servo motor
DESCRIPTION
sfTRANSCRIPT
MITSUBISHI
AC Servo Training Manual Mitsubishi Electric Asean Factory Automation Center
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CONTENTS
1. FUNDAMENTALS OF AC SERVO CONTROL - - - - - - - - - - - - 1-1
1.1 Definition of “servo” - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 1.2 Positioning and the performance of AC Servo - - - - - - - - - - - - - - - - 1-2 1.3 About MELSERVO - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
1.3.1 The road map of MELSERVO - - - - - - - - - - - - - - - - - - - - 1-6 1.3.2 Positioning of a product - - - - - - - - - - - - - - - - - - - - - - - 1-7 1.3.3 General-purpose Servo amplifier specification comparison table - - - - 1-7 1.3.4 The model series and the feature of a servo motor - - - - - - - - - - 1-8 1.4 Structure of AC Servo - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-10 1.4.1 The principle of operation of Servo amplifier - - - - - - - - - - - - - - 1-10 1.4.2 The characteristic and principle of operation of AC servo motor - - - - 1-17
1.4.3 The function and principle of encoder operation - - - - - - - - - - - - - 1-20 2. Positioning control Using AC Servo - - - - - - - - - - - - - - - - - - 2-1 2.1 Positioning Method and Stopping Accuracy - - - - - - - - - - - - - - - - - - 2-1 2.1.1 Types of Positioning - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 2.1.2 Positioning control and stopping accuracy for speed control methods - - - 2-3 2.1.3 Types of position control - - - - - - - - - - - - - - - - - - - - - - - - - 2-5 2.2 Fundamentals of Positioning Control - - - - - - - - - - - - - - - - - - - - - 2-6 2.2.1 Position detection and number of pulses per motor revolution - - - - - - 2-6 2.2.2 Theory of servo positioning control - - - - - - - - - - - - - - - - - - 2-6 2.3 Positioning Accuracy - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-9 2.3.1 Feed distance per pulse - - - - - - - - - - - - - - - - - - - - - - - - - 2-9 2.3.2 Concept of overall accuracy for machine and electrical accuracy - - - - - 2-9 2.4 Motor Rotational Speed at the Maximum Machine Speed - - - - - - - - - - 2-11 2.5 Command Pulse - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-12 2.5.1 Electronic gear function - - - - - - - - - - - - - - - - - - - - - - - - - 2-12 2.5.2 Maximum pulse frequency - - - - - - - - - - - - - - - - - - - - - - - - 2-18 2.6 Speed Pattern and Setting time - - - - - - - - - - - - - - - - - - - - - - - - 2-19 2.6.1 Speed Pattern and performance of droop - - - - - - - - - - - - - - - - - - 2-19 2.6.2 Setting Time (ts) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-20 2.7 Relationship Between Moment of Load Inertia and Position Loop Gain(kp) - - 2-21 2.7.1 Moment of load inertia - - - - - - - - - - - - - - - - - - - - - - - - - 2-21 2.7.2 Real-time auto tuning - - - - - - - - - - - - - - - - - - - - - - - - - - 2-22
3. Positioning Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 3.1 Classification of Positioning Controllers and Typical Miscellaneous Functions - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 3.1.1 The function of positioning controller - - - - - - - - - - - - - - - - - - 3-1 3.1.2 The function of Servo amplifier - - - - - - - - - - - - - - - - - - - - - - 3-1
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3.2 A classification and composition of positioning controller - - - - - - - - - 3-1 3.3 Setting data of positioning controller - - - - - - - - - - - - - - - - - - - 3-6 3.3.1 Basic parameter - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-6 3.3.2 The basic parameter for a starting point return - - - - - - - - - - - - 3-6
3.3.3 Positioning data - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-7 3.4 Position instruction interface - - - - - - - - - - - - - - - - - - - - - - - - 3-9 3.5 The foundations of the positioning control by positioning Controller - - - 3-11 3.5.1 The machine move direction and the servo motor rotation direction - - 3-11 3.5.2 The type of home position return - - - - - - - - - - - - - - - - - - 3-12 4. MELSERVO – J2S Performance and Functions - - - - - - - - - - - - 4-1 4.1 Basic Performance and Functions - - - - - - - - - - - - - - - - - - - - - - 4-1
4.2 Composition with peripheral equipment - - - - - - - - - - - - - - - - - - - - 4-2 4.3 Installation and Operation - - - - - - - - - - - - - - - - - - - - - - - - - 4-5 4.3.1 Operation flow from installation to operation start - - - - - - - - - - - - 4-5 4.3.2 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6 4.3.3 Wiring and sequence- - - - - - - - - - - - - - - - - - - - - - - - - - - 4-14 4.3.4 Standard connection diagram - - - - - - - - - - - - - - - - - - - - - - - 4-19
4.3.5 Power supply turned on - - - - - - - - - - - - - - - - - - - - - - - - - 4-31 4.3.6 Display and operation function - - - - - - - - - - - - - - - - - - - - - - 4-34
4.3.7 Parameter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-42 4.3.8 Parameter setting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-53
4.3.9 Checking the I/O signal - - - - - - - - - - - - - - - - - - - - - - - - - 4-54 4.3.10 Manual operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-57 4.3.11 Home position return - - - - - - - - - - - - - - - - - - - - - - - - - - 4-57 4.3.12 Automatic operation - - - - - - - - - - - - - - - - - - - - - - - - - - 4-57
4.3.13 Test operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-58 4.3.14 The operation procedure in each operation mode (conclusion) - - - - - 4-62
4.3.15 The function convenient for starting and diagnosis- - - - - - - - - - - 4-65
5. MELSERVO – H Performance and Functions - - - - - - - - - - - 5-1
5.1 I/O Terminal Function - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 5.2 Parameter function - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3 5.3 Display and Diagnosis Functions - - - - - - - - - - - - - - - - - - - - - 5-12 5.3.1 MR-PRU01A Parameter unit- - - - - - - - - - - - - - - - - - - - - - 5-12 5.3.2 Monitor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-14 5.4 Setup and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-16 5.4.1 H/W Setting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-16 5.4.2 Power ON- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-16 5.4.3 Parameter setup- - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-16 5.4.4 Checking the I/O single- - - - - - - - - - - - - - - - - - - - - - - - 5-19
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6. Selection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 6.1 Provisional selection of motor capacity - - - - - - - - - - - - - - - - - 6-1 6.1.1 Moment of load inertia ( JL ) - - - - - - - - - - - - - - - - - - - 6-1 6.1.2 Load torque ( TL ) - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 6.1.3 Formulae to calculate moment of load inertia and load torque - - 6-2 6.2 Reduction Ratio - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-4 6.3 Operation Patterns and Required Motor Torque - - - - - - - - - - - - 6-5 6.3.1 Acceleration torque ( Ta ) - - - - - - - - - - - - - - - - - - - - - 6-5 6.3.2 Deceleration torque ( Td ) - - - - - - - - - - - - - - - - - - - - - 6-5 6.3.3 Driving pattern - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-6 6.3.4 Determining motor capacity- - - - - - - - - - - - - - - - - - - - - - 6-7 6.4 Example of Capacity Selection Procedure - - - - - - - - - - - - - - - 6-9 7. The measure against a noise, leak current, harmonics - - - - - - 7-1 7.1 The measure against a noise - - - - - - - - - - - - - - - - - - - - - - - 7-1 7.2 Leak current - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3 7.3 Harmonics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5 7.3.1 A basic wave and harmonics - - - - - - - - - - - - - - - - - - - 7-5 7.3.2 The characteristic of a rectification circuit and generating harmonics - - 7-6 7.3.3 The measure against harmonics - - - - - - - - - - - - - - - - - - - - 7-6
8. Maintenance and check - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 8.1 Maintenance and check - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 8.1.1 Notes at the time of maintenance and check - - - - - - - - - - - - - 8-1 8.1.2 Item of inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 8.1.3 Part exchange - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-5 8.1.4 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7 8.1.5 Remedies for warning - - - - - - - - - - - - - - - - - - - - - - - - 8-13 8.1.6 The cause investigation method at the time of position gap generating- - 8-14
APPENDICES APP.1. Symbols for the specifications - - - - - - - - - - - - - - - - - - - - App-1
App.2. Type of Drive System - - - - - - - - - - - - - - - - - - - - - - - - App-2 App.3. Example Application- - - - - - - - - - - - - - - - - - - - - - - - - App-6 APP.4. Positioning Controller performance comparison - - - - - - - - - - App-9
1. FUNDAMENTALS OF AC SERVO CONTROL 1.1 Fundamentals of AC servo control
Definition of “Servo” For the purpose of the Japanese Industrial Standards, a servomechanism is defined as a control system designed to track a target that changes unpredictably, with the position, bearing, orientation, etc., of a physical object as the control quantity. When the target value (position, speed, etc.) is input to the servomechanism from the command section, the servomechanism detects the current value, and continually executes control to reduce the difference between the current value and target value. The elements that comprise a servomechanism are called servo elements. And in the case of Mitsubishi’s “MELSERVO-J2S” AC servo, these elements are the drive amplifier (AC servo amplifier), the motor (AC servomotor), and the detector. The configuration of this servomechanism is shown in Fig. 1.1.
Fig. 1.1 Configuration of a Servomechanism
1-1
1. FUNDAMENTALS OF AC SERVO CONTROL 1.2 General Characteristics of Servo
As implied in the foregoing section of a servomechanism, the basic function and performance requirement of a servomotor is to track a continually changing target quickly in response to speed/position control. To enable a servomotor to fulfill this requirement, it must be designed with greater consideration given to the moment of inertia of the rotor (also called GD2), and electrical responsibility, than is necessary for a general purpose motor. The reason for this is to ensure that the servomotor can respond to sudden changes in the voltage and current from the servo amplifier. The servo amplifier that drives the servomotor must also be capable of quickly and accurately transmitting the speed and position control commands to the servomotor. With these points in mind, the following gives a comparison between the typical characteristics obtained when using a servomotor in combination with a servo amplifier and the characteristics of a motor driven by a general purpose inverter (a widely used type of variable speed controller) (1) Comparison of characteristics of a servomotor and general purpose
inverter
The characteristics of a motor are commonly assessed by looking at its speed-torque characteristics. Fig 1.2 compares a servomotor and a general purpose motor used in combination with general purpose inverter on this basis. The superior qualities of the servomotor are clear from this figure. It has three main advantages: (a) The motor have a wide speed
control range (b) It maintains a constant output
torque from high speeds (the rated speed) to low speeds (the stalling speed).
(c) It has a high maximum torque. Note: Since the motor’s maximum
torque is high but its moment of inertia is low, it is capable of sudden acceleration and deceleration
When selecting a servomotor, the function and performance of the machine concerned must always be considered in the light of the points explained above.
1-2
1. FUNDAMENTALS OF AC SERVO CONTROL
Some actual figures for servomotor characteristics are presented below to add some details to our explanation.
Table 1.1 Main Servomotor Characteristics Item Specification Descriptions
Speed control range 1 : 1000 to 5000 (1 : 10)
Can be used down to 1/1000th of the rated speed without any concern of reduced rotational stability or reduced torque
Output torque characteristics
No torque drop in low speed operation
A constant output torque is maintained throughout the speed control range, whether at the continuous output torque or maximum torque. In other words, the motor can be used safely over the entire speed range even with rated torque load.
Maximum torque Approx. 300% (150%)
An instantaneous maximum torque of approximately 300% of the rated torque can be obtained. This enables the motor to accelerate and decelerate suddenly, which means that it can be for high frequency positioning
Note: The figures in parentheses are typical specifications for a general purpose inverter.
(2) Application of AC servomotors The main characteristics of servomotors have been described. In addition, servomotors become capable of a function that is beyond other variable speed controllers when used in combination with servo amplifiers: the positioning function. The positioning function is described in detail in Chapter 2; here typical servomotor applications made possible by the characteristics described in section (1) on the previous page and the positioning function are explained. (a) Machines that require positioning
Using the AC servomechanism in combination with specialized positioning controller (see chapter 6) enables accurate positioning with good reproducibility. A general purpose Mitsubishi AC servomechanism is capable of a positioning resolution of 120000 to 4000 divisions per motor axis revolution, which is sufficient to achieve positioning in units of 1um with machine travel in the range 24 to 8 m/min. Example application: Machine tools, wood working machines, conveyors, packaging machines, inserter/mounters, feeder, cutters and specialized machinery.
1-3
1. FUNDAMENTALS OF AC SERVO CONTROL
(b) Machines that requires a wide range of speed variation The AC servomotor has a speed control range of 1:1000, and features highly accurate speed control, with a coefficient of speed fluctuation of no greater than 0.03%. It also features constant output torque, a characteristics not featured by other variable speed motors. Because of these characteristics, it is used for control of production lines and other applications where highly accurate variable speed drive is required. Example Applications: Printing presses, paper processing machines, film manufacturing line, wire making machines, winding machines, feed mechanisms of specialized machines, conveyors, main shafts of winding/unwinding machines, and wood working machines.
(c) High frequency positioning Positioning is performed as explained in (a) on the previous page. The maximum torque of the AC servomotor is 300% of the rate torque and a motor, when it is unloaded, can follow the acceleration and deceleration from the stopped state to the rated speed in a mere several tens of milliseconds, which means it can drive positioning operations at frequencies of 100 times per minutes and higher. Another important characteristic of the AC servomotor is that it has no parts that make mechanical contact, in contrast to other positioning mechanism (clutch, brake, DC motors, etc.); this makes it maintenance-free and means that it is not greatly influenced by the ambient temperature. Example applications: Press feeder, bad-making machine, sheet cutting machine, loader/unloaders, filling machine, packaging machines, conveyors.
(d) Torque control Since recent digital servomotors feature torque control in addition to conventional functions such as speed control and position control, they can be used for applications that involve tension control, such as winding/unwinding machines.
1-4
1. FUNDAMENTALS OF AC SERVO CONTROL
(3) Other characteristics, Summary In addition to the speed control range already dealt with, there are other basic aspects of the performance of a motor- such as responsibility- that show its speed control characteristics. Fig 1.3 compares an AC servomotor and general purpose inverter on the basis of control performance and functions of an inverter and general purpose AC servo in actual use.
Responsibility The responsibility is a measure of the speed of follow-up in response to changes in commands and disturbance. It is a guide to the maximum severity of sudden load fluctuation that can be dealt with by following commands without causing any speed fluctuation. For example, a motor that has a responsibility of 600 rad/s will be able to tolerate a load fluctuation of approximately 100Hz with no appreciable influence on speed.
1-5
1. FUNDAMENTALS OF AC SERVO CONTROL 1.3 About MELSERVO 1.3.1 The road map of MELSERVO
Demand item introduction is better to better of new technology and the industrial world that surely reflected technical innovation in the new product for general purpose AC servo in 1982. The environment that surrounds Servo now is shifting to the next generation. MR-J2-Super series raised the function and the performance of the MR-J2 conventional series and conventional compatibility for the performance of a machine in the maximum output sake to the correspondence to the further high speed and high precision, shortening of starting time, fullness of diagnosis and a maintenance, and these demands. The road map of MELSERVO is shown in the following table.
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1. FUNDAMENTALS OF AC SERVO CONTROL 1.3.2 Positioning of Product
Positioning of MELSERVO series is shown in a right table.
1.3.3 General-purpose Servo amplifier specification comparison table
Model
Item
MR-H-AN / KAN4 MR-H-BN / KBN4 MR-H-CN / KCN4
MR-HTN Series
MR-J2S-A
MR-J2S-B(*) Series
MR-CA MR-CA1
Series
MR-J2-03A5
MR-J2-03B5(*) MR-J2-03C5
Appearance
Feature
Highly performance The variation of a motor is abundant.
Those with setup software (MRZJW3-SETUP61 or subsequent ones)
Those with bus joint MR-H-BN
With a built-in 1 axis controller (MR-H-ACN)
Next-generation Servo Replacement of MR-J2 A servomotor is ABS-equipped standard.
Those with setup software (MRZJW3-SETUP111 or subsequent ones)
Replacement from super-type
Minimize Motor distinction function Those with setup software (MRZJW3-SETUP61 or subsequent ones)
Mini small down size Servo
MR-J2 series DC24V correspondence
Those with setup software (MRZJW3-SETUP61 or subsequent ones)
DIN rail attachment is possible.
32 axis multi-drops are possible.
Capacity 50W-55kW 50W-7kW 30W-400W 10W-30W
Gear. Brake With With With (however, it removes
with 30W slowdown machine)
With (on sale schedule)
Encoder signal Serial communication Serial communication Serial communication Serial communication A position per resolution 8192/16384 p/rev 131072 p/rev 4000 p/rev 8192 p/rev Detection system INC/ABS INC/ABS INC INC
Rated rotation speed
2000/3000 1000/2000/3000 3000 3000 Rotation speed
(r/min) Max Rotation speed
2000/2500/3000/4500 1200/1500/2500/3000/4500 4500 10W-20W, 5000
30W, 4500
Max torque 300% 300%
300%(400%, LESS 10W) 300%
Control mode Position/ speed / torque Position / speed / torque Position/speed (internal 2 speed) Position / speed / torque Frequency response 250Hz 550Hz 200Hz 250Hz Control theory Model adaptive control Model adaptive control Model adaptive control Model adaptive control Auto tuning Real time Real time Real time Real time Personal computer I/F Standard equipment Standard equipment Option Standard equipment
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1. FUNDAMENTALS OF AC SERVO CONTROL
Built-in card option Available Unavailable Unavailable Unavailable Speed control range 1:5000 1:5000 - 1:1000 The external power supply for I/F
Not required Not required Required DC24V Required DC24V
Regeneration brake resistance
Built-in Built-in An external option Unavailable
Dynamic brake Built-in Built-in Nothing Built-in Display (main part) 4-figure display 5-figure display 3-figure display 4-figure display
Other setting key Parameter unit Four-piece setting button Four-piece setting button Four-piece setting button Analog monitor 2CII (12 bit) 2CII (8 bit) Nothing Nothing Pulse part circumference output
A, B, Z Phase A, B, Z Phase Z phase A, B, Z phase
Test mode operation Available Available Available Available Motor-less operation Available Available Unavailable Available EN correspondence Acquisition (-UE) Acquisition Acquisition Acquisition UL-cUL standard correspondence
Acquisition (-UE) Acquisition Acquisition Acquisition
Correspondence motor
HC-MF series HA-FF series HC-SF series HC-RF series HC-UF series
HA-LHK series HA-LFK series
HC-KFS series HA-MFS series HC-SFS series HC-RFS series HC-UFS series
HC-PQ series HC-AQ series
<Note> this data is a thing as of June, 1999. * : one of the new sale schedule 1.3.4 Model Series and Feature of Servo Motor In AC Servo MELSERVO-C, J2S, and H-N series, it has had various motors in stock by machine
correspondence.
All the motors of MELSERVO-J2S series are the same sizes as a motor conventionally
in ABS and a 17-bit (130,000 pulses) encoder standard equipment.
Series name Capacity (W)
The encoder resolution pulse/rev
Correspondence of encoder
Rated rotation speed / maximum
rotation speed Adaptation
Servo amplifier type name
Protection form Usage
Mic
ro sm
all c
apac
ity
HC-AQ
10W-30W
8192
Only INC
3000/5000r/min 3000/4500r/min
MR-J2-5
IP55
• Small slider • Small actuator • Micro robot
Supe
r-lo
w in
ertia
smal
l cap
acity
HC-PQ 30W-400W 4000 Only INC 3000/4500r/min MR-C IP44 • inserter, molding,
bonding • Printed circuit board
hole-open machine • circuit tester • Label Printing
machine • Micro robot • robot tip part Etc.
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1. FUNDAMENTALS OF AC SERVO CONTROL
HC-MFS 50W-750W 131072 ABS, INC 3000/4500r/min MR-J2S IP55
(IP65)
HC-MF 50W-750W 8192 ABS/INC 3000/4500r/min MR-H-N IP44
HC-KFS 50W-400W 131072 ABS,INC
3000/4500r/min MR-J2S IP55
(IP65)
HC-KF 50W-400W 8192 ABS,INC
3000/4500r/min MR-H-N IP44
Low
iner
tia sm
all c
apac
ity
HA-FF
50W-600W
8192
ABS,INC
3000/4000r/min
MR-H-N
IP44 (IP65)
• LCD, wafer conveyance equipment
• Food machine • Press machine • small loader • Small robot • small X-Y table
Etc.
HC-SFS 0.5kW -7.0kW 131072 ABS,INC
MR-J2S IP65 (IP67)
Mid
dle
iner
tia m
iddl
e ca
paci
ty
HC-SF 0.5kW -7.0kW 16384 ABS,INC
1000/1500r/min 1000/1200r/min 2000/3000r/min 2000/2500r/min 2000/2000r/min 3000/3000r/min
MR-H-N IP65 (IP67)
• Conveyance machine
• exclusive machine • robot • loader • wiring, tension
equipment • X-Y table • examination
machine Etc.
HC-RFS 1.0kW -5kW 131072
ABS/INC 3000/4500r/min MR-J2S
IP65 (IP67)
low
iner
tia m
iddl
e C
i
HC-RF 1.0kW
-5kW 16384 ABS,INC
3000/4500r/min MR-H-N IP65
(IP67)
• chip box • loader • Quantity frequency
conveyance machineetc.
