals. Today's processors vary widely in their capabilities to control real world devices. Some control as few as 6 inputs and outputs (I/O) and others 40,000 or more. One processor can control more than one process or manufacturing line. Processors are often linked together in order to provided continuity throughout the process. The number of inputs and outputs PLCs can control are limited by the overall capacity of the PLC system
hardware and memory capabilities. The job of the processor is to monitor status or state of input devices, scan and solve the logic of a user program, and control on or off state of output devices.
RAM or Random Access Memory is a volatile memory that would lose it's information if power were removed..
This is why some processor units incorporate a battery back up. The type of RAM normally used is CMOS or
Complementary Metal Oxide Semiconductor. CMOS RAM is used for storage of the user's program (ladder logic diagrams) and storage memory.
ROM or Read Only Memory is a non-volatile type of memory. This means you don't need an external power source to keep information. In this type of memory, information can be read, but not changed. For this reason the manufacture sometimes calls this firmware. It is placed there for the internal use and operation of processor units.
EEPROM or Electrically Erasable Programmable Read Only Memory is usually an add-on memory module that is used to back up the main program in CMOS RAM of the processor. In many cases, the processor can be programmed to load the EEPOM's program to RAM if RAM is lost or corrupted.
Input Module
There are many types of input modules to choose from. The type of input module used is dependent upon what real world input to the PLC is desired. Some examples of inputs are limit switches, electric eyes, and pushbuttons. DC inputs, such as thumbwheel switches, can be used to enter integer values to be manipulated by the PLC. DC input cards are used for this application. Since most industrial power systems are inherently noisy, electrical isolation is provided between the input and the processor. Electromagnetic interference (EMI) and Radio Frequency Interference (RFI) can cause severe problems in most solid state control systems. The component used most often to provide electrical isolation within I/O cards is called an optical isolator or optocoupler. The wiring of an input is not complex. The object is to get a voltage at a particular point on the card. Typically there are 8 to 32 input points on any one input module. Each point will be assigned a unique address by the processor. Analog input modules are special input cards that use analog to digital conversion (A to D) to sense variables such as temperature, speed, pressure, and position. The external device normally is connected to a controller (transducer) producing an electrical signal the analog input card can interpret. This signal is usually 4 to 20 Ma or a 0 to 10 volt signal.
Output Module
Output modules can be for used for ac or dc devices such as solenoids, relays, contractors, pilot lamps, and LED readouts. Output cards usually have from 6 to 32 output points on a single module. The output device within the card provides the
connection from the user power supply to the load. Usually silicon controlled rectifiers (SCR), triac, or dry contact relays are use for this purpose. Individual outputs are rated most often at 2 to 3 amperes. Output cards, like input cards have electrical
isolation between the load being connected and the PLC. Analog output cards are a special type of output modules that use digital to analog conversion (D to A). The analog output module can take a value stored in a 12 bit file and convert it to an analog signal. Normally this signal is 0 -10 volts dc or 4 to 20 Ma. This analog signal is often used in equipment such as motor operated valves and pneumatic position control devices.
ANALOG
Analog inputs and/or outputs can be 0 to 10V; -10 to +10V; -5v to +5v; 0 to 20mA and 4 to 20mA.
The analog signals are sent to the PLC input where they are read in and converted into a numerical value.
Analog outputs are numerical values in the PLC which are sent to the outputs where they are converted into a variable signal (volts or mA).
The "raw" numerical value from an analog input signal can be processed further for use within the user program.
This raw value is usually scaled before such use to make it easier to process. i.e. a 20mA max signal maybe converted into 1024 units but in the real world 20mA may equate to, say, 600 degrees. It can be seen that if the actual input was 13mA to use the un-scaled value to set min/max alarms in the PLC would be difficult; therefore the user program firsts "scales" the raw values into something more sensible.
For example a sub-routine could scale the raw value to, 1024 units = 600 units, to set min/max alarms now would be easier. i.e.. 300 units = 300 degrees.
E.G.
Process = 0 to 600 degrees
Input = 0 to 20mA (0 degrees = 0 units; 600 degrees = 1024 units)
Raw value = 0 to 1024 units.
Scale = 0 to 600
The sub routine would have to carry some maths to perform the following.
MAX SCALED VALUE / MAX RAW VALUE * ACTUAL RAW VALUE
Max Scaled Value = 600
Max Raw Value = 1024
Actual Raw Value = 700 (variable)
Using the above equation the scaled value would be 410.16 (degrees)
If the actual raw value was 1000 the scaled value would be 585.94 (degrees)
If the actual raw value was 200 the scaled value would be 117.18 (degrees)
Encoder Selection Notice
The encoder is divided into incremental rotary encoders and absolute rotary encoders. The following are two kinds of encoder installation Precautions Note:
Incremental Rotary Encoder selection should pay attention to three parameters:
(1) Mechanical installation dimensions, including location only the mouth of the shaft diameter, the installation holes; cable outlet way; installation space volume; work environment protection rating meets the requirements. Incremental Rotary Encoder selection should pay attention to three parameters:
(2) Resolution, that is, the work of the encoder output pulses for each lap number, is designed to be used to meet the required precision.