Low
iner
tia la
rge
capa
city
HA-
LHK 11kW -22kW
16384
ABS/INC corresponden
ce is possible.
2000/2000r/min MR-H-N IP44
• Ejection molding machine
• Semiconductor fabrication machinesand equipment
• A lifter, an automatic warehouse system
• Large-sized conveyance machine
• Press Feeder • press transfer Etc.
HC-UFS
0.1kW -5kW
131072
ABS/INC
MR-J2S
IP65
Flat
type
HC-UF
0.1kW -5kW
16384
ABS,INC
2000/3000r/min2000/2500r/min3000/4500r/min
MR-H-N
IP65
• Robot • Conveyance
machine • Food machine • Wiring and tension
equipment Etc.
Larg
e ca
paci
ty
HA-LFK 30kW
-55kW
16384 ABS/INC
2000/2000r/min MR-H-N4 IP44
• Ejection molding machine
• Semiconductor fabrication machinesand equipment
• Large-sized conveyance machineEtc.
1-9
1. FUNDAMENTALS OF AC SERVO CONTROL 1.4 Mechanism of the AC servo 1.4.1 Servo amplifier block diagram and principle of operation
The basic function and principle of operation of a servo amplifier are described here by reference to the block diagram presented below.
Fig 1.3 Block Diagram of AC Servomotor
1-10
1. FUNDAMENTALS OF AC SERVO CONTROL
(1) Main Circuit
The basic function of the main circuit is to rectify and smooth a commercial power supply (3-phase,
200 to 230 VAC, 50/60Hz) by means of a converter (diode bridge, capacitor), and supply a 3-phase
current of any voltage and frequency that is subjected to sine wave PWM control by the inverter
(power transistor module)- to the motor to control its speed and torque.
(a) Converter, smoothing capacitor The commercial power supply is rectified by a diode bridge and then has its ripple reduced by a smoothing capacitor to generate a low-ripple DC power supply.
(b) Inverter The inverter generates, from the DC power supply created by the converter and smoothing capacitor, a current matched to the frequency and load torque at the motor’s rotational speed.
Fig 1.5 Configuration of the inverter section Fig 1.6 Inverter output current
1-11
1. FUNDAMENTALS OF AC SERVO CONTROL
As shown in Fig. 1.7, the direction of rotation and the rotational speed (frequency) of the motor are determined by the direction of the current and the width of turn on time in each direction, which depend on the ON/ OFF switching of the transistors in the inverter section. This type of the control, in which the size of the current is controlled by the width of turn on time, is called PWM control (pulse width control).
Fig. 1.7 Current Control Using the PWM Method (c) Regenerative brake
1) Regenerative brake circuit The regenerative brake operates when the actual rotational speed of the motor is higher than the speed reference- e.g. during deceleration, during descent on a vertical axis, or when a braking force is applied to an unwinding shaft – to achieve a braking effect by absorbing (consuming) the rotational energy of the motor and load in the servo amplifier. This kind of operation is called ‘ regenerative ’, and servo amplifiers normally incorporate a regenerative circuit. This regenerative circuit acts as a load on the motor, and its rate of energy consumption determines the regenerative braking force. The amount of rotational energy consumed varies according to the operating condition. When a large amount of energy has to be consumed, a circuit capable of consuming this energy is provided outside the servo amplifier.
2) Types of regenerative brake circuit Where a small braking capacity is required (the amount of rotational
energy to be consumed is small ), braking is achieved by using the energy to temporarily charge the smoothing capacitor mentioned previously. This is called the condenser regenerative method and can be used for applications up to about 0.4kW.
In case where a medium braking capacity is required, a method in which current is passed through resistors and the energy consumed as heat is adopted; this is called the resistor regenerative methods. The problems associated with this method include the need to use large resistors if the amount of energy to be consumed is large, and adverse effects on surrounding parts due to heat radiating from the resistors.
In case where a large braking capacity is required, a method in which energy is returned to the power supply has recently been adopted in order to avoid the deficiencies of the resistor regenerative method. This is called the power supply regenerative method and it can be use when the amount of energy involved exceeds 11kW.
1-12
1. FUNDAMENTALS OF AC SERVO CONTROL
(d) Dynamic brake When it stops with the output of inverter parts, such as the time of power cut off and alarm generating, ( base interception ), a motor serves as a free run, and time long to a stop may be required, the long overrun may become large, and it may serve as fault of colliding with a stroke end. A dynamic brake functions to stop the motor quickly in the event of a base circuit cut-off by short circuiting the servomotor terminals through an appropriate resistor and consuming the rotational energy as heat. a dynamic brake is usually installed separately from the motor and amplifier, but it is incorporated into some models of servo amplifier. Since a dynamic brake has no holding power when a mechanical brake if the motor drive motion on a vertical axis.
1-13
1. FUNDAMENTALS OF AC SERVO CONTROL
Due to the delay in the control circuit, the motor will rotate with delay on input of the command pulse to the position control section. The pulses that accumulate during this delay are held at the deviation counter; these pulses are called droop pulse. The droop pulses are output to the speed control section as speed commands. (2) Control Circuit
While carrying out operation processing of the amount of control (a position, speed, current) at high speed and with high precision from an instruction value (target value) and the present value using a microcomputer and realizing Servo control with high accuracy by high response, the monitor of the contents of control and protection of a unit are performed. The outline of the contents of control is explained below.
(a) Position Control
In a pulse sequence, control of the rotation speed and the direction of a motor and highly precise positioning are performed.
1-14
1. FUNDAMENTALS OF AC SERVO CONTROL
(b) Speed Control The output of a position control part deviation counter is proportional to instruction speed, and this serves as speed instructions. A speed instruction part outputs the deviation of speed instructions and motor speed as current instructions. In addition, when operating in speed control mode, analog voltage (0-±10V) is inputted from the exterior as speed instructions.
(c) Current Control and 3-phase generating circuits
A current control part controls the current of a motor so that the inverter of the main circuit is controlled and a motor moves as position instructions or a speed instruction. In order to achieve this control, the phases of the 3-phase alternating current are set to coincide with the magnetic field of the motor(determined by the positions of the rotor’s permanent magnets) and a current that corresponds to the speed deviation is output
1-15
1. FUNDAMENTALS OF AC SERVO CONTROL When supplying current to a synchronous motor, the position of the magnetic fields (magnetic pole positions) must be aligned with the phases. To achieve this alignment, the motor’s detector detects the magnetic pole positions and continually feeds back this information to the servo amplifier. On the basis of this signal, the servo amplifier generates the reference 3-phase current in the 3- phase generating circuit. The current control section multiplies the reference 3-phase current by speed deviation to generate 3 –phase current commands and controls the PWM circuit. Note: Induction type servomotors do not have independent magnetic fields. Accordingly, magnetic pole position detection is not necessary when they are used. A PWM system is a system which several times of switching pulses is generated in 1 cycle, and the pulse width is changed, and changes output voltage. The thing of the number of switching pulses generated in 1 second is called career frequency. In the case of a PWM system, the motor vibration and the motor noise of a frequency ingredient proportional to this career frequency occur. Fig 1.9 Principle of PWM Control (MR-J2S)
1-16
1. FUNDAMENTALS OF AC SERVO CONTROL 1.4.2 Characteristics and principle of operation of the AC servomotor
(1) Characteristic The output torque of the servomotor is proportional to the current supplied to it. See Section (3). Since the servo amplifier continually detects the motor speed and executes control to change the amount of current supplied in accordance with the speed deviation, the servomotor is able to produce a constant torque from low speeds to high speeds. The torque characteristics of a servomotor operated in combination with a servo amplifier are shown in the figure to the right.
(2) Principle of operation All motors, whether large or small operate according to the same principle: when a current is passed through a conductor in a magnetic field, a force – whose direction can be determined by using Fleming’s left-hand rule- is imparted to the conducted (see the figure to the right). The SM type (synchronous) AC servomotor has permanent magnets as its rotor and windings through which the current is made to flow as its stator; the current passed through the stator windings is controlled in order to achieve the required rotor motion (rotational speed and direction, output torque).
Fig 1.12 Torque characteristics of a servomotor (MELSERVO-J Series)
Principle by which motor Torque is generated
Principle of Operation of SMType AC Servomotor
1-17
1. FUNDAMENTALS OF AC SERVO CONTROL
The amplifier transistors are switched ON and OFF so as to supply current to each motor winding when it is perpendicular to the magnetic flux from the rotor magnet. The applied voltage is switched at a frequency of several kilohertz, and the current is smoothed by the reactance of the windings and take the form of a sine wave. The intervals during which the winding voltage is plus and minus are known from the magnetic pole position detection signal which emitted by the detector connected directly to the motor shaft Since this system ensures that the magnetic flux and current flow are always perpendicular to each other, the problem of getting out of step that affects normal synchronous motors does not occur. The generated torque T, determined by the following formula:
T = K1 • Φ • Ia ……….(1-1) Is proportional to the winding current, Ia, while the rotational speed, determined by the following formula: V - Ia • Z Is proportio Meaning of T: to V: a
………(1-2)
(3) Principle ofThe principsame for ansynchronoufrom the crothe rotor domagnet whicurrent, Ia,equation (1this type ofthe rotor withe current grooves duand the mawinding cur
N =
K2 • Φnal to the applied voltage, V.
symbols: rque; la: current; N: rotational speed; K1K2: constants pplied voltage; Φ: magnetic flux; Z: winding resistance
the IM (induction motor) type of AC servomotor le of torque generation is the induction motor as it is for a
s motor. However, as can be seen ss sectional diagram to the right, es not incorporate a permanent
ch means that separate supply of and magnetic flux, Φ, (see -1) and (1-2)) is impossible. In motor, current is passed through ndings and torque is generated by
caused to flow in the rotor’s e to electromagnetic inductance gnetic flux created by the stator rent.
Fig. 1.14 Cross section of IM type AC servomotor
1-18
1. FUNDAMENTALS OF AC SERVO CONTROL
Both torque current and magnetic flux current flow in the stator windings. The relationship between the two is expressed by the following formula: I1 = Ia + Ib ………..(1-3) I1: Stator winding current Ia: Torque current Ib: Magnetic flux current Note: The equation above represents a vector sum, no an arithmetic sum. The two currents in an IM type AC servomotor must be controlled separately; this form of control is called vector control. Vector control gives an IM type AC servomotor the same torque characteristics as an SM type AC servomotor.
(4) Types of servomotor and their characteristics There are two main type of servomotor – AC servomotor and DC servomotors- but the category of AC servomotor is further divided into the SM type (synchronous motors) and the IM type (inductance motors). Table 1.2 indicates the configuration and characteristics of each type of servomotor. Table 1.2
Characteristics Type Configuration Advantages Disadvantages
SM type AC servomotors
• Maintenance-free • Excellent resistance to adverse
environmental conditions • Large torque is possible • Dynamic braking possible
when power is cut • Light and compact • High power rate
• The servo amplifier is somewhat more complex than that of a DC motor
• A 1:1 correspondence between the motor and servo amplifier is required
• The magnet can become demagnetized.
IM type AC servomotor
• Maintenance-free • Excellent resistance to adverse
environmental conditions • High speed/Large torque is
possible • Large capacity combined with
high efficiency • Sturdiness construction
• The servo amplifier is somewhat more complex than that of a DC motor.
• Braking is not possible when the power is cut off.
• Characteristics change with temperature.
• A 1:1 correspondence between the motor and servo amplifier is required
DC servomotor
• Simple construction of the servo amplifier
• Dynamic braking possible when the power is cut
• Low cost (for low capacity models)
• High power rate
• Maintenance and periodic inspections are required to ensure proper commutator circumference.
• Debris is created as the brushes wear; not suitable for clean locations.
• Cannot be used at high speed with a large torque due to the commutator brushes.
• The magnet can become demagnetized.
1-19
1. FUNDAMENTALS OF AC SERVO CONTROL
The servomotors growing base on DC motors that is liable to control. However, with the development of electronic devices, and the microprocessor in particular, it became possible to execute complex control faster and more cheaply, and the market shifted to maintenance-free, easily manufactured AC motors; currently, SM type AC servomotors are used in place of DC motors for most applications requiring more than 0.4KW. IM type AC motors are sturdy constructed and can combine large size with high speed. Since their efficiency improves as their capacity increases, they are mainly used for applications requiring 7.5KW or more. Due to improvements in their suitability for high-accuracy applications, their use is increasing in large-scale production lines; an area formerly dominated by DC motors and vector control inverters. DC servomotors have the advantage that small capacity models can be produced cheaply, and because of this they continue to be used mainly for applications requiring less than about 80W. Fig. 1.15 shows the recent development in the use of servomotors.
0. 01 0. 1 1 11
Capacity
(kW)
IM type AC servomotor 55 22
SM type AC servomotor
DC servomotor
1980
1985
1990
1995
2000
Figure 1.15 Recent development in the use of servomotors
1.4.3 Principle of operation of encoder As explained previously, in servo control the actual value (motor speed, position) is feedback for comparison with the command value and control is executed to reduce the deviation between the two. (1) Construction of encoders
The construction of the most commonly used type of detectors is shown below.
1-20
1. FUNDAMENTALS OF AC SERVO CONTROL
(2) Function of encoders and the signal types The three major functions of encoders mounted on servomotors are:
1) Detection of the motor position 2) Detection of the motor speed 3) Detection of the magnetic pole position of the motor (does
not apply to IM type AC servomotors and DC servomotors) A 2-phase pulse output incrementally as the motor rotates is used for functions 1) and 2).
For position and speed detection Several thousand pulses per revolution (number differs according to the motor) Used for home position return etc. 1 pulse per revolution For detecting position magnetic pole
1.4.2.1.1.1 pulse per revolution 2 (not used with IM type AC servomotors
or DC servomotors)
Fig 1.17 Encoder Signals
(3) Interface for encoder signals The two types of interface shown below can be used for encoder output signals. Recently, the differential driver output system, which has the advantage of reliable signal transmission, has become the more commonly used.
Waveforms tend to be dulled during transmission over long distances. Badly affected by noise. High frequency transmission is possible. Resistive against noise.
1-21
1. FUNDAMENTALS OF AC SERVO CONTROL
(4) Absolute position encoders Fitting absolute position encoders to motors is becoming an increasingly common practice. The reasons for this include the need to improve time-efficiency (an absolute position detection system makes it unnecessary to perform a home position return operation after the power has been cut off). Since an absolute position detection system must be able to determine the rotational position when the power is switched ON, the encoder has to output another signal in addition to the increment signals. (A,B) introduced in (2) above. This signal is the absolute position signal, and in case of the encoder shown to the right it would comprise 7 bits. A block diagram for an absolute position system is shown below. Note: In addition to increment signals (phase A and B), absolute position detectors feature absolute position detection within single motor revolutions and a counter that counts the number of motor revolutions and a counter that count the number of motor revolutions from the home position. Since this information is stored in memory, once the position has been fixed by performing a home position return operation the servo amplifier and controller always know the motor position even if the power is switched OFF. This means that is only necessary to perform a home position return operation after switching the power ON once; position and speed control can be continued without repeatedly performing home position return operations.
Fig 1.20 Block Diagram of Absolute Position System.
1-22
2. POSITIONING CONTROL USING AC SERVO
2.1 Positioning Method and Stopping Accuracy 2.1.1 Types of positioning
There are two types of method for stopping the moving part at a fixed position within a required accuracy: mechanical methods and electrical methods. Examples of mechanical methods include use of a stopper (inverter stopper control and AC servo torque limit are used up until the point the moving parts makes contact with the stopper). And forced positioning by trapping the moving part (using a cylinder-actuated mechanism, for example), but when these methods are used the moving parts can only be stopped at particular positions. In contrast, the electrical method makes use of a position sensor that make it easy to stop at any required position. Electrical positioning can also be divided into a variety of types depending on the methods used for position detection and control, but there are two major methods- the speed control method and the position control method. (1) Speed control methods
The motor is not equipped with the position output device but there is a device for positioning purposes (such as limit switch) installed in the machine.
(2) Position control methods There is no device for position detection in the machine, but the detector fitted to the servomotor is capable of precise position control.
These two types of method are compared in Table 2.1. Table 2.1 Comparisons of Positioning Methods
Method type
Method Description Schematic Diagram
A limit switch is located at a point past which the moving part traverses; when the moving part actuates this switch, the switch outputs a signal that stops the motor. Generally, two switches are used; the signal from the first causes the motor to reduce to low speed and the signal from the second switches the motor OFF and causes application of a brake that stops the moving part. Since this method does not require the use of a positioning controller and involves only simple control, the necessary equipment can be installed cheaply.
Spee
d C
ontro
l
Lim
it sw
itch
met
hod
Guide to stopping accuracy …approx. + 0.5 to 5.0mm (Note)
B
INV
IMIMIMIM
Limit switch For stopping
Limit switch to Reduce the speed
Ball screw
Travel distance
Low speed
High speed IM: Induction Motor B: Brake INV: Inverter
Moving part
2-1
2. POSITIONING CONTROL USING AC SERVO
Method type
Method Description Schematic Diagram
A pulse generator (pulse encoder) that detects the position of a revolving shaft is fitted to the shaft of the motor that drives the moving parts, and the number of pulses output by the encoder is counted by a high speed counter. The number of pulses is proportional to the distance moved, and when the counter reaches the set count value it output a stop signal to stop the moving part. When this method is used the system can be configured without using devices such as limit switches and the stopping position such as limit switches and the stopping position can be changed easily. (High-speed counter units such as the Melsec-A series AD61 can be used in such system)
Spee
d co
ntro
l
Puls
e co
unt m
etho
d
Guide to stopping accuracy …approx. + 0.5 to 5.0mm (Note)
An AC servomotor whose rotation is proportional to the number of pulses input is used. High speed positioning over distances proportional to the number of pulses corresponding to the travel distance to the servo amplifier of the Ac servomotor. (Units such as the Melsec-A series 3 axis positioning unit AD75 can be used in such systems.)
Command pulse input
Ball screw
INV
IMIMIMIM
Travel distance
Mediumspeed
Lows
peed
High speed
AD61 High speed counter
PLGMoving part
PC
IM: Induction Motor PLG: Pulse Generator INV: Inverter PC: Programmable controller
Position control
Pulse count method
Guide to stopping accuracy …approx. + 0.001 to 0.05mm
Command pulse input
AD75 Positioning control unit
Ball screw
Servo Amplifier
SM
Travel distance
PLGMoving part
PC
IM: Induction Motor PLG: Pulse Generator PC: Programmable controller
Note: The stopping accuracy indicated are based on a low speed of between 10 mm/sec and 100 mm/sec.
2-2
2. POSITIONING CONTROL USING AC SERVO
2.1.2 Positioning control and stopping accuracy for speed control methods (1) Limit switch method
When the part whose motion is driven by the motor is to be stopped automatically, its position is normally detected by a device such as a limit switch and the motor is stopped by the signal from the limit switch (generally, a brake is applied at the same time). The graph in figure 2.1 plots the speed of the moving part (vertical axis, mm/sec) against time (Horizontal axis, seconds); the shaded portion of the graph is therefore the distance move in millimeters.
V
C
Heavy load
Light load
[mm/sec] Speed V
S [mm]
V B C
A Time E D [sec] E D2 D1 Fig 2.1 Operation (Speed) pattern Fig 2.2 Dispersion of overrun distance
The overrun distance after the limit switch has been actuated corresponds to the area of CDE, and the stopping accuracy is the dispersion of this area of CDE. The factors that affect the stopping accuracy (the factors that cause variation in the area of CDE) by referring to Fig.2.2. They are changes in the stopping time, ED, (caused by fluctuation in load torque or brake torque), fluctuation in the speed of the moving part at point C, dispersion in the sensor operation position at point C, and dispersion in the time delay between sensor operation and the point at which the motor actually starts decelerating. It is of course necessary to keep the dispersion of these characteristics as low as possible, but the most effective strategy is to reduce the speed (V). Therefore, if the stopping accuracy when the moving part is stopped while it is traveling at the normal speed is unsatisfactory, the most common solution is to install a limit switch (see Table 2.1) that will reduce its speed to the low speed before it is stopped. This approach is widely used because it is convenient and improves accuracy, but its disadvantage is the longer time required for positioning; a longer time must be allows because if the period of constant low speed travel (duration of “creep speed”) is not made long enough, the speed of the moving part as it passes the “stop” limit switch will not be stable due to factors such as load fluctuation. Another disadvantage is that an increase in the number of stop positions makes more sensors necessary.
2-3
2. POSITIONING CONTROL USING AC SERVO
(3) Pulse count method
An improved version of the limit switch method is the pulse count method. This method allows selection of stop positions without restriction and allows any number of deceleration points to be established; this makes time reductions possible for travel over short distances. The stopping accuracy is no better or worse than that of the limit switch method, but since the present position of the moving part is continually monitored it is easy to compensate if the stop position is over shot. However, the stopping accuracy is affected by the same factors as listed for the limit switch method and no improvement can be expected. The method of positioning using of a servomotor is not subject to the disadvantages described for the other methods above. As in the pulse count method, the position of the moving part is continually detected, and it is stopped within the required accuracy by respected speed control as it approaches the target position, slowing it from high speed to a stop without any period of travel at the creep speed. This method can be called a “position control method”, in contrast to the “speed control methods” described above.
2-4
2. POSITIONING CONTROL USING AC SERVO
2.1.3 Types of position control A servomechanism performs positioning control by continually detecting the position and feeding back position information. The types of detection method are shown in Table 2.2. (Note that the open loop method is not a servo control method but is shown for the purpose of comparison with the closed loop method.)
Fig 2.2 Types of Position Control Method Type of loop System configuration Characteristics
Open loop
• There is no feedback so this is not servomechanism
• In the event of an overload the motor get out of step and stops.
• Only small capacity systems can be configured.
Table Stepping motor Positioning controller
Mot
or sh
aft
dete
ctio
n
Sem
i-clo
sed
loop
Det
ectio
n at
feed
sc
rew
end
Closed loop
Positioning controller
Positioning controller
Positioning controller
Because importanMELSERVO ACwith the detector
Servo am-plifier
Reduction gear
• Simple configuration • Fastest response of all system types • Reliable control system • Reduction gear backlash has to be
compensated
Table
Servo-motor
Speed
encoder
o
Servo am-plifier
• Rather complex configuration (involves a separately installed detector).
• The system is reliable to instability caused by the reduction gears and feed screw
Reduction gear
Servo-motor
Position detector
Speed
encoder Table
Servo am-plifier
• Reduction gear backlash doesn’t have to be compensated
• Requires an expensive position
detector. • The system is liable to instability
caused by the reduction gears and the feed screw, and it is not possible to increase the speed of response.
• Reduction gear backlash doesn’t have to be compensated
Reduction gear
Servo-motor
Position detector
Speed
Reduction gear
encoder
Linear scale
Table
ce is placed on stability of the control system and ease of use, servomechanisms are configured as semi-closed loop system n the motor shaft.
2-5
2. POSITIONING CONTROL USING AC SERVO
2.2 Fundamentals of Positioning Control Using AC Servo
The following is an explanation of positioning control when using the pulse command.
2.2.1 Position detection and number of pulse per motor revolution As explained in Section 2.1.3, MELSERVO series AC servomechanisms are configured as semi-closed loop in which the motor rotational position (machine position) is detected by an encoder (detector) that is connected directly to the motor shaft. The encoder generates a pulse signal in accordance with the rotation angle of the motor and this pulse signal is input to the servo amplifier and used for position control.(for more details on encoders, refer to section 1.3.4) This feedback pulse becomes the standard that operates for a unit (resolution) of movement of the machine connected with the motor, and it can perform highly precise positioning control, so that there are many pulses per motor rotation. In the case of the servomotor of a model HC-KFS, they are 131072 pulses (it is expressed as 131072/rev). (Refer to section1.3.4 ).
2.2.2 Theory of servo positioning control Position controller (AD75 series) Servo Amplifier
Position
CMX CDV
Deviation counter SM
PLG Com
man
d
∆λc ∆λ0
Speed command
Speed lifi
Feedback pulse (131072 p/rev) Encoder
In the case of HC-KFS series
Table
Electronic gear
movements per pulse Ap <= 65535 AI <= 65535 Am1, 10, 100, 1000
PLG
The number of pulses Ap Movements AI X mag-
nification Am
Setting unit 1/10µm 1/105inch 1/105degree 1Pulse
+ -
X4
Ball
Fig. 2.3 Composition of position Servo
Positioning by the servomotor is controlling a motor so that servo amplifier’s takes in the command pulse and the feedback pulse according to motor number of rotations at a deviation counter and the difference serves as zero, when the command pulse is inputted from positioning controller.
2-6
2. POSITIONING CONTROL USING AC SERVO
For this reason, servomotor can carry out strict positioning by the command pulse. A motion of the motor axis per command pulse to servo amplifier (machine) is to the foundations of the positioning control by servo.
(a) The feed distance is proportional to the total number of command pulse;
(b) The speed of a machine is proportional to the speed of the pulse train (pulse frequency).
(c) As long as it carries out the completion of positioning in the range of last ±1 pulse and there are no position commands henceforth, it is holding the position in the state of a servo lock.
(1) Deviation counter and amount of motor rotations While the counter is counting up the command pulses received from the position controller, the counter value is simultaneously decremented as the feedback pulses are returned. When the deviation counter pulses were large, the speed command is also large, and the motor rotates at high speed. On approaching the target stopping position the no. of command pulses decreases; when it reaches zero the output from the deviation counter drops and the motor speed consequently drops too. When the deviation counter reaches zero, the speed command value also becomes zero and the motor stops. In other words, the output from the deviation counter is automatically controlled so that the no. of feedback pulses(i. e. the amount of motor rotation) is made to equal to the no. of command pulse. For example, for rotating motor HC-KFS of MELSERVO-J2S series of feedback pulse 131072 p/rev 1/2, it is from positioning controller. It is necessary to carry out a 65536 pulse input.
(2) Motor rotational speed By control of a deviation counter, the rotation speed of a motor is proportional to the speed of pulse train from the rotation angle of a motor being proportional to the quantity of the pulse train. For example, if an instruction pulse is carried out in 1 minute in 393.216X3000 rotation X 131072 pulse =393.216X106 pulses and 1 second in order to operate the motor of HC-KFS series by 3000 r/min, it is necessary to input 393.216X106 / 60= 6553.6X103 pulses (for it to be expressed as 6553.6kpps) from positioning instruction equipment. Usually, it inputs using the electronic gear function by the side of instruction equipment and servo amplifier.
2-7
2. POSITIONING CONTROL USING AC SERVO
(3) The completion of positioning, and servo lock
If the output (droop pulse) of a deviation counter becomes zero (i.e., if the number of command pulses and the number of feedback pulses are in agreement), it will become the completion of positioning. Then, there is work which is going to make the rotation correction of the motor in the direction in which the feedback pulse from the encoder inputs into the deviation counter if a servo motor is turned by a certain external force, the speed command from a deviation counter come out, it always collects, and a pulse becomes zero, and it is always going to limit to the regular position. This function is called the “servo lock”.
2-8
2. POSITIONING CONTROL USING AC SERVO
2.3 Positioning Accuracy
2.3.1 Feed distance per pulse The feed distance per pulse is the minimum unit which a machine motion. The feed distance per one pulse as shown in Fig. 2.4 (1), in case a ball screw and a slowdown machine do not have the machine system becomes like the formula (2-1). When machine system is except a ball screw, and when a slowdown machine sticks, in order to calculate the feed distance per one pulse, it thinks on the basis of feed distance (deltas) of the machine per motor 1 rotation. If the feed distance per motor 1 rotation of Fig. 2.4 is substituted for ∆S of a formula (2-1), the feed distance (deltal0) can be calculated per pulse.
∆ S ∆ S ∆λo = = (mm/pulse) -----------(2-1)
P f 0 131072 Where Pf0 is the No. of feedback pulses per motor revolution. However, the Pf0 values for different motor model are indicated below. HC-PQ Motor 4000 [pulse/rev] HC-MF motor 8192 [pulse/rev]. HC-SF motor 16384 [pulse/rev]. Fig. 2.4 as following shows examples of mechanical systems and the corresponding calculation formula.
2.3.2 Concept of overall accuracy for machines and electrical accuracy The overall accuracy of a machine, ∆ε, is the mechanical accuracy plus the electrical accuracy. The mechanical accuracy is set y the machine’s manufacturer. The electrical accuracy depends on the feed distance per pulse - ∆lο (mm/pulse)- for the machine’s shaft. In a Mitsubishi MELSERVO series system, travel is finally stopped to within an accuracy of +1 output electrical gear pulse (or +∆lο when calculated in terms of the machine axial motion), and the servo lock is imposed at this point. While the servo lock is effective, the position is held provided that no command pulses are input. Therefore, in order to ensure that the electrical accuracy ∆lο does not affect the overall accuracy of the machine ∆ε, the system is generally set so that the following condition is satisfied: ∆lο < (1/5 to 1/10) x ∆ε−−−−−−−−−−−−−−−(2-2) REMARK Overall machine accuracy, ∆ε,and feed distance per pulse, ∆lο The feed distance per pulse, ∆ε, can be determined by taking the overall accuracy of the machine, ∆lο into consideration.
2-9
2. POSITIONING CONTROL USING AC SERVO
(1) Ball screw(direct connection) (2) Ball screw( connected via gears) (3) Rack and pinion
Feed distance per motor revolution
∆S= PB
Z1 1 ∆S = PB • = PB •
Z2 n
1 ∆S = PL•Z• n
Z: No. of pinion teeth
(4) Roll feed (5) Chain drive(direct connection) (6) Driver by chain and timing belt
Feed distance per motor revolution
1 ∆S= π• D •
n
1 ∆S = PC• Z•
n
Z: No. of sprocket teeth
Z1 1 ∆S = PT• Z • =Pr •Z • Z2 n
Z : No. of pulley teeth
Driv
e sy
stem
V
PL Z
PLGM I /n
PLG M
V
PB PLG M
V
Z1
Z2
PB
PLGM
PT
VZ
Z2
Z1
V
Z
PC
PLGI /n M
V
D
PLG
M
I /n
Drive system
Fig 2.4 Feed Distance per Motor Revolution for Various Mechanical Systems
2-10
2. POSITIONING CONTROL USING AC SERVO
2.4 Motor rotation speed at the maximum machine speed As shown in Fig 2.5, if the mechanical system is driven by a ball screw through gears, the motor’s rotational speed N (rpm) for a particular machine speed, V (mm/min), can be determined using formula (2-3) below Motor’s rotational speed =Machine speed x 1 ----------(2-3) Ball screw lead Reduction ratio If the ball screw lead is expressed as PB (mm) and the reduction ratio as 1/n, formula (2-3) can be expressed thus: N = V . n [rpm] - - - - - (2-4) PB If maximum machine speed, Vo is fixed, a high positioning accuracy can be obtained and the power of the motor can be used effectively by making the motor rotational speed that corresponds to Vo as close as possible to the rate rotational speed Nr (rpm) without exceeding it.
Table
Servo Motor
Servo Amplifier
V
Command pulse train
Pa
Encoder
Ball screw
Z2
Z1
Ball screw load Pa [mm] Feed distance per command pulse ∆lο [mm/pulse] Reduction ratio 1/n (=Z1/Z2)
Fig 2.5 Relationship between machine speed and motor speed
2-11
2. POSITIONING CONTROL USING AC SERVO
2.5 Command Pulses
In a positioning servomechanism, a number of feedback pulses equal to the number of pulses input from the positioning controller is returned during motion, and, when running steadily, the motor operates at a speed at which the command pulses and feedback pulses balance each other out. It must be confirmed that there is a consistent relationship between the smallest command unit for positioning and the feed distance pr pulse (see section 2.3.1) , and that the pulse frequency at the motor’s maximum rotational speed is acceptable for both the position controller and the servo amplifier.
2.5.1 Electronic gear function
The electronic gear function of MELSERVO-J2S series AC servomechanisms makes it unnecessary to select a detector that matched to the mechanical system, and allows flexible positioning. The following is a description of the electronic gear function.
PC1
∆l1 Fc1= Fc.
Positioning controller
Command pulse
magnification
Deviation counter SM
PLG×4
Command pulse
Pc fC ∆lC (PC0)
CMX CDV
CMX/CDV
=1/50 to 20
Feed screw lead, PB
V
Servomotor
*1000 P/R *Position feedback pulses Pro = 1310752P/R
Pfo
A
Electronic gear
Fig 2.6 Electronic Gear Function Fig 2.6 is a block diagram for the electronic gear function. A guide to this function and the associated relational equations is presented below. For MELSERVO-H series systems, the value of PF0 is either 8192 or 16384 p/rev, depending on the motor used, but the relational equations are the same as those for the MELSERVO-J2S series. Meaning of symbols in Fig 2.6 PC : Number of command pulse [unit = phases] PC1 : Number of deviation counter input pulses [unit = phases] Pf : Number of feedback pulses [unit = pulses] Pf0 : Number of feedback pulses per motor revolution [unit = p/rev] PC0 : Number of command pulses per motor revolution [unit = p/rev] fC : Command pulse frequency [unit = pps] fC1 : Deviation counter input command frequency [unit = pps] ∆lο : Machine travel per feedback pulse [unit = mm/pulse] ∆lc : Machine travel per command pulse [unit = mm/pulse] CMX : Command pulse magnification numerator CDV : Command pulse magnification denominator
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2. POSITIONING CONTROL USING AC SERVO
(1) Relation between electronic gear setting and command pulse
(a) The number of deviation counter input is obtained by multiplying the number of command pulses by the electronic gear ratio. PC1 = PC . CMX - - - - - - (2-5)
CDV Where,
PC : Number of command pulse [unit = pulse] PC1 : Number of deviation counter input pulses [unit = pulse] CMX : Command pulse magnification numerator CDV : Command pulse magnification denominator
The relationship between PC and PC1 when the electronic gear ratio (CMX/CDV) is 8 shown in Fig 2.7.
Fig 2.7 Input/Output Relationship at the Electronic Gear Setting section
when the gear ratio is 8
(b) The same relationship for pulse frequency:
fC1 = fC . CMX - - - - - - - (2-6) CDV
fC : Command pulse frequency [unit = pps] fC1 : Deviation counter input pulse frequency [unit = pps]
PC
PC1 = Pf
t
(c) Since the electronic gear is configured outside the position control loop, a resolution (∆lο) of 0.09 degrees on the motor shaft is always maintained regardless of the value set for the command pulse magnification.
(d) If the value set for the electronic gear ratio is “1” or less, a single input command pulse will not be output to the deviation counter. A pulse will only be output when the number of the input command pulses multiplied by the magnification factor reaches a value of “1”.
t
PC Fig 2.8 Gear ratio is ½
PC1 = Pf
2-13
2. POSITIONING CONTROL USING AC SERVO
(e) The setting ranges for the electronic gear ratio, the numerator, and the denominator are indicated below.
1 CMX < < 500 - - - -- -- - - - - (2-7)
50 CDV (2) Relationship between the electronic gear ratio setting and the
mechanical system. (a) The motor shift rotation angle that represents one unit of machine
travel is the angle corresponding to one feedback pulse.
P B - - - - - - - - - (2-8) ∆l0 = Pf0
(3) Since one command pulse input to the deviation counter causes a motor rotation corresponding to one position feedback pulse, it is possible to set the motor rotational angle per command pulse, which is equal to machine travel, to any required values by multiplying the command pulse by the electronic gear ratio; this makes it possible to set units with no fraction (1 µm, 10 µm, etc.)
By analogy with formula (2-5), the relationship between the number of command pulses per motor revolution, PCO, and the number of feedback pulses per motor revolution, PCO, as follows:
CMX P oc CDV
• = Pf0 -- - - - - - (2-5)
Formula (2-8) can be re-expressed as follows to obtain the travel per command pulse:
PB ∆l = - - - - - - (2-8) o PC0
Combining these two relationship:
PB PB CMX CMX ∆l0 = = ∆l = = - - - - - - - (2-9) 0 • PC0 Pf0 CDV CDV
Therefore, by setting the electronic gear ration as follows:
CMX ∆l Pc f0⎯⎯⎯ = ⎯⎯ = ∆l • ⎯⎯ - - - - - - - (2-11) cCDV ∆l0 PB
The travel per command pulse, ∆lc, can be set to any value, regardless of any consideration arising from the mechanical system (Pf0, PB).
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2. POSITIONING CONTROL USING AC SERVO
(4) The motor speed is determined by the pulse train frequency (fC1) input to the deviation counter after the command pulse has been multiplied by the electronic gear ration (a frequency of 200 kpps is equivalent to a speed of 300 rpm). Consequently, even if the number of pulses output from the positioning controller (the command pulse frequency) is low, the motor can be driven at high speed by making f C1 highly.
Since the deviation counter input pulse frequency (fC1) is in balance with the feedback pulse frequency (fF) when the motor is running at a constant speed, the relationship between the motor speed and electronic gear under this condition can be expressed by formula (2-11)
CMX N fC1 = fC• f0 CDV 60
= P • - - - - - - - (2-11)
Where, fC : Command pulse frequency [unit = pps] fC1 : Deviation counter input pulse frequency [unit = pps] N : Motor rotational speed [ unit = rpm]
It follows that the electronic gear ratio when the motor is run at a rotational speed of N with a command pulse frequency of fc can be obtained using this formula:
CMX f 1 N C1 = = •Pf0• - - - - - - ( 2 – 12)
CDV f C f C 60
REMARK
Functions of the electronic gear (1) Allows the positioning accuracy ∆l0 and the setting resolution ∆lc to be set
independently of each other, making it possible to set units without fractions of ∆lc. (2) The deviation counter input pulse frequency when the motor is run at the rated
rotational speed is fixed (see equation (2-11)), but it is possible to run the motor at lower command pulse frequencies.
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2. POSITIONING CONTROL USING AC SERVO
Example 2.1
Question (1) Calculate the amount L0 of machine movements per feedback 1 pulse. Question (2) How much for the Servo amplifier side electronic gear ratio K in per
command pulse at the time of making the AD75 side electronic gear into 1/1 and amount L0= 0.1of m[micro-m/pulse]?
Question (3) In K for which it asked with the question (2), a motor is 3000 [r/min]. What is the command pulse frequency (fc) at the time.
Question (4) What is the Servo amplifier side electronic gear ratio K at the time of command pulse frequency 200kpps?
PB=8mm Speed=24m/Pf0=131072p/
MR-J2S servo Amplifier AD75 position controller
Fc Positioning data
CMX CDV
Deviation counter SM
PLGX4
A
HC-KFS Servomotor
Sending screw lead PB=8[mm/rev]
Pro
Electronic gearCMX ≤65535 CDV ≤65535 CMX/CDV 1/50 ∼500
Servomotor HC-KFS, 3000r/min 131072p/rev
Pulse No.(Ap) Amount of movements X
magnification Am
Unit 1/10µm 1/105inch 1/105degree 1Pulse
The movements per one pulse. Ap ≤65535 Al ≤65535 Am = 1 10 100 1000
The maximum pulse command frequency AD75P Open collector 200kpps Differential system 400kpps Note: The open collector system, itchanges by wiring length. Ifexceeded, it will become positiongap and alarm.
The maximum command frequency =200kpps
CMX= ? CDV= ?
Ap= ?
Al= ? Am= ?
Question(1) Formula (2-8)
PB 8 ∆λ = = ≈ 0.061 X 10-3 (mm/pulse) o Pfo 131072 ∗ When it considers as 300mm of positioning, it will become 300/0.061x10-3 =
4918032.787 pulses will come out.
Question(2) Formula (2-10)
CMX P 131072 1024 fo K = ⎯⎯⎯ = ∆ λ c • ⎯ = 0.1X 10-3 X ⎯⎯⎯ = ⎯⎯ CDV PB 8 625 ∆λ c at the time of putting in the above-mentioned electronic gear PB CMX 8 1024 ∆λ = ⎯⎯ X ⎯⎯⎯ = ⎯⎯⎯X ⎯⎯ = 0.0001 (mm/pulse) c Pfo CDV 131072 625
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2. POSITIONING CONTROL USING AC SERVO
∗ When it considers as 300mm of positioning, it becomes 300/0.0001= 3 million pulses come out. ∗ There is the necessity of checking whether maximum command frequency 200kpps of AD75 positioning command equipment being exceeded by the electronic gear ratio for which it asked above.
Question (3) Formula (2-11) N 3000
= P f X ⎯ =131072 X ⎯⎯⎯ = 6553600 ( PPS) F c 1 o 60 60
Formula (2-6)
CDV 625 F = ⎯⎯ • f c 1 CMX 1024
c = ⎯⎯ X 6553600 = 4000000 = 4000 (kpps)
∗ Command pulse frequency can exceed maximum command pulse frequency 200kpps of AD75, and cannot control it. (It asks for the Servo amplifier side electronic gear at the time of maximum command pulse frequency 200kpps of AD75.)
Question (4) Formula (2-6)
CDV CMX f 6553600 4096 c1 F = • f ⇒ = = = c c 1 CMX CDV f c 200X103 125
The positioning accuracy ∆λo at the time of putting in the above-mentioned electronic gear is checked.
P CMX 8 4096 B ∆λ = ⎯⎯ X ⎯⎯ = ⎯⎯⎯X ⎯⎯ = 0.002 (mm/pulse) c P f o CDV 131072 125
The conclusion of the example 2.1 The case of 300mm of positioning is considered.
F Position
Data
CMX=4096CDV=125
Deviation
t
PLG X4
A
HC-KFS Servomotor V
PB=8
The amount of positioning move-ments is 300(mm)
P f o
The number of pulsesafter a Servo amplifierelectronic gear ratio(the No. of motor
AD75 Position controller
Ap=4000 Al=800XAm=
MR-J2s Amplifier
Positioning The maximum command frequency =200kpps
Command pulse150000[pulse] Pf0=131072p/rev
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2. POSITIONING CONTROL USING AC SERVO
2.5.2 The maximum input pulse frequency The Servo amplifier maximum input frequency becomes settled following condition.
MR-J2S series selects the value of an electronic gear by the formula (2-11) and (2-12) so that the servomotor can be used to rated rotation speed on the maximum input pulse frequency (open collector --200kpps, differential receiver --500kpps).