. (3) Electrical interface, the encoder outputs are push-pull output common mode (F-type HTL format) , the voltage output (E), open collector (C, common C for the NPN-tube output, C2 for the PNP-tube output), long-term driver outputs.
A manner that its output and its control system interface circuit match.
Absolute rotary encoders Selection Notice (1) of the mechanical parts: ① measuring length and angle measurement, the measured length of how mechanical conversion (there are some in the above description, such as the call is not clear to discussion). Absolute rotary encoders Selection Notice
Measured angle is within a 360-degree (single circle), or may be too 360 degree (multi-turn). Measured angle is 360 degrees inside the (single circle), or may be too 360 degree (multi-turn). The production process is in one direction rotating cycle to work, or back and forth direction of the work cycle. The direction of the production process is a rotating cycle to work, or back and forth direction of the work cycle. ② shaft connected to install the form, there are axial coupling through the soft link, or sleeve-type connections. ② shaft connected to install the form, there are axial coupling through the soft link, or sleeve-type connections. ③ use of the environment: dust, water vapor, vibration, impact? (2) Electrical part ① Connect the output of receiving part of that? ② signal form? ③ resolution requirements? ④ control requirements?
Incremental Rotary Encoder selection should pay attention to three parameters:
(1) Mechanical installation dimensions, including location only the mouth of the shaft diameter, the installation holes; cable outlet way; installation space volume; work environment protection rating meets the requirements. Incremental Rotary Encoder selection should pay attention to three parameters:
(2) Resolution, that is, the work of the encoder output pulses for each lap number, is designed to be used to meet the required precision.
. (3) Electrical interface, the encoder outputs are push-pull output common mode (F-type HTL format) , the voltage output (E), open collector (C, common C for the NPN-tube output, C2 for the PNP-tube output), long-term driver outputs.
A manner that its output and its control system interface circuit match.
Absolute rotary encoders Selection Notice (1) of the mechanical parts: ① measuring length and angle measurement, the measured length of how mechanical conversion (there are some in the above description, such as the call is not clear to discussion). Absolute rotary encoders Selection Notice
Measured angle is within a 360-degree (single circle), or may be too 360 degree (multi-turn). Measured angle is 360 degrees inside the (single circle), or may be too 360 degree (multi-turn). The production process is in one direction rotating cycle to work, or back and forth direction of the work cycle. The direction of the production process is a rotating cycle to work, or back and forth direction of the work cycle. ② shaft connected to install the form, there are axial coupling through the soft link, or sleeve-type connections. ② shaft connected to install the form, there are axial coupling through the soft link, or sleeve-type connections. ③ use of the environment: dust, water vapor, vibration, impact? (2) Electrical part ① Connect the output of receiving part of that? ② signal form? ③ resolution requirements? ④ control requirements?
Servo Motor Brake
Users tend to electromagnetic braking, regenerative braking, dynamic braking of the role of the confusion, chose the wrong accessories.
Dynamic brake resistor formed by the dynamic braking, in failure, emergency stop, power outages by reducing energy consumption, servo motor brake mechanical feed distance.
Regenerative braking refers to the servo motor is slowing down or stop the energy generated when braking through the inverter circuit back to the DC bus, through the resistance-capacitance circuit to absorb.
Differences among the three parties
(1) regenerative braking must work properly when the server works, failure, emergency stop, power outages and other circumstances can not brake motor. Dynamic brakes and electromagnetic brakes work without power supply . Differences among the three parties
(2) The regenerative braking system to automatically carry out the work, while the dynamic brake and the electromagnetic brake work takes an external relay control.
(3) The electromagnetic brake is usually in the SV OFF start, otherwise, may result in amplifier overload. Dynamic brakes in general SV OFF or main power circuit after the start, otherwise the dynamic braking resistor may cause overheating
Select accessories Note
(1) Some systems such as transfer devices, lifting devices, etc. require servo motor stop as soon as possible. While in failure, emergency stop, power regenerative braking power when the server does not slow down the motor. At the same time the mechanical system inertia also larger then required to use dynamic brakes to select based on dynamic brake light and heavy load, the motor speed of work.
(2) Some systems to maintain a static position of mechanical devices required to provide a greater motor output torque and a longer time to stop, if you use self-locking function of servo motors tend to cause overheating or amplifier overload. This situation should choose with electromagnetic brake motor.
(3) Mitsubishi servers have built-in regenerative braking unit, but regenerative braking may give rise to more frequent DC bus voltage is too high, then need to reprovision regenerative braking resistor. Regenerative braking resistor is need for a separate distribution, with much of the regenerative braking resistor instructions refer to the use of samples. should be noted that the number of samples of braking on the list is the motor no-load data. the actual selection of the first according to system load inertia and the sample the motor inertia and inertia than calculated. longer brake on the list the number of samples divided by the (usual than 1). The data thus obtained is the number of allowed braking
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