Furthermore, the maximum input pulse frequency of the whole including position controller turns into the above-mentioned Servo amplifier and the maximum frequency with which are satisfied of both controller. (The maximum output pulse frequency of positioning controller is reference in Appx. 4)
Exercise 2.2 (1) How many kpps is the maximum input pulse frequency of the open collector
input of MR- J2S (3000 r/min) series? (2) When you use the rated rotation speed of MR-J2S below on the maximum
input pulse frequency, what is the range of the electronic gear K of MR-J2S? (3) How many kpps is the maximum input pulse frequency as MR-J2S and
the AD75 whole in the open collector input?
(1) They are 200kpps. (2) It is the range of the value K of an electronic gear from formula (2-11), and (2-12).
3000 3000 f 6553.6 X103 32768 c1 f c 1 = P X ⎯⎯ =131072 X ⎯⎯ = 6553.6X10 f 0
60 60 f 3pps 500 >k ≥ ⎯ = ⎯⎯⎯⎯⎯ = ⎯⎯
c 200 X10 3 1000 (3) The max. frequency that is satisfied for both MR-J2S and AD75, is 200kpps.
Exercise 2.3 (1) How many kpps is the maximum input pulse frequency of the differential
driver input of MR-J2S (3000 r/min) series? (2) When you use the rated rotation speed of MR-J2S below on the maximum
input pulse frequency, what is the range of the electronic gear K of MR-J2S? (3) How many kpps is the maximum input pulse frequency as MR-J2S and
AD75 whole in the differential driver input?
(1) They are 500kpps. (2) It is the range of value K of an electronic gear from formula (2-11), and (2-12).
3000 3000 f 6553.6X103 32768 c1 f c 1 = P X⎯⎯ =131072 X ⎯⎯ = 6553.6X10 f o 60 60 f
3pps 500 >k ≥ ⎯ = ⎯⎯⎯⎯ = ⎯⎯⎯ c 500X10 3 2500
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2. POSITIONING CONTROL USING AC SERVO
(3) The frequency with which are satisfied of both MR-J2S and AD75 is 400kpps.
2.6 A speed pattern and stop setting time
2.6.1 Speed pattern and performance of droop
The “droop pulses” are the pulses that accumulate in the deviation counter of the servo amplifier as a result of the display between the No. of command pulses and No. of feedback pulses received at the deviation counter. The performance of the deviation counter pulses is shown in Fig2.9.
(1) Performance between t0 and t2
The feedback pulses from the encoder are displayed in relation to the command pulses due to the acceleration lag of the servomotor, and the droop pulses “ε” are generated.
f K• f
t 0 t 1 t 2 t 4 t 5 t[sec]t 3 D
C E B
A Tpsd ts
Feedback Pulses
(actual form of
movement)
Command pulses
(1) (2)
[pps]
Pulses frequency
c1 c ε= ⎯ = ⎯⎯⎯ (pulse) ------(2-13) PG1 PG1
Fig. 2.9 Speed Pattern and Droop Pulses
PG1: Position loop gain.
(2) Performance between t2 and t3
The command pulses are synchronized with the servomotor’s rotational speed and the motor runs with a position lag equivalent to the droop pulses obtained in formula (2-13).
(3) Performance between t3 and t4
The system attempts to make up the position lag equivalent to droop pulses obtained in formula (2-13). If there are still droop pulses remaining at point t4 ( the point at which input of command pulses finishes), the motor continues to revolve even though no command pulses are being input.
(4) Performance between t4 and t5
The motor continues to rotate to clear all the remaining droop pulses. The interval between t4 and t5 is the “setting time” required to stop within accuracy 1 pulse.
(5) Motor operation
Both the rotational speed of the servomotor and the droop pulses change as exponential functions over time.
Finally, when the droop pulses have reached 1 pulse accuracy limit, the servo lock is applied.
As a result, the No. of command pulses (area ABCD) +1 is equal to the actual feed distance (area
AECF); And, the quantity of pulses that accumulate during acceleration, (1)(area ABEA) is equal to
the reduction in the No. of deviation counter pulses during deceleration, (2) (area CFDC).
2-19
2. POSITIONING CONTROL USING AC SERVO
Exercise 2.4 Referring to the left figure, it can set on the following conditions as PG 1= 36 [sec-1] – collect and ask for Pulse epsilon
Fc1=K•fc =180k,18k,0.9k,72 [pps] Also calculate the feed length from the droop pulses(assuming that ∆λo=0.01 [mm/pulse] in each case.) (Electronic gear ratio k= 1/16)
t[sec]
[pps]
t 0 t 1 t 2 t 4 t 5 t 3
Pulse
freq
uenc
y
Respectively, it is as follows refer to this formula ε=k•fc /PG1 (pulse). k•fc = 180kpps (1318r/min)
180000 ε = ⎯⎯⎯⎯ = 5000(pulse), Feed length equivalent 5000X 0.01=50(mm)
36 k•fc =18kpps (132r/min)
18000 ε = ⎯⎯⎯ =500 (pulse), Feed length equivalent 500 X 0.01=5(mm)
36 k•fc = 0.9kpps (6.6r/min)
900 ε = ⎯⎯ =25 (pulse), Feed length equivalent 25 X 0.01 = 0.25(mm)
36 k•fc = 72pps (0.53r/min)
72 ε = ⎯⎯ = 2 (pulse), Feed length equivalent 2X 0.01=0.02(mm)
36
2.6.2 Setting time (ts) Since it finishes issuing commands, and time until position is completed and expressed a baton time is decided in this setting time with part mounting machines, such as an in- serter and molding, stop setting time is a factor with very important time shortening.
Setting time Command Pulses
Droop pulses
Operation pattern comparison of J2-Super and J2 stop establishment time Conditions: Servomotor: HC-MFS13 Servo Amplifier: MR-J2S – 10A
Load inertia ratio: 3 times
J2S J2 Stop Setting time 0.9 ms 5 ms
2-20
2. POSITIONING CONTROL USING AC SERVO
(1) The view of stop setting time Stop setting time can calculate an outline value by the model side position control
gain 1 (PG1) of model adaptive control. However, since the value of the position control gain 1 receives influence in the situation of a machine, the value of a load inertia moment, etc. greatly, when sending and stop setting of a high response of high frequency operation are required, it needs to take correspondence also including the machine system into consideration. Stop setting time until it becomes about ten or less pulses serves as the following formula experientially.
Ts
Command
t
Pr5 (INP) is set as 10.
0 pulse 10 Pulse
ts ≅ 3 (sec) PG1
If it collects in the accuracy that the machine is demanding and a pulse enters, even if a servomotor moves, it will consider that it stopped and the completion signal of positioning will be outputted.
Stop setting time affects the cycle time at the time of high frequency positioning.
2.7 Relationship between the machine system and response setup
2.7.1 Response setup
By the conventional control system, the position loop gain and speed loop gain of Servo need to be adjusted according to each machine condition. Especially, to the inertia moment ratio of load, or machine rigidity, the relation with each loop of a servo system needed to be known enough, and adjustment sometimes took time plentifully. In MELSERVO-H, J2S, and C series, since model adaptive control and real-time auto tuning are performed, an ideal model part and a real loop part are automatically adjusted to the optimal gain only by setting an auto tuning response setup as the value corresponding to the rigidity of a machine. About an auto tuning response setup, it can set up with a parameter. Since MR-J2S were summarized into the table below, please make it reference.
2-21
2. POSITIONING CONTROL USING AC SERVO
Table 2.3 MR-J2S basic parameter Pr.2
Setting value
Auto tuning response
The standard of a machine
1 ~ 3 Low response What has low machine rigidity? A belt, a chain drive, the large machine of a backlash, etc.
4 ~ 6
Low-middle
response
The rigid level of an average general-purpose machine. A belt, a chain, a rack & pinion drive, etc. The setting value at the time of shipment.
7 ~ 9 Middle response A little high level of machine rigidity. When you want to improve a response by the ball screw, the rigid high timing belt, etc.
A ~ C Middle-high response
The use that machine rigidity is high and positions in high frequency.
D ~ F High response The use, which wants for machine rigidity to be used very high, and the position to super-high frequency.
Note) machine starts hunting, or a setting value is made small when gear sound is loud.
In raising a performance, it enlarges a setting value, such as shortening stop setting time.
2.7.2 Real-time auto tuning
If an auto tuning response setting value is set as a parameter and a servo motor is moved, the load inertia moment at that time will be tuned up automatically, and the gain (a position, speed) of each control loop will be set as the optimal value to the set-up response setting value. At this time, since vibration will occur or it will become unstable if the auto tuning response setting value over a machine system is not suitable, please improve an auto tuning setting value again. The inertia moment result of the tuned-up load can be checked by a state display monitor's load inertia moment ratio. The recommendation load inertia moment ratio has restrictions of a response, regeneration energy, a dynamic brake, etc. Usually, a load inertia moment ratio recommends 30 or fewer times as a standard to a servo motor. (Each catalog is consulted for details.)
2-22
2. POSITIONING CONTROL USING AC SERVO
Although it can set up by real-time auto tuning by most machines, when there is the necessity of adjusting to a limit, the manual carries out gain adjustment.
<Reference> The method of adjustment of a manual gain When a load inertia moment is excessive and the tuning with it is not obtained with a rise-and-fall axis, and when a machine cannot respond by auto tuning response setup, the manual performs each gain adjustment for the very large imbalanced load. For details, please refer to the section 6.3.3.
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2. POSITIONING CONTROL USING AC SERVO
2-24
Memo
3. POSITIONING CONTROLLER
3.1 Servo function and positioning controller
Positioning control by AC Servo is performed by the positioning controller and the Servo amplifier that generate the command pulse sequence sharing a function as follows respectively.
3.1.1 The function of positioning controller (1) The output of the command pulse equivalent to the amount of sending of a machine; (2) Determination of machine speed (command pulse frequency); (3) Determination of an operation pattern (at the time of accelerator or decelerator constant); (4) A theoretical machine position is memorized.
3.1.2 The function of Servo Amplifier (1) A pulse sequence is followed from positioning controller, and it is positioning
control to the command position; (2) Servo lock function; (3) The output function of the positioning completion signal.
3.2 A classification and composition of positioning instruction equipment
Positioning unit
Setting
data
Writing and read-out of data
Parameter data positioning data Zero return data
Peripheral equipment
Input X CMX CDV
Deviation counter SM
PLGX4
Reverse pulse Electronic Gear
A
Feedback pulse
Speed command D/A
converter
Forward pulse
Sequence program
Output Y
Servomotor Servo Amplifier Sequencer
Figure 3.1 Composition of a positioning system
a) The deviation counter integrates the pulse sequence taken out from the positioning unit,
this pulse collects, and D/A conversion is carried out, and quantity becomes direct-current analog voltage, and becomes speed command;
b) The motor rotates by speed command, simultaneously, from PLG, a deviation counter is returned and covered with a feedback pulse, and a pulse is subtracted;
c) If the pulse sequence, which has come out of the positioning unit, becomes slowdown command, a deviation counter will collect, a pulse will be lost and a motor will stop.
3 - 1
3. POSITIONING CONTROLLER
Servomotors are being used in an increasingly wide variety of applications and there is a growing trend to combine them with controllers for supply as systems; these developments account for the extremely large number of positioning systems for use with servomotors that are currently being developed and put on the market. Therefore, the selection of the most suitable positioning controller for a particular application is as important a factor as the selection of the servomotor in determining the level of system efficiency, and the performance to cost ratio, that can be achieved. The following is a discussion of the classification and function of positioning controllers on the basis of the concept outlined above.
(1) Position system A servo position system including positioning controller and Servo amplifier is as follows.
Stand-alone type - - - - - - - - - - (1 axis controller with built-in amplifier)
System
FX2N – 1PG FX – 1GM
FX – 10 GM
FX 2N – 10GM FX – 20GM E – 20GM A1SD75P - P3 A1SD75M
+ Servo Amplifier
Servomotor
+
MR – J2 C MR - HACN
+
FX series
Motiocontro
Multi-axis controller system
Note. About model selection, it refers to Appx. 4.
Sequencer familiartype
(2) The number of controUsually, it says whether simultaneously controllableinto a simultaneous controlmore numbers of control ax
1 axis - - - -Controlled axes No.
2 axes - - - -3 axes - - - -4 axes - - - -8 axes - - - -32axes - - -
(3) Simultaneous control
A series
+ Servo Amplifier s Q serie A1SD778MAD75P - S3 AD75M AD778M
A171SH/ A172SH A173UH / A273UH
+ Servo Amplifier
Servomotor
Servomotor
n ller
lled axes how many sets of a servomotor or servo amplifier are by one set of positioning controller. Moreover, it is divided system or an independent control system when it has two or es. - A1SD75P1-S3, A1SD75M1, FX-10GM, MR – J2 C, MR – H CAN; - A1SD75P2-S3, A1SD75M2, FX-20GM, - A1SD75P3-S3, A1SD75M3 - A171SH - A172SH, A1SD778M, AD778; - - A1173UH, A273UH;
and independent control
3 - 2
3. POSITIONING CONTROLLER
(a) Simultaneous control In positioning controller with the number of control more than one axis, the function that enable control of multiple axes simultaneously is called the simultaneous control function. That is, control of multiple axes is made from the single program, and operation modes (automatic, manual operation, home position return, etc.), and starting and a stop are performed simultaneously. It is recently becoming common for controllers with this function to feature an interpolation control capability.
(b) Independent control The functions that have the capability to control more than one axis, the function that enables control of the individual axes independently is called the independent control function. That is, control of each axis is made from each program, and operation modes (automatic, manual operation, home position return, etc.), and starting and a stop control are executed independently for each axis.
(4) Interpolation control The interpolation function controls the motion of the multiple axes involved in the control in relation to each other. The interpolation function includes liner interpolation and circular interpolation.
(a) Liner interpolation The multiple axes are controlled so that the start point and end point(target position) are connected by the shortest path. In this case, since the generated path is a straight line, the control mode is called liner interpolation. Usually, two-axis liner interpolation and three-axis liner interpolation are available.
X-axis Z-axis
End point
Start point
Y-axis End point
Start point X-axis
Y -axis
(b) Two-axis linear interpolation (b) Three-axis linear interpolation
Fig. 3.2 Axis Motion in Linear Interpolation Control
3 - 3
3. POSITIONING CONTROLLER
Applicable 2-axis linear - - - - FX- 20GM, AD75P2-S3, AD75M2, etc; 3-axis liner - - -AD778M, A273UH, etc. ( 2-axis is also possible)
(c) Circular interpolation
The multiple axes are controlled so that the start point and end point(target position) are connected by an arc. Since an infinite number of arcs can be defined if only start and end points are specified, the radius of the arc, center of the arc and/ or direction of the arc are specified in a program in addition to the two points so that a specific are can be defined.
CW
CCW
Start point Locus of the center of the arcs
End point
Fig. 3.3 Axis Motion in Circular Interpolation Control
Applicable models ----- A273UH, AD75-P2/P3-S3, AD75M2/M3, AD778,FX20GM, Etc. (5) Absolutely position detection
An absolutely position detector is installed in a servomotor so that the machine position is retained in the positioning command device when the power off. This allows automatic operation to be restarted from the present position without carrying out a home position return after turn on the power.
The absolute positioning control system consists of a motor equipped with the absolute position transducer, a compatible Servo amplifier, and a positioning controller.
3 - 4
3. POSITIONING CONTROLLER
Positioning controller
Servo amplifier Encoder
A273UH
Built-in type Servo amplifier MR-J2B series
MR - J2 B series MR - H BN series
A171SH
A172SH
A173UH
AD75M
A1SD75M
MR-J2B series
MR - J2 B series
MR - H BN series
HC-MF HC-MFS
HA-FF
HC-KFS
HC-SF
HC-SFS
HC-RF
HC-RFS
HC-UF
HC-UFS
HC-MF
Note 1. Each positioning controller can combine which Servo amplifier.
(6) The type of positioning program
The program types for each of the device types are summarized below.
Sequence program ------ A1SD75, AD75, A1SD778M, AD778; The command only for positioning----FX- 1GM, FX10GM,
Positioning program
Motion program ----A273UH, A171SH, A172SH, A173UH (NC language and an exclusive language) Point of contact (BCD, binary)--- MR-HACN, MR- J2C.
3 - 5
3. POSITIONING CONTROLLER
3.3 Setting data of positioning controller
The setting data of AD75P positioning controller is explained.
3.3.1 Basic parameter
Basic Parameter
Group No. Unit
Setting Range Initial
Type Item mm inch degree pulse Value Setting unit 0:mm 1:inch 2:degree 3:pulse 3
Number of pulses per revolution (Ap)
1 ~ 65535 pulse 20000
Travel value per revolution(Al)
0.1 ~ 6553.5 µm 0.00001 ~
0.65535inch 0.00001 ~
0.65535degree 1 ~65535pulse 20000
Travel value per pulse
Unit magnification(Am)
1 10 100 1000
1
Pulse output mode
0:PLS/SIGN mode 1:CW/CCW mode 2:A-phase/B-phase mode (Magnification of 4) 3:A-phase/B-phase mode (Magnification of 1)
1
1 Change among
sequencer is
impossible.
Direction of rotation 0: Present value increases when forward pulse is output 1: Present value increases when reverse pulse is output 0
Speed control
0.01 ~ 6000000.00
µ/min
0.001 ~ 600000.000
inch/min
0.001 ~ 600000.000
degree/min
1 ~ 1000000
pulse/s
200000
Acceleration time [ 0] 1 ~65535ms/1 ~ 8388608ms 1000 Deceleration time [ 0] 1 ~65535ms/1 ~ 8388608ms 1000 Starting bais speed
0.01 ~ 6000000.00
µm/min
0.001 ~ 600000.000
inch/min
0.001 ~ 600000.000
degree/min
1 ~ 1000000
pulse/s
0
2 Change among
sequencer is
possible. Stepping motor mode
0:standard mode 1: Stepping motor mode 0
3.3.2 The basic parameter for a starting point return
Unit
Setting range Initial
Item mm inch degree pulse Value
Home position return method
0:Near-zero point dog method 1:Stopper stop (1) (caused by time-out of the dwell timer) 2:stopper stop(2) (caused by the zero point signal when in contact with stopper 3:Stopper stop (3) (method without near-zero point dog) 4:Count method (1) (zero point signal is used) 5:Count method (2) (zero point signal is not used)
0
Home position return direction
0:Forward direction (address increases) 1:Reverse direction (address decreases) 0
Zero position address -214748364.8 ~
214748364.7 µm -21474.83648 ~
21474.83647inch 0 ~
359.99999degree -2147483648 ~
2147483647pulse 0
Home position return speed
0.01 ~ 6000000.00
mm/min
0.001 ~ 600000.000
inch/min
0.001 ~ 600000.000
degree/min
1 ~ 1000000
pulse/s
1
Creep speed
0.01 ~ 6000000.00
mm/min
0.001 ~ 600000.000
inch/min
0.001 ~ 600000.000
degree/min
1 ~ 1000000
pulse/s
1
Home position return retry 0:Home position return is not retried in accordance with the upper/lower limit switch. 1:Home position return is retried in accordance with the upper/lower limit switch. 0
3 - 6
3. POSITIONING CONTROLLER
3.3.3 Positioning data
Unit Setting Range Initial Item mm inch degree pulse value Operation pattern
00 : Positioning end 01 : Continuous positioning control 11 : Continuous locus control
00
Control method
_
Acceleration time No. The acceleration time 0-3 is chosen from the inside of a basic parameter [2] 0 Deceleration time No. The acceleration time 0-3 is chosen from the inside of a basic parameter [2] 0 Positioning address Absolute
-214748364.8 ~ 214748364.7 µm
-21474.83648 ~ 21474.83647inch
0 ~ 359.99999degree
-2147483648 ~ 2147483647pulse 0
Incremental (other than speed/position switching control)
-214748364.8 ~ 214748364.7 µ m
-21474.83648 ~ 21474.83647inch
-21474.83648 ~ 21474.83647degree
-2147483648 ~ 2147483647pulse
0
Positioning travel value
Speed/ position switching control
0 ~ 214748364.7 µ m
0 ~ 21474.83647inch
0 ~ 21474.83647degree
0 ~ 2147483647pulse 0
Absolute 0 ~
359.99999degree 0 ARC. address The auxiliary or central point
Incremental
-214748364.8 ~
214748364.7 µm
-21474.83648 ~
21474.83647inch -21474.83648 ~ 21474.83647degree
-2147483648 ~
2147483647pulse 0
0.01 ~6000000.00 mm/min
0.001 ~600000.000 inch/min
0.001 ~600000.000 degree/min
1 ~ 1000000 pulse/s
Commanded speed
-1(current speed: the same speed as the previous positioning data no.)
0
Dwell time 0 ~ 65535ms(the completion signal of positioning turns on this time). Or it is jump place data No.1-600 at the time of a JUMP command. 0
M code 0 ~ 32767(Or it is data No.1-10 of Conditions JUMP at the time of a JUMP command.) 0
Notation of peripheral device
Description of setting Instruction code
ABS linear 1 Linear control of axis 1(ABS) 01H INC linear 1 Linear control of axis 2(INC) 02H
Fixed-pitch feed 1 Fixed pitch feed of axis 1 03H ABS linear 2 Linear control of axis 2(ABS) 04H INC linear 2 Linear control of axis 2 (INC) 05H
Fixed-pitch feed 2 Fixed pitch feed of axis 2 06H ABS circular interpolation
Circular interpolation control by auxiliary point designation(ABS)
07H
INC circular interpolation
Circular interpolation control by auxiliary point designation (INC)
08H
ABS circular right Circular interpolation control by center point designation(ABS, CW)
09H
ABS circular left Circular interpolation control by center point designation (ABS, CCW)
0AH
INC circular right Circular interpolation control by center point designation (INC, CW)
0BH
INC circular left Circular interpolation control by center point designation (INC, CCW)
0CH
Forward speed control speed control(forward) 0DH Reverse speed control speed control (reverse) 0EH
Forward speed/ position
speed/ position switching control (forward) 0FH
Reverse speed/ position
speed/ position switching control (Reverse) 10H
Present value change
Present value change 11H
JUMP instruction JUMP instruction 12H
3 - 7
3. POSITIONING CONTROLLER
Data No.
Pattern Control method
Acc [ms]
Dec [ms]
Address [µm]
Command speed
[mm/min]
Dwell time [ms ]
M code
1 0: End 1:ABSlinear 1 0:100 0:100 50000.0 2000.00 0 02 0: End 1:ABSlinear1 0:100 0:100 75000.0 2000.00 0 03 0: End 1:ABSlinear1 0:100 0:100 100000.0 2000.00 0 04 0: End 1:ABSlinear1 0:100 0:100 150000.0 2000.00 0 05 0: End 1:ABSlinear1 0:100 0:100 200000.0 2000.00 0 06 0: End 1:ABSlinear1 0:100 0:100 25000.0 2000.00 0 07 0: End 0:No axes 0:100 0:100 0.0 0.00 0 08 0: End 0:No axes 0:100 0:100 0.0 0.00 0 09 0: End 0:No axes 0:100 0:100 0.0 0.00 0 0
10 0: End 0:No axes 0:100 0:100 0.0 0.00 0 0
Example of a positioning data setting
3 - 8
3. POSITIONING CONTROLLER
3.4 Position command interface
Conventionally, the pulse train was the most common type of position command output from the position command output from the positioning controller to the servo amplifier. Recently, as software and digital control have come to be widely adopted, using microprocessors (CPU) in the control unit, the style of position command is changing; the ultimate type of control system integrates the positioning controller and the servo amplifier by connecting of sophisticated and highly accurate positioning systems. If a pulse train is used as the position command, there are several types of interface. A summary of the types of position command interface, the corresponding models, and the features of each type of interface is presented below.
Bus connection ------ [Positioning command equipment]
(SSC network correspondence) A171SH, A172SH, A173SH, A273 AD75M, A1SD75M;
(Servo amplifier) Position commandinterface
MR – J2B, MR - HBN Pulse sequence system ------ (positioning control equipment) (General-purpose interface) FX – 1GM, FX – 10GM, FX-20GM, AD75P, A1SD75P (Servo Amplifier) MR – J2A, MR – J2SA, MR – HAN; Point-of-contact system (Servo amplifier with a built-in positioning function) MR – J2C, MR - HACN
(The type of pulse train interface) (a) Forward and reverse pulse train system, and a pulse train and a direction distinction signal system. There are a system inputted from a separate terminal by the rotation direction as a method of specifying the rotation direction of a motor, and a system switched with the rotation direction distinction signal in a pulse sequence. Moreover, it becomes 2 phase pulse train system when inputting a direct pulse sequence from a synchronous encoder.
Pulse train for forward rotation
Forward rotation
Reverse rotation
Pulse train for reverse rotation
Pulse train Phase A pulse train
Direction determination sign
Phase B pulse train
2phase pulse train method Forward/ reverse rotation pulse train method of rotation
Direction determination sign method
Fig. 3.4 Command system of rotation direction. (b) An open collector system and a differential driver system
3 - 9
3. POSITIONING CONTROLLER
These two kinds exist as hardware of an interface. Although the easy open collector system was conventionally in use, recently, the differential driver system has become popular since it can handle high speed pulse trains and improve the noise resistance. In connection with our company AD75, the differential formula is recommended.
[The example of hardware composition ]
Position controller
Servo amplifier
Open-collector type
Equivalent to SN75113
Driver Receiver
Differential driver type (Max 10M)
Position controller
Servo amplifier
Fig. 3.5 Example of hardware of pulse sequence
[Pulse train type]
Pulse train
Command
Open-collector Type
Differential driver type
Pulse train
Pulse train
Fig. 3.6 Pulse sequence form
3 - 10
3. POSITIONING CONTROLLER
3.5 The Basic of the Positioning Control Using a positioning controller
3.5.1 The direction of a machine motion and the servo motor rotation direction
The rotation direction of a servomotor has determined the counterclockwise rotation as right rotation in view of the load side. Moreover, the “positive” direction of mechanical motion is usually defined as the direction in which coordinates value increase. In order to unite the move direction of a machine, and the rotation direction of a servo motor, when the rotation direction of a servo motor needs to be changed, the rotation direction is set up and changed with the parameter of positioning controller etc. Since normal operation becomes impossible, a change of the rotation direction by exchange of direction of a servo motor terminal cannot be made. The change method of this rotation direction is the same even if the model of positioning controller is different. Moreover, to check the direction of motor rotation, run the motor by using JOG functions.
Ball Screw Table
Servomotor
The direction in which the table is moved by the ball screw when the motor rotates in the forward direction.
The direction in which the coordinate values of the machine position increase
Home Position
Forward direction (CCW)
Fig. 3.7 Rotation direction of servo motor Fig. 3.8 Example of setting of rotation direction
3 - 11
3. POSITIONING CONTROLLER
3.5.2 The type of home position return
(1) The type of home position return
Type of home position return
Type of zero point Operation
Near –zero point dog
signal
Machine home
position
(first zero point)
The near-zero point signal OFF → ON, it slows down at creep
speed, and after The near-zero point ON → OFF, while stopping
an output pulse with the zero signal from Servo amplifier, a clear
signal is outputted, a deviation counter collects, a pulse is made
into zero, and a home position return is completed.
High-speed home
position return
Machine home
position
(first zero point)
Creep speed is not used but the home position return to the
machine starting point only at home position return speed (high-
speed). The first time needs to define the machine starting point
by dog type home position return.
Home position return for
programming
Programming home
position
(second zero point)
The home position return which returns to the program starting
point (standby position) set up with the parameter at home
position return speed.
Dog type home position return, high-speed home position return and home position return for programming.
man
ual
- au
tom
atic
Ze
ro
poin
tre
turn
A
utom
atic
Zer
o po
int r
etur
n
Creep speed
High-speed home position return
Machine home position return
home position return for programming home position return speed
Dog type home position return
(first home position)
(The second home position)
home position return for programming
Zero-point signal
Machine home point
(to be set by parameter)
Home position shift amountNear-zero point dog
3 - 12
3. POSITIONING CONTROLLER
(2) The type of the home position return method
There are the following four kinds of the home position return methods.
home position return methods The operation pattern of a home position return
op
erat
ion The near-zero point dog signal OFF→ON, it slows
down at creep speed, and after the near-zero point dog signal ON→OFF, while stopping an output pulse with the zero signal from Servo amplifier, a clear signal output is carried out, a deviation counter collects, a pulse is made into zero, and a starting point return is completed.
Dog type
home
position
return
feat
ure Although cautions are required for the determination of
dog length or an attachment position enough, there is a point with sufficient unreasonableness not starting a machine with the sufficient repetition accuracy of a starting point return etc.
Correspondence model: AD75, motion series
ope
ratio
n
If a Dog signal turns on, while slowing down at home position return speed, the count start of the zero signal is carried out. Shortly after a zero signal serves as the number of times of a setup, a pulse sequence signal output is suspended, a clear signal is outputted to Servo amplifier, a servomotor is stopped, and it considers as the home position.
The time of the number of zero signal counts (setting value =4) is shown in the following figure.
Dog type
home
position
return(2)
Fe
atur
e
Cautions are not comparatively needed for the determination of Dog length or an attachment position. However, variation arises at the time of a count start with the accuracy and starting point return speed of repetition operation, such as a switch used for detection of dog point. Since repetition accuracy of a home position return is worsened by this, cautions are required.
Correspondence model: FX series
Ope
ratio
n
If a Dog signal turns on, it will slow down at creep speed from home position return speed. Continuation starting of the home position return on near-dog signal ON and a home position return can also be performed. After the amount part movement of movements specified from near-dog signal ON, if the first zero signal is detected, a pulse signal output will be suspended immediately and a clear signal will be outputted to Servo amplifier. And a servomotor is stopped and it considers as the home position.
Count type
home
position
return (1)
Feat
ure
Cautions are not comparatively needed for the determination of dog length or an attachment position. However, variation arises at the time of a count start with the accuracy and home position return speed of repetition operation, such as a switch used for detection of dog. Since repetition accuracy of home position return is worsened by this, cautions are required. Correspondence model: AD75, motion series
Ball screw
Stroke end in the forward direction
Machine home position
Near-zero point dog
Home position return
Home position return direction Creep speed
Operation pattern
Stroke end in the reverse direction Near-zero
point dog
Table
ServomotorForward direction
Zero-point signal
Clear signal
Creep speed
Home position return speed
Near-zero dog signal
Operation pattern Machine home position
3 4 2 1 Zero-point signal
Clear signal
t The amount of movements after near-dog signal ON(Move distance is set up with a parameter.)
Creep speed
The amount of movements after near-dog signal ON
Home position return speed
Zero point
Near-zero dog off on
The zero of the beginning after near-zero dog ON the amount of movements
near-zero dog signal should take sufficient distance from the present position.
V
3 - 13
3. POSITIONING CONTROLLER
Home position return method The example of the operation pattern of the home position return
Ope
ratio
n
If a Dog signal turns on, it will slow down at creep speed from home position speed. Continuation starting of the home position return on near-zero dog signal ON and the home position return can also be performed. After the amount part movement of movements specified from near-zero dog signal, a pulse signal output is suspended immediately and a clear signal is outputted to Servo amplifier. And a servomotor is stopped and it considers as the home position.
Count type
home
position
return (2)
F
eatu
re
Cautions are not comparatively needed for the determination of Dog length or an attachment position. However, variation arises at the time of a count start with the accuracy and starting point return speed of repetition operation, such as a switch used for detection of Dog. Thereby, since repetition accuracy of the home position return is worsened, the error whose cautions are about 1 required occurs.
Correspondence model: AD75 series
o
pera
tion
If a near-zero dog signal turns on, while slowing down at creep speed from home position return speed, the count of lapsed time is started. A stopper is made to dash and suspend a machine, a pulse sequence signal output is suspended after setting time (dwelling time) progress, and a clear signal is outputted to Servo amplifier. And a servomotor is stopped and it considers as the starting point. If it is not after setting time (dwelling time) progress even if a Dog signal turns off on the way, it will not become the completion of a home position return.
Stopper
type home
position
return (1)
Fea
ture
Cautions are required for the determination of Dog length, creep speed, and setting time (dwelling time) enough. It is necessary to make creep speed sufficiently low in order to lessen the shock at the time of stopping, and it needs to apply torque restrictions to take the intensity of a stopper or a machine into consideration enough. Setting time (dwelling time) seasons time until a machine reaches a stopper with time for fault load protection of Servo amplifier to operate, and is set as it. Furthermore, since distortion occurs and the repetition accuracy of a home position return becomes bad in order to make a stopper dash and suspend a machine, cautions are required.
Correspondence model: AD75 series
Near-zero point dog
stopper
Dwelling time count Dwelling time count
end (the completion of home position return)
Torque limit
Machine home position
V
t
Creep speed
Home position speed
Near-zero dog signal off on
The amount of movements after near-dog signal ON(Move distance is set up with a parameter.)
The amount of movements after near-dog signal ON
Near-zero dog signal off should take sufficient distance from the present position.
3 - 14
3. POSITIONING CONTROLLER
Ope
ratio
n
If a Dog signal turns on, it will slow down at home position return speed, and will move further. A stopper is made to dash and suspend a machine, a setting torque restriction value is reached from Servo amplifier, and a pulse output stops and carries out the completion of a home position return from a controller by the zero signal with the signal (under torque restrictions) which checked the stop state.
Stopper
type home
position
return (2)
F
eatu
re
The same cautions as stopper type home position return (1) is needed. Moreover, if the above-mentioned torque restriction signal is not inputted even if a Dog signal turns off on the way, it does not become the completion of a home position return. Setting the torque limit by AD75 or giving a linear analog command to Servo amplifier.
Correspondence model: AD75 series
Home position return method The example of the operation pattern of the home position return
Ope
ratio
n
It is the starting point return method that can be performed in the case of a position detection system absolutely. Let the position be the starting point by moving a machine to arbitrary positions by JOG operation etc., and performing a starting point return. (A motor does not move)
Data set type
home position
return method
Fea
ture
After a power supply turn on before performing home position return, it is necessary to pass a zero point. The error of about 1% of maximum comes out of the present value display at the time of a power supply OFF, and the present value display at the time of a power supply ON by motor rotation. The home position return data used for only selection of the home position method, and a setup of a home position address. Correspondence model: AD75, motion series
Mechanical stopper
After moving the machine to the required position in the jog mode, execute “data set” to establish this position as the home position.
JOG
Deviation counter clearance
Torque limit effective
Zero point signal
(completion ofhome positionreturn)
Torque limit
Near-zero dog
Machine home position
Machine home position
3 - 15
3. POSITIONING CONTROLLER
MEMO
3 - 16
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
4.1 Function List The following table lists the functions of this servo. For details of the functions, refer to the corresponding chapters and sections.
Function Description (Note)
Control mode Remark
Position control mode This servo is used as position control servo. P Speed control mode This servo is used as speed control servo. S
Torque control mode This servo is used as torque control servo. T
Position/speed control change mode
Using external input signal, control can be switched between position control and speed control.
P/S
Speed/torque control change mode Using external input signal, control can be switched between speed control and torque control.
S/T
Torque/position control change mode
Using external input signal, control can be switched between torque control and position control.
T/P
High-resolution encoder High-resolution encoder of 131072 pulses/rev is used as a servo motor encoder.
P, S, T
Absolute position detection systemMerely setting a home position once makes home position return unnecessary at every power-on.
P
Gain changing function You can switch between gains during rotation and gains during stop or use an external signal to change gains during operation.
P, S
Adaptive vibration suppression control
Servo amplifier detects mechanical resonance and sets filter characteristics automatically to suppress mechanical vibration.
P, S, T
Low-pass filter Suppresses high-frequency resonance which occurs as servo system response is increased.
P, S, T
Machine analyzer function Analyzes the frequency characteristic of the mechanical system by simply connecting a servo configuration software-installed personal computer and servo amplifier.
P
Machine simulation Can simulate machine motions on a personal computer screen on the basis of the machine analyzer results.
P
Gain search function Personal computer changes gains automatically and searches for overshoot-free gains in a short time.
P
Slight vibration suppression control
Suppresses vibration of 1 pulse produced at a servo motor stop. P
Electronic gear Input pulses can be multiplied by 1/50 to 50. P Parameters No. 3, 4
Auto tuning Automatically adjusts the gain to optimum value if load applied to the servo motor shaft varies. Higher in performance than MR-J2 series servo amplifier.
P, S
Position smoothing Speed can be increased smoothly in response to input pulse. P Parameter No. 7
S-pattern acceleration/ deceleration time constant
Speed can be increased and decreased smoothly. S, T Parameter No. 13
Regenerative brake option Used when the built-in regenerative brake resistor of the servo amplifier does not have sufficient regenerative capability for the regenerative power generated.
P, S, T
Brake unit Used when the regenerative brake option cannot provide enough regenerative power. Can be used with the MR-J2S-500A MR-J2S-700A.
P, S, T
4 - 1
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
4 - 2
Function Description (Note)
Control mode Remark
Return converter Used when the regenerative brake option cannot provide enough regenerative power. Can be used with the MR-J2S-500A MR-J2S-700A.
P, S, T
Alarm history clear Alarm history is cleared. P, S, T Parameter No. 16
Restart after instantaneous power failure
If the input power supply voltage had reduced to cause an alarm but has returned to normal, the servo motor can be restarted by merely switching on the start signal.
S Parameter No. 20
Command pulse selection Command pulse train form can be selected from among four different types.
P Parameter No. 21
Input signal selection Forward rotation start, reverse rotation start, servo-on and other input signals can be assigned to any pins.
P, S, T Parameters No. 43 to 48
Torque limit Servo motor-generated torque can be limited to any value. P, S Parameter No. 28
Speed limit Servo motor speed can be limited to any value. T Parameter No. 8 to 10,72 to 75
Status display Servo status is shown on the 5-digit, 7-segment LED display P, S, T
External I/O signal display ON/OFF statuses of external I/O signals are shown on the display. P, S, T
Output signal (DO) forced output
Output signal can be forced on/off independently of the servo status. Use this function for output signal wiring check, etc.
P, S, T
Automatic VC offset Voltage is automatically offset to stop the servo motor if it does not come to a stop at the analog speed command (VC) or analog speed limit (VLA) of 0V.
S, T
Test operation mode Servomotor can be run from the operation section of the servo amplifier without the start signal entered.
P, S, T
Analog monitor output Servo status is output in terms of voltage in real time. P, S, T Parameter No. 17
Servo configuration software Using a personal computer, parameter setting, test operation, status display, etc. can be performed.
P, S, T
Alarm code output If an alarm has occurred, the corresponding alarm number is output in 3-bit code.
P, S, T
Note: P: Position control mode, S: Speed control mode, T: Torque control mode
P/S: Position/speed control change mode, S/T: Speed/torque control change mode, T/P: Torque/position control change mode
4.2 Servo system with auxiliary equipment
MR-J2S series Servo amplifier has come to be able to perform all operations, such as connection with external
apparatus, a monitor and diagnosis, and setup parameter, from the button front of amplifier, as shown in the
following figure. Therefore, those works can be easily done also in the state of wearing in a board.
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
(1) MR-J2S-100A or less
(Note2) 3-phase 200V to 230VAC power supply or 1-phase 230VAC power
l
No-fuse (NFB) or fuse
Magnetic contactor(MC)
To CN2
To CN3
To CN1B
Junction terminal
To CN1A
L 1 L 2
L 21
L 11
Protective earth(PE)
Servo
Personal computer
U V W
Servo fsoftware
MRZJW3-SETUP121E
Servo f
Regenerative brake option
D
P
C
CHARGE
Options and auxiliary
No-fuse
Magnetic
Servo configuration
Regenerative brake Remark
Control circuit terminal
(Note1) Encoder cable
Options and auxiliary Remark
Cable
Command
(Note1)Power supply
L 3
Note: 1. The HC-SFS, HC-RFS series have cannon 2. A 1-phase 230VAC power supply may be used with the servo amplifier of MR-J2S-70A or less. Connect the power L 1 and L 2 terminals and leave 3 open.
Power factor improving reactor (FR-BAL)
Power factor improving
4 - 3
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
(2) MR-J2S – 200A or more
Power factor improving reactor (FR-BAL)
3-phase 200V to 230VAC power
No-fuse breaker (NFB) or fuse
Magnetic contactor (MC)
To CN2 To CN3
To CN1B
Junction block
To CN1A
L1 L2 L3
L21 L11
Servo lifi
Regenerative brake
P CU V W
Options and auxiliary
No-fuse
Magnetic
Servo configuration
Regenerative brake
Remark Options and auxiliary Remark
Personal computer
ServoconfiguratiosoftwareMRZJW3-SETUP121E
Cable
Command
Power factor improving
4 - 4
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
4.3 Installations and Operation If a product is purchased, it will operate by building a servomotor and Servo amplifier into a machine and a control board. Although these works is done on a product according to attached "handling description", according to a work procedure, the flow of the whole work in the 4.3.1 and clause is explained to the 4.3.2 about the point of each work in order.
4.3.1 The flow of the work to install and operation
The usual work Test operationⅠ Test operation III
Wiring Wiring (Not include motor)
4.3.3、4.3.4
(Wiring between a motor and amplifier )
Turn on power supply Turn on power supply Turn on power supply
4.3.5
Parameter setup
4.3.8
Parameter setup Parameter setup
Output signal check
4.3.9
Input/Output signal check
Manual operation
4.3.10
JOG Operation Motor-less operation
4.3.13 4.3.13
Home position return
4.3.11
Home position return
Automatic operation
4.3.12
Automatic operation
It is the usual work proce-
dure. The point is explained t
o 4.3.2 clause shift.。
Easy operation of the machine
incorporating a motor indepen-
dent or the motor can be per-
formed without the wiring fro
m external instruction equipmen
t.
It perform only to check a
machine of operation before
wiring convenient for operation
to be well impossible from an
operation board, and check
The check of only the circu
m- ference of the electric instr
uc- tion without motor of ope
ration can be performed. In or
der to perform starting poi
nt return and automatic operati
on, it is necessary to prepare t
he electric virtual starting poi
nt.
One positioning operation is
made without the wiring from
external instruction equipment
to the machine incorporating
a motor independent or the
motor.
It perform only to check a
machine of operation before
wiring convenient for operation
to be well impossible from an
operation board, and check
only by Servo.
Test operation II
A personal computer (Servo setup software)
is connected.
Turn on power supply
Parameter setup
4.3.13
Position Operation
4.3.2 Installation
4 - 5
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
4.3.2 INSTALLATION
(1) Environmental conditions
Environment Conditions
[ ] 0 to 55 (non-freezing) Operation
[ ] 32 to 131 (non-freezing)
[ ] 20 to 65 (non-freezing)
Ambient temperature
Storage [ ] 4 to 149 (non-freezing)
Operation Ambient humidity Storage
90%RH or less (non-condensing)
Ambience Indoors (no direct sunlight) Free from corrosive gas, flammable gas, oil mist, dust and dirt
Altitude Max. 1000m (3280 ft) above sea level
[m/s2] 5.9 [m/s
2] or less
Vibration [ft/s
2] 19.4 [ft/s
2] or less
(2) Installation direction and clearances
CAUTION
The equipment must be installed in the specified direction. Otherwise, a fault may occur. Leave specified clearances between the servo amplifier and control box inside walls or other equipment.
(a) Installation of one servo amplifier
Control box Control box
10mm (0.4 in.) or more
10mm (0.4 in.) or more
40mm (1.6 in.) or moreServo amplifier
40mm (1.6 in.) or more
Wiring clearance 70mm (2.8 in.) Top
Bottom
4 - 6
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
(b) Installation of two or more servo amplifiers Leave a large clearance between the top of the servo amplifier and the internal surface of the control box, and install a fan to prevent the internal temperature of the control box from exceeding the environmental conditions.
Control box
30mm (1.2 in.) or more
30mm (1.2 in.) or more
10mm (0.4 in.) or more
40mm (1.6 in.) or more
100mm (4.0 in.) or more
Servoamplifier
(c) Others When using heat generating equipment such as the regenerative brake option, install them with full consideration of heat generation so that the servo amplifier is not affected. Install the servo amplifier on a perpendicular wall in the correct vertical direction.
(3) Keep out foreign materials
(a) When installing the unit in a control box, prevent drill chips and wire fragments from entering the servo amplifier. (b) Prevent oil, water, metallic dust, etc. from entering the servo amplifier through openings in the control box or a fan
installed on the ceiling. (c) When installing the control box in a place where there are toxic gas, dirt and dust, provide positive pressure in the
control box by forcing in clean air to prevent such materials from entering the control box.
(4) Cable stress
(a) The way of clamping the cable must be fully examined so that flexing stress and cable's own weight stress are not applied to the cable connection.
(b) In any application where the servo motor moves, the cables should be free from excessive stress. For use in any application where the servo motor moves run the cables so that their flexing portions fall within the optional encoder cable range. Fix the encoder cable and power cable of the servomotor.
(c) Avoid any probability that the cable sheath might be cut by sharp chips, rubbed by a machine corner or stamped by workers or vehicles.
(d) For installation on a machine where the servomotor will move, the flexing radius should be made as large as possible. Refer to section 12.4 for the flexing life.
4 - 7
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
[The servo motor installation.]
(1) Environmental condition
Environment Conditions Ambient temp. 0 to +40 (Non- freezing)
Ambient humidity 80% RH or less (Non-condensing)
Storage temp.
-15 to +70 (Non- freezing)
Storage humidity 90% RH or less (Non-condensing)
Ambient Indoors (no direct sunlight) Free from corrosive gas, flammable gas, oil mist, dust and dirt
Altitude Max. 1000m(3280 ft) above sea level
HC-AQ series
HC-KF series HC-MF series HA-FF series HC-UF13~73
HC-KFS series HC-MFS series HC-UFS13~73
X,Y:49m/s2(5G)
HC-SF81 HC-SF52~152 HC-SF53~153 HC-RF Series HC-UF72・152
HC-SFS81 HC-SFS52~152 HC-SFS53~153 HC-RFS series HC-UFS72・152
X,Y:24.5m/s2(2.5G)
HC-SF121・201 HC-SF202・352 HC-SF203・353 HC-UF202~502
HC-SFS121・201 HC-SFS202・352 HC-SFS203・353 HC-UFS202
X:24.5m/s2(2.5G) Y:49m/s2(5G)
HA-LH11K2 ~22K2
HC-SF301 HC-SF502・702 HC-SFS301 X:24.5m/s2(2.5G)
Y:29.4m/s2(3G)
Vibration
HA-LF30K24~55K24 X,Y:9.8m/s2(2G)
The amplitude of each oscillating conditions is as follows.
Speed [r/min]
200
100
80
60
50
40
30
20
500 1000 1500 2000 2500 3000 3500
[μm]
Vib
ratio
n am
plitu
de
(bot
h am
plitu
des)
Vibration
Y X
Servomotor
4 - 8
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
(2) Installation orientation The following table lists directions of installation:
Servomotor series Direction of installation Remarks HC-KF HC-MF HA-FF HC-SF HC-RF HC-UF HC-KFS HC-MFS HC-SFS HC-RFS HC-UFS
HC-AQ
For installation in the horizontal direction, it is recommended to set the connector section downward.
HA-LH
May be installed in any direction
HA-LF Horizontal direction with the legs downward. Use either the legs or flange for installation
(3) Transportation Do not hold encoder or shaft to carry the servomotor.
(4) Load mounting precautions a. When mounting a pulley to the servo motor shaft provided with a keyway, use the screw hole in the
shaft end. To fit the pulley, first insert a double-end stud into the screw hole of the shaft, put a washer
against the end face of the coupling, and insert and tighten a nut to force the pulley in.
b. For the servomotor shaft with a keyway, use the screw hole in the shaft end. For the shaft without a
keyway, use a friction coupling or the like.
c. When removing the pulley, use a pulley remover to protect the shaft from impact.
d. To ensure safety, fit a protective cover or the like
on the rotary area, such as the pulley, mounted to
the shaft. Servomotor
Double-end stud
Nut
WasherPulley
e. When a threaded shaft end part is needed to mount
a pulley on the shaft, please contact us.
f. During assembling, the shaft end must not be
hammered.
g. To orientation of the encoder on the servomotor
cannot be changed.
h. For installation of the servo motor, use spring
washers, etc. and fully tighten the bolts so that they
do not become loose due to vibration.
4 - 9
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
(5) Permissible load for the shaft (a) Use a flexible coupling and make sure that the misalignment of the shaft is less than the
permissible radial load;
(b) When using a pulley, sprocket or timing belt, select a diameter that will fit into the permissible radial load.
(c) Do not use a rigid coupling as it may apply excessive bending load to the shaft, leading to shaft breakage.
Permissible Radial Load Permissible Thrust Load Servomotor
(note 1) L [] [N] (Note2) [kgf] [N] (note2) [kgf]
053・13 25 88 9.0 59 6.0 23・43 30 245 25.0 98 10.0
HC-MF HC-MFS
73 40 392 40.0 147 15.0 053 30 108 11.0 98 10.0 13 30 118 12.0 98 10.0
23・33 30 176 18.0 147 15.0 HA-FF
43・63 40 323 33.0 284 29.0 81 55 980 100.0 490 50.0
121~301 79 2058 210.0 980 100.0 52~152 55 980 100.0 490 50.0 202~702 79 2058 210.0 980 100.0 53~153 55 980 100.0 490 50.0
HC-SF HC-SFS
203・353 79 2058 210.0 980 100.0 103~203 45 686 70.0 196 20.0 HC-RF
HC-RFS 353・503 63 980 100.0 392 40.0 72・152 55 637 65.0 490 50.0
202 65 882 90.0 784 80.0 352・502 65 1176 120.0 784 80.0
13 25 88 9.0 59 6.0 23・43 30 245 25.0 98 10.0
HC-UF HC-UFS
73 40 392 40.0 147 15.0 11K2 85 2450 250 980 100.0
HA-LH 15K2・22K2 100 2940 300 980 100.0
HC-KF HC-KFS
23・43 30 245 25.0 98 10.0
0135 16 34 3.5 14 1.5 0235 16 44.0 4.5 14 1.5 HC-AQ 0335 16 49 5.0 14 1.5
30K24・37K24 140 3234 330 1470 150 HA-LF
45K24・55K24 140 1900 500 1960 200
Note1. For the symbols in the table, refer to the following diagram:
Radial Load
Thrust load
L
L: Distance from flange mounting surface to load center
2. It is a reference value.
4 - 10
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
(6) Protection from oil and water (a) The servomotor of a right table is not
waterproofing structure. The Oil and water
should get down to a servomotor and please do
not start. Especially, HC-AQ, HC-KF, HC-MF,
HC-KFS, HC-MFS should not require the oil and
water for an axial penetration part.
Servo motor series Protection HC-KF・HC-MF HA-LF・HA-FF
IP44
HC-AQ・HC-KFS・HC-MFS IP55 HA-LH JP44
Servomotor
Oil or water
Height above oil level
h
Lip V - ring
ServomotorGear
(b) When the gearbox is mounted horizontally, the oil level in the gearbox should always be lowerthan the oil seal lip on the servo motor shaft. If it is higher than the seal lip, oil will enter the servomotor, leading to a fault. Also, provide a breathing hole in the gearbox to hold the internal pressure low. The HC-MF series servomotor is not equipped with a V-ring or an oil seal and cannot beused with the gearbox as described above. Oil should be shut off on the gearbox side. The HA-FF series servomotor equipped with an oil seal is available. Please contact Mitsubishi.
Servomotor Height level h
(mm) Servomotor
Height level h (mm)
053, 13 8 72 , 152 20
23 , 33 12 202 ~ 502 25 HA-FF
43, 63 14 13 12
81 20 23 , 43 14
121 ~ 301 25
HC-UF HC-UFS
73 20
52 ~ 152 20 11K2 30
202 ~ 702 25 HA-LH
15K2 , 22K2 40
53 ~ 153 20 30K24 , 37K24 45
HC-SF HC-SFS
203 ~ 353 25 HA-LF
45K24 , 55K24 48 HC-RF
HC-RFS 103 ~ 503 20
4 - 11
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
(c) When installing the servomotor horizontally, face the power cable and encoder cable down- ward. When installing the servomotor vertically or obliquely, provide a trap for the cable.
Cable trap
cover
(Incorrect) Capillary phenomenon
Oil/water pool
Servo motor
(d) Do not use the servomotor with its cable socked in oil or water. (Figure on the right)
(e) When the servomotor is to be installed with the shaft end at top, provide measures to
Gear Lubricating oil
Servomotor
prevent oil from entering the servomotor from the gearbox, etc.
(7) Cooling fan
The HA-LH and HA-LF servomotors have a cooling fan. Leave the following distance between the servomotor’s suction face and the wall.
Cooling fan Wind
L or longer
Servomotor
Servomotor series Distance L
HA-LH 50 mm HA-LH 150 mm
4 - 12
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
(8) Cable stress a. Please fully consider the clamp method of a cable and crookedness stress and cable prudence
stress do not join a cable connection part.
b. Please an impossible stress does not join a cable for the use which a servo motor moves. When
a servo motor moves, a cable crookedness part should become within the limits of the detection
machine cable of an option -- wiring of a detection machine cable and a servo motor is
contained by cable raise in basic wages. Please fix the detection machine cable of servo motor
attachment, and a power supply cable.
c. The crookedness life of a detection machine cable is shown in the following figure. Please see a
margin somewhat from this in fact. When you attach in a machine which a servo motor moves,
please enlarge a crookedness radius as much as possible.
1X107
5X1071X108
5X106
1X106
5X105
1X105
5X104
1X104
5X103
1X103
4 7 10 20 40 70 100 200
a
b
Notes . This graph is a calculation value. It is not a guarantee value. Please see a margin somewhat from this in fact.
4 - 13
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
4.3.3 Wiring system and Power-on sequence (1) The main circuit wiring system and a power-on procedure
(a) The following figure show the wiring of a power supply of servo Amplifier. The main circuit power supply (3 phase,
200 VAC(L1, L2, L3), single phase 230VAC(L1, L2)) connect with the electromagnetic contactor. Configure up
an external sequence to switch off the magnetic contactor as soon as an alarm occurs.
(b) Please supply to the control circuit power supply L11, and that L21 is simultaneous with the main circuit power
supply or the point. If the main circuit power supply is not switched on, the warning will be displayed on a display
part, if the main circuit power supply is switched on, warning will disappear and will operate normally.
(c) Servo amplifier can receive a Servo-on signal (SON) in about 1s after the main circuit power up. Therefore, if
SON is turned on simultaneously with power up, a base circuit turns on 3 phase power supply after about 1s, and
further, in about 20ms, completion signal of preparation (RD) is turned on, making servo amplifier ready operate.
(d) If a reset signal (RES) is turned on, it becomes base interception and the servomotor shaft coasts.
(2) The example of connection
A power supply and a main circuit should wire, as shown in the following figure. Please be sure to use a no fuse breaker
(NFB) for the input line of a power supply. When you correspond to UL/C-UL standard, please use the fuse corresponding
to this standard.
RA OFF ON
MCMC
SK
NFB MC
L1
L2
L3
L11
L21
EMG
SON
SG
VDD
COM
ALM RA Alarm
Emergency stop Servo on
3 phase
Note 2
Emergency stop
200-230VAC
Single phase AC230V
Note 1
Servo Amplifier
Note 1. 1-phase 230V power supply may be used with the servo amplifier of MR-J2S-70A or less. Connect the
power supply to L1 and L2 terminals and leave L3 open. 2. Trouble(Alarm) is connected with COM in normal alarm-free condition. When this signal is switched
off, the output of controller should be stopped by the sequence program.
Figure 4.1 Main circuit wiring
4 - 14
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
(3) Timing chart
20ms 20ms 20ms 10ms 10ms
10ms10ms
10ms
60ms
60ms
SON
(1s) ON
OFF ON
OFF ON
OFF ON
OFF
ON OFF
Basic circuit
Servo on (SON) Reset (RES)
Ready (RD)
Power supply
Notes 1. A 0.8s failure signal outputs at the time of a power supply turn on ( OFF between ALM-SG).
2. The Servo on signal could be ON once power supply was turned on.
3. An alarm signal is turned on when the servo system was normal.
Fig. 4.2 Timing chart of power up
(4) The alarm occurrence timing chart
When an alarm occurs in the servo amplifier, the base circuit is shut off and the servomotor
is coated to a stop. Switch off the main circuit power supply in the external sequence. To
reset the alarm, switch the control circuit power supply off, then on. However, the alarm
cannot be reset unless its cause of occurrence is removed.
Alarm name Alarm code Alarm name Alarm code Memory error 1 AL12 Motor output ground
fault AL24
Clock error AL13 Overvoltage AL33 Memory error 2 AL15 Parameter error AL37 Encoder error 1 AL16 Overload 1 AL50 Board error 2 AL17 Overload 2 AL51 Encoder error 2 AL20 Watchdog 88888
4 - 15
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
ONOFFON
OFF
ONOFFON
OFFON
OFFON
OFF
1s
Brake operation
50ms or more 60ms or moreAlarm occurs.
Remove cause of trouble.
Brake operation
Power off Power on
ValidInvalid
Main circuitcontrol circuitpower supplyBase circuit
Dynamic brake
Servo-on(SON)
Reset(RES)
Ready(RD)Trouble(ALM)
Fig. 4.3 Alarm occurrence timing chart
(a) Overcurrent, overload 1 or overload 2 If operation is repeated by switching control circuit power off, then on to reset the overcurrent (AL.32), overload 1 (AL.50) or overload 2 (AL.51) alarm after its occurrence, without removing its cause, the servo amplifier and servomotor may become faulty due to temperature rise. Securely remove the cause of the alarm and also allow about 30 minutes for cooling before resuming operation.
(b) Regenerative alarm If operation is repeated by switching control circuit power off, then on to reset the regenerative (AL.30) alarm after its occurrence, the external regenerative brake resistor will generate heat, resulting in an accident.
(c) Instantaneous power failure Undervoltage (AL.10) occurs if power is restored after a 60ms or longer power failure of the control power supply or after a drop of the bus voltage to or below 200VDC. If the power failurepersists further, the control power switches off. When the power failure is reset in this state, thealarm is reset and the servomotor will start suddenly if the servo-on signal (SON) is on. To prevent hazard, make up a sequence that will switch off the servo-on signal (SON) if an alarm occurs.
(d) In position control mode (incremental) When the alarm occurs, the home position is lost. When resuming operation after deactivating the alarm, make the home position return.
4 - 16
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
(5) Common line
The following diagram shows the power supply and its common line.
DC24VCN1ACN1B
CN1ACN1B
DO-1
SG
OPC
PG NG
SG
P15R
LG
TLAVC etc.
SD
OP
MRMRR
SM
DI-1
COMVDD
ALM .etc
LGSD
RDPRDN
SDPSDN
LG
CN3
RA
CN2
SD
MO1MO2
LG
SG
TXD
RXD RS-232C
RS-422
(Note)
Analog input( 10V/max. current)
Servo motor
Ground
SDLG
Servo motor encoder
Isolated15VDC 10%30mA
LA etc.
Analog monitor output
SON, etc.
PP NP
LG
Note: For the open collection pulse train input. Make the following connection for the different line driver pulse train input.
Differential linedriver output35mA max.
LARetc.
Fig. 4.4 Connection of common line
4 - 17
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
(6) Interface power supply Although DC24V are used as a power supply for digital input-and-output signals, when using the power supply VDD with
built-in amplifier, VIN-VDD is connected externally. When power supply capacity runs short, an external power supply
can be used.
For use of internal power supply For use of external power supply
VDD
COM
24VDC
SGTR
Servo amplifier
R: Approx. 4.7
SON, etc.(Note)For a transistor
Approx. 5mA
V CES 1.0VI CEO 100 A
Switch
COM
SG
Switch
SON, etc.
24VDC200mA or more
Servo amplifier
R: Approx. 4.7
VDD24VDC
Do not connectVDD-COM.
Note: This also applies to the use of the external power supply.
Fig. 4.5 Connection of interface power supply
4 - 18
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
4.3.4 Standard connection example
(1) Position control mode (1-1) Connection of all input-and-output signals
VDD
RA1 RA2 RA3
18
15
5
14
8
9
16
17
1
11
EMG
SON
RES
PC
TL
LSP
LSN
SD
SG
P15R
LG
10
12
ALM
19 ZSP
6 TLC
14
7
16
17
4
LA
LAR
LB
LBR
LG
OP
P15R
SD
1
6
CN1B
CN3
13 COM
3
TLA
CN1A
4
13
3
SDLG
14
MO1LG
MO2
A
A
COMINP
LZ
CR
PG
NPNG
RD
SG
PP
LZR
SDLG 1
26 8
24 5 21
4 22
7
23 3
25 6
1
20 12 14
35 16
DOG
COM
RLS
STARTCHG
FLS 13 15
11
STOP
COM
2
36
19
DC24V
Positioning module
Ready COM INPS
PGO(24V)PGO(5V)
PGO COMCLEAR
CLEAR COM
PULSE FPULSE FPULSE RPULSE R
PULSE F
PULSE R
(Note 10) 10m(32ft) max.Servo amplifier
CN1A CN1B
Trouble Zero speed
Limiting torque
Encoder A-phase pulse(differential line driver)
Encoder B-phase pulse(differential line driver)
Control common
Encoder Z-phase pulse(open collector)
Plate
Plate
Emergency stop
Servo-on Reset Proportion controlTorque limit selection
Forward rotation stroke end Reverse rotation stroke end
Upper limit setting Analog torque limit ±10V/max. torque
Servo configuration software
Personal computer
Communication cable
Monitor outputMax. 1mA Reading in bothdirections
2m(6.5ft) max.
10k
10k Plate
19918
515
2
10
123
8
13
Plate
2m(6.5ft) max.
PULSE COM
PULSE COM
Fig. 4.6 Connection of position control (I)
4 - 19
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
(1-2) Connection of the minimum required input-and-output signal In order to operate a motor, below the minimum needs to be connected. Connection of an output signal is
unnecessary.
a) Servo on ------
Since it is a signal for employing the main circuit efficiently, it is required before operation to surely turn
on. If turned on, it will be in a Servo lock state.
b) Forward and reverse rotation stroke end ------
Usually, it connects with limited switch (LS) in a machine end. If turned off, it will not move in the
direction. It moves to an opposite direction. When there is no machine end LS like roll feeder, please
always short-circuit between SG.
c) Forward and reverse pulse train ------
If a pulse train is inputted, a motor will move according to the frequency and the number of pulses. A
Servo lock will be stopped and carried out if there is no input.
d) Reset ------
It is used for release of alarm. Since, as for alarm release, the main circuit power supply OFF can also be
performed, it is not an absolutely required signal. Moreover, if a reset signal is turned on, a Servo lock
will be canceled and it will become a motor free-lancer.
e) Emergence stop ------
Please be sure to connect an emergency stop signal (EMG) with SG with an emergency
stop switch (B point of contact) too hastily at the time of operation.
VDD
18
CN1A
15
5
14
8
9
16
17
EMG
SON
RES
PC
TL
LSP
LSN
SG 10
ALM
19 ZSP
6 TLC
Servo amplifier
CN1B
CN2
CN1B
Servo
motor
Servo on reset
13 COM
3
OPC
COM
PP
SG
NP
CRSG
SD
11
10
20plate
9
3
2
8
Forward pulse train
Forward rotation stroke end
Reverse pulse train
Emergence stop
Reverse rotation stroke end
Encoder cable
<note 1>
<Note 1> This figure is connection of an open collector system. Refer to 4 - 20 pages of the connection of a differential line driver system.
Fig. 4.7 Connection at time of position control (II)
4 - 20
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
(1-3) Connection of the minimum required input-and-output signal operating by AD75 / A1SD75 a) Servo on b) Forward and reverse rotation stroke end c) Forward and reverse pulse train - - As shown in the following figure, it connects with the
terminal of AD75 / A1SD75. d) Reset e) Clear --- It is used for the counter clearance at the time of a zero return. f) Zero pulse --- It is used as a starting point signal at the time of a zero return. g) Ready -- A Servo on state is outputted to AD75, and it is used as an interchange lock signal. h) Emergence stop --Please be sure to connect an emergency stop signal (EMG) with SG
with an emergency stop switch (B point of contact) too hastily at the time of operation.
VDD
18
15
5
14
8
9
16
17
EMG
SON
RES
PC
TL
LSP
LSN
SG 10
ALM
19 ZSP
6 TLC
Servo amplifier
CN1B
CN2
CN1B
Servo
motor
Servo on Reset
Reverse Rotation strike end
13 COM
3
Encoder Cable
COM
INP
LZ
CR
PG
NP
NG
19
9
18
5
15
2
10
12
3
RD
8
SG
PP
LZR
SD
LGplate
CN1A
13
1
26 8
24 5 21
4 22
READY
COM
INPS
7
CLEAR 23 3
25 6
1
20 2
PGO(24V) PGO(5V)
PGO COM CLEAR COM PULSE F- PULSE F+ PULSE R- PULSE R+
PULSE F PULSE R
19
Position module
Emergency stop
Forward Rotation strike end
AD75P 。 ( A1SD75P 。 ) 10 M or less
※The connection details about AD75/AISD75 should refer to the description of AD75/AISD75.
Fig. 4.8 Connection of position control (III).
4 - 21
4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS
(1-4) Connection of the minimum required input-and-output signal by operating in FX-10GM a) Servo on b) Forward and reverse rotation stroke end c) Forward and reverse pulse train --- As shown in the following figure, it connects with the
terminal of FX-10GM. d) Reset c) Clear --- It is used for the counter clearance at the time of a zero return. d) Zero pulse --- It is used as a starting point signal at the time of a zero return.
VDD
18
15
5
14
8
9
16
17
EMG
SON
RES
PC
TL
LSP
LSN
SG 10
ALM
19 ZSP
6 TLC
Servo amplifier
CN1B
CN2
CN1B
Servo motor
Servo on Reset
Forward rotation strike end
Reverse rotation strike end
13 COM
3
Encoder cable
INP
RD
CN1A
2 (
COM
P15R
OP
LG
OPC
COM
PP
SG
NP
CR
SG
SD
18
19
9
4
14
1
11
9
3
10
2
8
20plate
COM2 SVRDY COM2
COM4 PG0 24 + VC FP
COM5 RP CLR COM3
12
1
2
14
13
7 ,178 ,186
9 ,1916
3
4
11
5
15
SVEND
FPO
RPO
FX-10GM Position module
M or less
Emergency stop
g) Ready --- A Servo on is outputted to FX-10GM, and it is used as an interchange lock signal.
h) Emergence stop -- Please be sure to connect an emergency stop signal (EMG) with SG with an emergency stop switch (B point of contact) too hastily at the time of operation.
* The connection details about FX-10GM should
refer to the description of FX-10GM.
Fig. 4.9 Connection of position control (IV)
4 - 22
4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
[ Supplementary explanation ] 1. The kind of pulse train input As for an instruction pulse, it is common to forward or reverse pulse train by the open collector system or the differential system, and when it is FX-10GM, FX-20GM, and AD75 P/A1SD75P, it is equivalent to this. The following pulse train can also respond with MR-J2-Super series amplifier to set the command pulse train form in parameter No. 21.
(1) Input pulse waveform selection
Pulse train form Forward rotation command
Reverse rotation command
Pr. 21 setting Remarks
Forward rotation pulse train Reverse rotation pulse train
0 0 1 0
AD71 (A phase)/A1SD71 FX-20GM/10GM(Default setting)
Pulse train + sign
0 0 1 1
AD71 (B phase)/A1SD71(Default setting) FX-20GM/10GM
A-phase pulse train B-phase pulse train
0 0 1 2
Forward rotation pulse train Reverse rotation pulse train
(Default setting) 0 0 0 0
AD75(A phase), A1SD75(A phase) (Default setting)
Pulse train + sign
0 0 0 1
AD75(B phase), A1SD75(B phase)
A-phase pulse train B-phase pulse train
0 0 0 2
PP
NP
Neg
ativ
e lo
gic
PP
NP L H
PP
NP
PP
Posi
tive
logi
c
NP
PP
NP H L
(Note) Arrow or in the table indicates the timing of importanting a pulse train.
PP
NP
(2) The kind of hardware Selection of the next composition can be performed according to the hardware of command unit.
(a) Open collector system (b) Differential line drive system
1.2K Ω
SG
SD
Servo amplifier
VDD
PP
NP
OPC
1.2K Ω
PP
NP
Servo amplifier
P G
N G
SD
2. Torque limit
Whenever it sets up parameter No.28 (internal torque 1), the maximum torque is restricted during operation.
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(2) Speed control mode (2-1) Connection of all input-and-output signal.
RA1 RA2 RA3
1810
SP1SG
CN1A
155
14
89
1617
1
11
EMGSONRES
ST1ST2LSPLSN
SD
SGP15R
LG
10
2
ALM
19 ZSP
6 TLC
155
14
716
17
4
LZLZRLALARLBLBRLGOPP15RSD
1
6
CN3
13
8
7SP2
VC
12TLA
19
18 SA
RD
RA5 RA4
CN1A
3 VDD
COM
9 COM
4
13
3
SDLG
14
MO1LGMO2
CN3
A
A
Speed selection 1
Emergency stopServo-on Reset
Forward rotation start Reverse rotation start
Forward rotation stroke end Reverse rotation stroke end
Speed selection 2
10m(32ft) max.
Upper limit setting
(Note 10) Analog torque limit 10V/max. torque
Upper limit setting
Analog speed command 10V/rated speed
2m(6.5ft) max.
PlatePlate
Servo configuration software
Personal computer
CN1B
Trouble Zero speed
Limiting torque
Speed reached
Ready
Control commonEncoder Z-phase pulse(open collector)
Encoder Z-phase pulse(differential line driver)
Encoder A-phase pulse(differential line driver)
Encoder B-phase pulse(differential line driver)
PlateCommunication cable 2m(6.5ft) max.
Monitor outputMax. 1mA Reading inboth directions
10k
10k
Servo amplifier
CN1B
(note1) This figure is connection at the time of 0 - +10V instructions.
Fig. 4.10 Connection of speed control (I).
4-24
4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
Connection of the minimum required input-and-output signal In order to operate a motor, below is the minimum signal that needs to be connected. Connection of an output signal is unnecessary. a) Servo on ---- Since it is a signal for employing the main circuit efficiently, it is required
before operation to surely turn on. If turned on, it will be in a Servo lock state. b) Speed selection ---- It chooses whether speed commands are made into a parameter setting
value or an external analog setting value. The following figure is the case where it is based on external analog speed instructions.
c) Forward and reverse starting ---- It is used as a starting signal. d) Reset ------ It is used for release of alarm. Since, as for alarm release, the main circuit
power supply OFF can also be performed, it is not an absolutely required signal. Moreover, if a reset signal is turned on, a Servo lock will be canceled and it will become a motor free-lancer.
e) Emergence stop ------ Please be sure to connect an emergency stop signal (EMG) with SG with an emergency stop switch (B point of contact) too hastily at the time of operation.
Encoder cable
30m or less
2m or less
10m or less
Personal Computer Servo configuration
Software
18
10
SP1
SG
CN1A
15
5
14
8
9
16
17
Plate
1
11
EMG
SON
RES
ST1
ST2
LSP
LSN
SD
SG
P15R
LG
10
2
ALM
19 ZSP
6 TLC
Servo amplifier
CN1B
CN2
CN3
Speed selection 1
13
CN1B
Servo Motor
+
8
7SP2
VC
12TLA
Analog speed command +10 V/Max. torque
3 VDD
COM
Upper limit setting
Communication cable
Emergency stop Servo on Reset Speed selection 2
Forward rotation start Reverse rotation start
<Note1>
<Note 1>This figure is connection at the time of 0 - +10V commands.
4-25
4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
Fig. 4.11 Connection at time of speed control ( II )
[Supplementary explanation] Composition of a speed command circuit (1) Speed selection (SP1, SP2)
Motor speed is decided by the setting value of a parameter (SC1, SC2, SC3), or the analog value from the outside, and chooses either by the change of a speed setting selection signal.
Speed command SP1 SP2
Parameter Low (SC1) ON OFF
Middle (SC2) OFF ON
Setting speed High (SC3) ON ON
External speed command (VC) OFF OFF
(2) Starting signal (ST1, ST2) Forward and reverse starting signal (ST1, ST2) perform starting and a stop of a motor. If ST1 and ST2 are both turned off or turned on, a slowdown and the stop of are done and it will be in a Servo lock state. When performing a speed setup on external analog voltage, the relation between the motor rotation direction, and voltage polarity and a starting signal becomes as follows.
Polarity of analog voltage (VC) Forward rotation start ST1 ON
Reverse rotation start ST2 ON
+ Forward rotation Reverse rotation
- Reverse rotation Forward rotation
(3) The example of external wiring The composition of the speed command circuit by external analog voltage is shown. When forward and reverse operation of the polarity of analog voltage are as following:
Servo amplifier
Fig. 4.12 Composition of speed command circuit I
ST1 8
ST2 9
CN1
SG 10
P15R 11
VC 2
LG 1
SD
1KΩ
2KΩ
Forward rotation start
Speed comman
Reverse rotation start
(4) Torque Limit By setting parameter No. 28 (internal torque limit 1), torque is always limited to the maximum value during operation.
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(3) Torque control mode
Connection of all input-and-output signals
RA1
RA2
RA3
1810
SP1SG
15514
9810
1
11
EMGSONRES
RS1RS2SG
SD
P15R
LG12
ALM
19 ZSP
6 VLC
155
14
716
17
4
LZLZRLALARLBLBRLGOP
P15RSD
1
6
CN1B
CN3
13
8
7SP2
TC
2VLA
19 RD RA4
CN1A
3 VDD
COM
9 COM
4
13
3
SDLG
14
MO1LGMO2
CN3A
A
Speed selection 1
Servo amplifier
CN1A
CN1B
10m(32ft) max.
Plate
( Emergency stop Servo-on Reset
Forward rotation startReverse rotation start
Speed selection 2
Upper limit setting
Analog speed limit 0 to 10V/ rated speed
Upper limit setting
Analog torque command 8V/ max. torque
Servo configuration software
Personalcomputer
Communication cable 2m(6.5ft) max.
Plate
Plate
Monitor output Max. 1mA Reading in bothdirections
10k
10k
2m(6.5ft) max.
Control common Encoder Z-phase pulse(open collector)
Encoder Z-phase pulse(differential line driver) Encoder A-phase pulse(differential line driver) Encoder B-phase pulse(differential line driver)
Trouble Zero speed Limiting torque
Ready
<Note 1>This figure is connection at the time of 0 - +8V com
Fig. 4.13 Connection of torque control
4-27
4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
[Supplementary explanation] (1) Composition of the torque control circuit
(a) Torque command and generated torque
A relationship between the applied voltage of the analog torque command (TC) and the torque generated by the servo motor is shown below. The maximum torque is generated at 8V. Note that the torque generated at 8V input can be changed with parameter No. 26.
Generated torque limit values will vary about 5% relative to the voltage depending on products. Also the generated torque may vary if the voltage is low ( 0.05 to 0.05V) and the actual speed isclose to the limit value. In such a case, increase the speed limit value.
Torque limit and torque control Since the torque that a motor generates is proportional to current, if the current of AC servomotor is
controlled, the torque that a motor generates is controllable free. Usually, although AC servo motor (synchronized type) has a little more than 300% of the maximum
torque, while controlling a position and speed, it calls it "torque limited" to limit so that torque may not occur beyond arbitrary values.
On the other hand, the torque control that is controlled so that the generating torque of motor keeps it constant to the value always exists.
Torque limited is used for protection of a slowdown machine, limited of the power at the time of forcing operation.
A torque control rolls round, and it is used, when setting always constant the power (tension) of joining material, even if speed changes. It depends for speed on generating torque and load torque.
The following table indicates the torque generation directions determined by the forward rotation selection (RS1) and reverse rotation selection (RS2) when the analog torque command (TC) is used.
(Note) External input signals Rotation direction Torque control command (TC)
RS2 RS1 Polarity 0V Polarity
0 0 Torque is not generated. Torque is not generated.
0 1 CCW (reverse rotation in driving mode/forward rotation in regenerative mode)
CW (forward rotation in driving mode/reverse rotation in regenerative mode)
1 0 CW (forward rotation in driving mode/reverse rotation in regenerative mode)
CCW (reverse rotation in driving mode/forward rotation in regenerative mode)
1 1 Torque is not generated.
Torque is not generated.
Torque is not generated.
Note. 0: RS1/RS2-SG off (open) 1: RS1/RS2-SG on (short)
Generally, make connection as shown below:
RS1RS2SGTCLGSD
8 to 8V
Servo amplifier
(b) Analog torque command offset Using parameter No. 30, the offset voltage of 999 to 999mV can be added to the TC applied voltage as shown below.
0 8( 8)
Max. torque
Gen
erat
ed to
rque
TC applied voltage [V]
Parameter No.30 offset range 999 to 999mV
4-28
4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(2) Torque limit
By setting parameter No. 28 (internal torque limit 1), torque is always limited to the maximum value during operation. A relationship between limit value and servo motor-generated torque is as in (5) in section 3.4.1. Note that the analog torque limit (TLA) is unavailable.
(3) Speed limit (a) Speed limit value and speed
The speed is limited to the values set in parameters No. 8 to 10, 72 to 75 (internal speed limits 1 to 7) or the value set in the applied voltage of the analog speed limit (VLA). A relationship between the analog speed limit (VLA) applied voltage and the servo motor speed is shown below. When the motor speed reaches the speed limit value, torque control may become unstable. Make the set value more than 100r/m greater than the desired speed limit value.
100 10
Rated speed
Speed [r/min] CCW direction
CW direction VLA applied voltage [V]
Forward rotation (CCW)
Reverse rotation (CW)Rated speed
(b) The following table indicates the limit direction according to forward rotation selection (RS1) and reverse
rotation selection (RS2) combination: (Note) External input signals Speed limit direction
Analog speed limit (VLA) RS1 RS2 Polarity Polarity
Internal speed commands
1 0 CCW CW CCW 0 1 CW CCW CW
Note.0: RS1/RS2-SG off (open) 1: RS1/RS2-SG on (short)
Generally, make connection as shown below: Generally, make connection as shown below:
SP1SP2SG
P15RVCLGSD
2k2k
Servo amplifier
Japan resistorRRS10 or equivalent
4-29
4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
Speed selection 1 (SP1), speed selection 2 (SP2) and the speed selection 3 (SP3), and speed limit value Choose any of the speed settings made by the internal speed limits 1 to 7 using speed selection 1(SP1), speed selection 2(SP2) and speed selection 3(SP3) or the speed setting made by the speed limit command (VLA), as indicated below.
(Note) Input signals Setting of parameter
No. 43 to 48 SP3 SP2 SP1 Speed limit value
0 0 Analog speed command (VLA) 0 1 Internal speed command 1 (parameter No. 8) 1 0 Internal speed command 2 (parameter No. 9)
When speed selection (SP3) is not used (initial status)
1 1 Internal speed command 3 (parameter No. 10) 0 0 0 Analog speed command (VLA) 0 0 1 Internal speed command 1 (parameter No. 8) 0 1 0 Internal speed command 2 (parameter No. 9) 0 1 1 Internal speed command 3 (parameter No. 10) 1 0 0 Internal speed command 4 (parameter No. 72) 1 0 1 Internal speed command 5 (parameter No. 73) 1 1 0 Internal speed command 6 (parameter No. 74)
When speed selection (SP3) is made valid
1 1 1 Internal speed command 7 (parameter No. 75)
Table 4.3 SP1, SP2 and SP3, and speed instruction value
Note.0: SP1/SP2/SP3-SG off (open) 1: SP1/SP2/SP3-SG on (short)
When the internal speed limits 1 to 7 are used to command the speed, the speed does not vary with the ambient temperature.
(c) Limiting speed (VLC) VLC-SG are connected when the servo motor speed reaches the limit speed set to any of the internal speed limits 1 to 3 or analog speed limit.
4-30
4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
4.3.5 Power supply turned on
(1) Checking Please check again the installation and wiring which were performed by 4.3.2 & 4.3.3 before the power supply was turned on.
(1-1) Installation Check that the installation has been carried out as described in section 4.3.2. During the check, pay special attention to the effects of heat generated in the panel on the ambient temperature of the servo amplifier, to contact between the cable and heat generating devices, and to oil and water proofing of the servomotor. (1-2) Wiring Check that the wiring has been carried out as described in Section 4.3.3. During the check, pay special attention to the main circuit connections. The following points are the major check points. Also refer to the instruction manuals and technical literature for the relevant equipment for further details and specific check points.
(2) Wiring Please carry out the next check before operating.
a) Connect the right power supply to the power supply
input terminal (L1, L2, L3) of Servo amplifier. Servo amplifier
Servo amplifier
b) The power supply wires (L1, L2, and L3) must not be
connected to the output terminals for the motor (U, V, W).
The servomotor power supply terminals (U, V, W) of the
servo amplifier match in phase with the power input
terminals (U, V, W) of servomotor.
c) Don't short-circuit the power supply terminal (U-V-W)
for servomotors and power supply input terminal (L1, L2,
L3) of Servo amplifier.
d) Ground the Servo amplifier servomotor certainly.
e) When you use a regeneration option, remove the lead
between D-P of a control circuit terminal stand. Moreover,
use the twist line. Servo amplifier
C O M (24VDC)
Control output signal RA
f) When you use a stroke and a limit switch, between LSP-
SG and between LSN-SG should be a short circuit in the
operation state.
4-31
4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
g) The voltage which surpasses DC24V doesn't join the
pin of connector CN1A & CN1B.
h)Don't mistake direction of the diode for surge absorption attached in DC relay for a control output. It breaks down, a signal is no longer outputted, and operation of protection circuits, such as an emergency stop, may become impossible.
Servo amplifier
SD
SG
i) Don't short-circuit SD and SG of connector CN1A & CN1B. j) The wiring cables are free from excessive force
(3) Environment Signal cables and power cables are not shorted by wire off cuts, metallic dust or the like.
(4) Machine a) The screws in the servo motor installation part and shaft-to-machine connection are tight. b) The servomotor and the machine connected with the servomotor can be operated.
4-32
4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(5) Power on After thoroughly checking the checking point, a power supply will be switched on in the following procedure.
a) Make sure the SON signal is OFF. ↓
b) Turn ON the power supply circuit breaker. ↓
c) Press the operating preparation button to Turn on the servo power before or simultaneously with the power supply to the command unit such as positioning control unit.
turn the input side MC ON ↓
d) Turn ON the power to the command unit. ↓
e)
f)
g)
h)
<ReferencRefer to th
Set parameters. Section 4.3.8
↓.
Check the I/O signals. Section 4.3
↓Turn the SON signals ON. * Make sure that the speed and position commands from the command unit are “0”
before turning this signal ON. ↓
Manual operation. Section 4.3.9
e> e Section 4.3.14 for the operation procedure in each operation mode.
4-33
4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
4.3.6 Display and operation (1) Display Use the display (5-digit, 7-segment LED) on the front panel of the servo amplifier for status display, parameter setting, etc. Set the parameters before operation, diagnose an alarm, confirm external sequences, and/or confirm the operation status. Press the "MODE" "UP" or "DOWN" button once to move to the next screen. To refer to or set the expansion parameters, make them valid with parameter No. 19 (parameter write disable).
Cumulative feedbackpulses [pulse]
Motor speed[r/min]
Droop pulses [pulse]
Cumulative commandpulses [pulse]
Command pulsefrequency [kpps]
Speed command voltageSpeed limit voltage[mV]
Torque limit voltageTorque command voltage
Regenerative loadratio [%]
Effective load ratio[%]
Peak load ratio[%]
Within one-revolutionposition low [pulse]
ABS counter[rev]
Load inertia momentratio [times]
Sequence
External I/Osignal display
Output signalforced output
Test operation Jog feed
Test operation Positioning operation
Test operation Motor-less operation
Software version L
Software version H
Automatic VC offset
Current alarm
Last alarm
Second alarm in past
Third alarm in past
Fourth alarm in past
Fifth alarm in past
Sixth alarm in past
Parameter error No.
Parameter No. 0
Parameter No. 1
Parameter No. 18
Parameter No. 19
Parameter No. 20
Parameter No. 21
Parameter No. 48
Parameter No. 49
(Note)
Note: The initial status display at power-on depends on the control mode.Position control mode: Cumulative feedback pulses(C), Speed control mode: Motor speed(r),Torque control mode: Torque command voltage(U)Also, parameter No. 18 can be used to change the initial indication of the status display at power-on.
MODEbutton
DOWN
UP
Status display Diagnosis Basicparameters
Expansionparameters 1Alarm Expansion
parameters 2
Parameter No. 50
Parameter No. 51
Parameter No. 83
Parameter No. 84
Instantaneous torque[%]
Within one-revolutionposition, high [100 pulses]
Bus voltage [V]
Test operationMachine analyzer operation
Motor series ID
Motor type ID
Encoder ID
[mV]
5-Digit, 7-Segment LED.
MODE UP DOWN SET
Used to set date Used to change the displayor data in each mode Used to change the mode
Fig. 4.20 Display changes figure
4-34
4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(2) Status display list
The following table lists the servo statuses that may be shown: Refer to Appendix 2 for the measurement point.
Name Symbol Unit Description Display range
Cumulative feedback pulses
C pulse Feedback pulses from the servo motor encoder are counted and displayed. The value in excess of 99999 is counted, bus since the servo amplifier display is five digits, it shows the lower five digits of the actual value. Press the "SET" button to reset the display value to zero. Reverse rotation is indicated by the lit decimal points in the upper four digits.
99999 to
99999
Servo motor speed r r/min The servo motor speed is displayed. The value rounded off is displayed in 0.1r/min.
5400 to
5400 Droop pulses E pulse The number of droop pulses in the deviation counter is displayed. When the
servo motor is rotating in the reverse direction, the decimal points in the upper four digits are lit. Since the servo amplifier display is five digits, it shows the lower five digits of the actual value. The number of pulses displayed is not yet multiplied by the electronic gear.
99999 to
99999
Cumulative command pulses
P pulse The position command input pulses are counted and displayed. As the value displayed is not yet multiplied by the electronic gear (CMX/CDV), it may not match the indication of the cumulative feedback pulses. The value in excess of 99999 is counted, but since the servo amplifier display is five digits, it shows the lower five digits of the actual value. Press the "SET" button to reset the display value to zero. When the servo motor is rotating in the reverse direction, the decimal points in the upper four digits are lit.
99999 to
99999
Command pulse frequency
n kpps The frequency of the position command input pulses is displayed. The value displayed is not multiplied by the electronic gear (CMX/CDV).
800 to
800 Analog speed command voltage Analog speed limit voltage
F V (1) Torque control mode Analog speed limit (VLA) voltage is displayed.
(2) Speed control mode Analog speed command (VC) voltage is displayed.
10.00 to
10.00
U V (1) Position control mode, speed control mode Analog torque limit (TLA) voltage is displayed.
0 to 10V
Analog torque command voltage Analog torque limit voltage (2) Torque control mode
Analog torque command (TLA) voltage is displayed. 10
to 10V
Regenerative load ratio L % The ratio of regenerative power to permissible regenerative power is displayed in %.
0 to
100 Effective load ratio J % The continuous effective load torque is displayed.
The effective value is displayed relative to the rated torque of 100%. 0 to
300 Peak load ratio b % The maximum torque generated during acceleration/deceleration, etc.
The highest value in the past 15 seconds is displayed relative to the rated torque of 100%.
0 to
400 Instantaneous torque T % Torque that occurred instantaneously is displayed.
The value of the torque that occurred is displayed in real time relative to the rate torque of 100%.
0 to
400 Within one-revolution position low
Cy1 pulse Position within one revolution is displayed in encoder pulses. The value returns to 0 when it exceeds the maximum number of pulses. The value is incremented in the CCW direction of rotation.
0 to
99999
4-35
4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
Name Symbol Unit Description Display range
Within one-revolution position high
Cy2 100 pulse
The within one-revolution position is displayed in 100 pulse increments of the encoder. The value returns to 0 when it exceeds the maximum number of pulses. The value is incremented in the CCW direction of rotation.
0 to
1310
ABS counter LS rev Travel value from the home position in the absolute position detection systems is displayed in terms of the absolute position detectors counter value.
32768 to
32767 Load inertia moment ratio dC 0.1
Times The estimated ratio of the load inertia moment to the servo motor shaft inertia moment is displayed.
0.0 to
300.0 Bus voltage Pn V The voltage (across P-N) of the main circuit converter is displayed. 0
to 450
(3) Changing the status display screen
The status display item of the servo amplifier display shown at power-on can be chan- ged by changing the parameter No. 18 settings. The item displayed in the initial status changes with the control mode as follows:
Control mode Status display at Power-on Position Cumulative feedback pulse
Position/speed Cumulative feedback pulse/ Servomotor speed Speed Servomotor speed
Speed/ torque Servomotor speed/ Analog torque command voltage Torque Analog torque command voltage
Torque/position Analog torque command voltage /Cumulative feedback pulse
4-36
4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(4) Diagnostic mode
Name Display Description
Not ready. Indicates that the servo amplifier is being initialized or an alarm has occurred.
Sequence
Ready. Indicates that the servo was switched on after completion of initialization and the servo amplifier is ready to operate.
External I/O signal display
Refer to section 6.6. Indicates the ON-OFF states of the external I/O signals. The upper segments correspond to the input signals and the lower segments to the output signals.
Lit: ON Extinguished: OFF
The I/O signals can be changed using parameters No. 43 to 49.
Output signal (DO) forced output
The digital output signal can be forced on/off. For more information, refer to section 6.7.
Jog feed
Jog operation can be performed when there is no command from the external command device. For details, refer to section 6.8.2.
Positioning operation
The servo configuration software (MRZJW3-SETUP121E) is required for positioning operation. This operation cannot be performed from the operation section of the servo amplifier. Positioning operation can be performed once when there is no command from the external command device.
Motorless operation
Without connection of the servo motor, the servo amplifier provides output signals and displays the status as if the servo motor is running actually in response to the external input signal. For details, refer to section 6.8.4.
Test operation mode
Machine analyzer operation
Merely connecting the servo amplifier allows the resonance point of the mechanical system to be measured. The servo configuration software (MRZJW3-SETUP121E or later) is required for machine analyzer operation.
Software version Low
Indicates the version of the software.
Software version High
Indicates the system number of the software.
Automatic VC offset
If offset voltages in the analog circuits inside and outside the servo amplifier cause the servo motor to rotate slowly at the analog speed command (VC) or analog speed limit (VLA) of 0V, this function automatically makes zero-adjustment of offset voltages. When using this function, make it valid in the following procedure. Making it valid causes the parameter No. 29 value to be the automatically adjusted offset voltage. 1) Press "SET" once. 2) Set the number in the first digit to 1 with "UP"/"DOWN". 3) Press "SET".
You cannot use this function if the input voltage of VC or VLA is 0.4V or more.
4-37
4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
Name Display Description
Motor series
Press the "SET" button to show the motor series ID of the servo motor currently connected. For indication details, refer to the optional MELSERVO Servo Motor Instruction Manual.
Motor type
Press the "SET" button to show the motor type ID of the servo motor currently connected. For indication details, refer to the optional MELSERVO Servo Motor Instruction Manual.
Encoder
Press the "SET" button to show the encoder ID of the servo motor currently connected. For indication details, refer to the optional MELSERVO Servo Motor Instruction Manual.
4-38
4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(5) Alarm mode
The current alarm, past alarm history and parameter error are displayed. The lower 2 digits on the display indicate the alarm number that has occurred or the parameter number in error. Display examples are shown below.
Name Display Description
Indicates no occurrence of an alarm.
Current alarm
Indicates the occurrence of overvoltage (AL.33). Flickers at occurrence of the alarm.
Indicates that the last alarm is overload 1 (AL.50).
Indicates that the second alarm in the past is overvoltage (AL.33).
Indicates that the third alarm in the past is undervoltage (AL.10).
Indicates that the fourth alarm in the past is overspeed (AL.31).
Indicates that there is no fifth alarm in the past.
Alarm history
Indicates that there is no sixth alarm in the past.
Indicates no occurrence of parameter error (AL.37).
Parameter error
Indicates that the data of parameter No. 1 is faulty.
Functions at occurrence of an alarm (a) Any mode screen displays the current alarm. (b) The other screen is visible during occurrence of an alarm. At this time, the decimal point in the fourth digit flickers. (c) For any alarm, remove its cause and clear it in any of the following methods (for clearable alarms, refer to Section
10.2.1): (a) Switch power OFF, then ON. (b) Press the "SET" button on the current alarm screen. (c) Turn on the alarm reset (RES) signal.
(d) Use parameter No. 16 to clear the alarm history. (e) Pressing "SET" on the alarm history display screen for 2s or longer shows the following detailed information
display screen. Note that this is provided for maintenance by the manufacturer.
(f) Press "UP" or "DOWN" to move to the next history.
4-39
4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(6) Operation of a display part
The LED display and push button (the following figure) of the front of amplifier perform a display and a setup of a parameter. An operation procedure is explained below.
(6-1) Power ON
(a) Switched Off the Servo On (SON) signal.
(b) It displays the C (return pulse accumulation) to a display part to switch on a power supply (NFB).
(in the case of position control mode)
(6-2) SON signal ON
5-digit, 7-segment LED MODE UP DOWN SET
Information: The initial display while the power supply on changed by control mode. In the case of position control mode : C (return pulse accumulation) In the case of speed control mode : r (motor rotation speed) In the case of torque-control mode: U (torque instruction voltage) Moreover, the initial display at the time of a power supply ON can be changed by parameter No.18.
If a Servo ON signal (SON) is turned on, it will be in the state which can be operated and a servo motor axis will lock. (Servo lock state) When not carrying out a Servo lock, it is not in the Servo lock state. Please check an external sequence by diagnostic display. The check method as following:
MODE Pushed once
SON signal ON
It will become this display if a Sir bone is carried out.
Power ON
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(6-3) State display The initial display of a state display changes with control modes. In the case of position control mode, if the state where it is displayed first pushes <DOWN> by "return pulse accumulation", the contents of a display will shift downward from on Fig. 4.20. <UP> If a switch is pushed, it will return upwards. It can choose in parameter No. 18 to give the first indication arbitrary contents.
(6-4) Diagnostic display If the <MODE> button is pushed from state display mode, it will move to diagnostic display mode. <UP> It unites with contents to see with the <DOWN> button.
(6-5) The display of alarm present alarm (error excessive)
↓ * A display blinks.
( UP )
↓
Alarm of once ago (over-voltage)
↓
( UP )
↓
Alarm of twice ago (With no alarm gen-
erating)
Alarm was occurred (over-speed during running) (Note) Although other displays can be seen also in al
arm generating, the decimal point of the 4th figure blinks by the case in every display mode.
Under example alarm generating When the rate of
effective load is seen the decimal point of the 4th
figure blinks.
A L 5 2
A 0 3 3
A 1 - -
A L 3 1
J 1 2 0
If <MODE> button is again pushed from diagnostic display mode, the pre-sentalarm code will be displayed to see the contents of alarm history. When thepresent alarm is not generated, it displays
If <UP>button is pushed, the alarm code
of 1 time ago is displayed, and a his-
t ory can be seen before 6 times. As fo
r an alarm history, after a power suppl
y OFF is saved.
(6-6) During operation at the alarm
generating time.
If alarm was happened during operation,
once alarm will be displayed from
every display screen.
A L - -
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
4.3.7 PARAMETER
Digital Servo carries out a digital setup of gain adjustment, offset adjustment of an analog input-and-output signal, etc. which were performed by conventional analog Servo with a parameter. Moreover, the change of a function is performed outside selection in the control mode of a position / speed / torque. The parameter table of MR-J2S type Servo amplifier is shown in the following table. (1) Parameter List (The details of the operation method refer to the section 4.3.8)
The sign of the control mode column expresses the parameter used in each mode. ( S : Position control mode , S: Speed control mode , T: Torque control mode)
Table 4.7 Parameter table
No. Symbol Name Control mode Initial value
Unit Setting Range
0 *STY Control mode, regenerative brake option selection P, S, T 0000 0 ~ 0605h
1 *OP1 Function selection 1 P, S, T 0002 0 ~ 1013h
2 ATU Auto tuning P, S 0105 1 ~ 040Fh
3 CMX Electronic gear numerator p 1 1 ~ 65535
4 CDV Electronic gear denominator P 1 1 ~ 65535
5 INP In-position range P 100 pulse 0 ~ 10000
6 PG1 Position loop gain 1 P 35 rad/s 4 ~ 2000
7 PST Position command acceleration/deceleration time constant
P 3 ms 0 ~ 20000
8 SC1 Internal speed command 1 S 100 r/min 0 ~ max speed
Internal speed command1 T 100 r/min 0 ~ max speed
9 SC2 Internal speed command 2 S 500 r/min 0 ~ max speed
Internal speed command 2 T 500 r/min 0 ~ max speed
10 SC3 Internal speed command 3 S 1000 r/min 0 ~ max speed
Internal speed command 3 T 1000 r/min 0 ~ max speed
11 STA Acceleration time constant S, T 0 ms 0 ~ 20000
12 STB Deceleration time constant S, T 0 ms 0 ~ 20000
13 STC S - pattern acceleration/deceleration time constant
S, T 0 ms 0 ~ 1000
14 TQC Torque command time constant T 0 ms 0 ~ 20000
15 *SNO Station number setting P, S, T 0 station 0 ~ 31
16 *BPS Communication baudrate selection, alarm history clear
P, S, T 0000 0 ~ 1113h
17 MOD Analog monitor output P, S, T 0100 0 ~ 4B4Bh
18 *DMD Status display selection P, S, T 0000 0 ~ 001Fh
19 *BLK Parameter block P, S, T 0000 0 ~ 100Eh
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
The sign of the control mode column expresses the parameter used in each mode. (P: Position control mode, S: Speed control mode , T: Torque control mode)
No. Symbol Name Control mode Initial value Unit Setting Range
20 * OP2 Function selection 2 P, S, T 0000 0 ~ 0111h
21 * OP3 Function selection 3 (Command pulse selection) P 0000 0 ~ 0012h
22 * OP3 Function selection 4 P, S, T 0000 0 ~ 0401h
23 FFC Feed forward gain P 0 % 0 ~ 100
24 ZSP Zero speed P, S, T 50 r/min 0 ~ 10000
25 VCM Analog speed command maximum speed S (Note1) 0 (r/min) 1 ~ 50000
Analog speed limit maximum speed T (Note1) 0 (r/min) 1 ~ 50000
26 TLC Analog torque command maximum output T 100 % 0 ~ 1000
27 *ENR Encoder output pulses P, S, T 4000 pulse 5 ~ 16384
28 TL1 Internal torque limit 1 P, S, T 100 % 0 ~ 100
29 VCO Analog speed command offset S (Note 2) mV -999 ~ 999
Analog speed limit offset T (Note 2) mV -999 ~ 999
30 TLO Analog torque command offset T 0 mV -999 ~999
Analog torque limit offset S 0 mV -999 ~999
31 MO1 Analog monitor ch1 offset P, S, T 0 mV -999 ~999
32 MO2 Analog monitor ch2 offset P, S, T 0 mV -999 ~999
33 MBR Electromagnetic brake sequence output P, S, T 100 ms 0 ~1000
34 GD2 Ratio of load inertia moment to servo motor inertia moment
P, S, T 70 0.1 times 0 ~3000
35 PG2 Position loop gain 2 P 35 rad/s 1 ~ 500
36 VG1 Speed loop gain 1 P,S 177 rad/s 20 ~ 8000
37 VG2 Speed loop gain 2 P,S 817 rad/s 20 ~ 20000
38 VIC Speed integral compensation P,S 48 ms 1 ~ 1000
39 VDC Speed differential compensation P,S 980 0 ~1000
40 For manufacturer setting 0
41 *DIA Input signal automatic ON selection P, S, T 0000 0 ~0111h
42 *DI1 Input signal selection1 P, S, T 0003 0 ~0015h
43 *DI2 Input signal selection2 (CN1B- Pin 5) P, S, T 0111 0 ~0DDDh
44 *DI2 Input signal selection3 (CN1B- Pin 14) P, S, T 0222 0 ~0DDDh
45 *DI2 Input signal selection4 (CN1B- Pin 8) P, S, T 0665 0 ~0DDDh
46 *DI2 Input signal selection5 (CN1B- Pin 7) P, S, T 0770 0 ~0DDDh
47 *DI2 Input signal selection6 (CN1B- Pin 8) P, S, T 0883 0 ~0DDDh
48 *DI2 Input signal selection7 (CN1B- Pin 9) P, S, T 0994 0 ~0DDDh
49 *DI2 output signal selection 1 P, S, T 0000 0 ~0551h
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1
Note) 1. It is the Servo motor rated rotation speed 2. It changes with Servo amplifier. * : It becomes effective by power supply OFF/ON after parameter setting change.
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
The sign of the control mode column expresses the parameter used in each mode. ( P: Position control mode , S: Speed control mode , T, Torque control mode)
No. Symbol Name Control mode Initial Value Unit Setting Range
50 For manufacturer setting 0000
51 * OP6 Function selection 6 P, S, T 0000 0 ~ 0100h
52 For manufacturer setting 0000
53 * OP8 Function selection8 P, S, T 0000 0 ~ 0110h
54 * OP9 Function selection9 P, S, T 0000 0 ~ 1101h
55 * OPA Function selection A P 0000 1 ~ 0010h
56 SIC Serial communication time-out selection P, S, T 0 s 1 ~ 60
57 For manufacturer setting 10
58 NH1 Machine resonance suppression filter1 P, S, T 0000 0 ~ 030Fh
59 HH2 Machine resonance suppression filter2 P, S, T 0300 0 ~ 030Fh
60 LPF Low pass filter, adaptive vibration suppression P, S, T 0000 0 ~ 1210h
61 GB2B Ratio of load inertia moment to servo motor inertia moment 2
P, S 70 0.1 times 0 ~ 3000
62 PG2B Position control gain 2 change ratio P 100 % 10 ~200
63 VG2B Speed control gain 2 change ratio P, S 100 % 10 ~ 200
64 VICB Speed integral compensation changing ratio P, S 100 % 50 ~ 1000
65 *CDP Gain change selection P, S 0000 0 ~ 0604h
66 CDS Gain change condition (note 3) P, S 10 0 ~ 9999
67 CDT Gain changing time constant P, S 1 ms 0 ~ 100
68 For manufacturer setting 0
69 CMX1 Command pulse multiplying factor numerator 2 P 1 0 ~ 65535
70 CMX2 Command pulse multiplying factor numerator 3 P 1 0 ~ 65535
71 CMX3 Command pulse multiplying factor numerator 4 P 1 0 ~ 65535
72 SC4 Internal speed command 4 S, T 200 r/min 0 ~ max speed
73 SC5 Internal speed command 5 S, T 300 r/min 0 ~ max speed
74 SC6 Internal speed command 6 S, T 500 r/min 0 ~ max speed
75 SC7 Internal speed command 7 S, T 800 r/min 0 ~ max speed
76 Tl1 Internal torque limit 2 P, S, T 100 % 0 ~ 100
77 For manufacturer setting 100
78 For manufacturer setting 10000
79 For manufacturer setting 10
80 For manufacturer setting 10
81 For manufacturer setting 100
82 For manufacturer setting 100
83 For manufacturer setting 100
84 For manufacturer setting 0
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2
Note) 1. It is the servomotor rated rotation speed.
2. It changes with Servo amplifier.
3. It is based on a setup of parameter No.65.
* : It becomes effective by power supply OFF/ON after parameter setting change.
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(2) Parameter setting chart
Position control mode
Speed control mode
Torque control mode Remarks
The parameter surely set up or checked before operation.
0, 1 0, 1 0, 1
The parameter surely set up according to machine specification and an operation pattern.
3, 4
The parameter set up if needed. 21 8 ~ 13 14
The parameter set up while carrying out machine operation (adjustment).
2 2
The parameter which makes a setting change of the expansion parameter.
19 19 19
(3) The parameter surely set up or checked before operation
If a setup is wrong, a motor will not move, or the parameter explained here becomes alarm. Please be sure to check
before operation, and when you differ from an initial value, change a setup.
(a) No. 0 ( * STY; Servo type)
Used to select the control mode and regenerative brake option.
Note. Application of a regeneration option. With the following table, please select the regeneration option
corresponding to each Servo amplifier, and set up a parameter.
(Note) Regeneration electric power (W)
Built-in
regeneration resistor
MR-RB032 (40Ω)
MR-RB12 (40 Ω)
MR-RB32 (40 Ω)
MR-RB30 (13 Ω)
MR-RB50 (13 Ω)
MR-J2S-10A Nothing 30
MR-J2S-20A 10 30 100
MR-J2S-40A 10 30 100
MR-J2S-60A 10 30 100
MR-J2S-70A 10 30 100 300
MR-J2S-100A 20 30 100 300
MR-J2S-200A 100 300 500
MR-J2S-350A 100 300 500
Servo ampli-fier
Notes . This value is not the permission electric power of resistance.
(b) No. 1 (* OP1; Function selection 1 )
Used to select the input signal filter, Pin CN1B-19 function and absolute position detection system.
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
Class No. Symbol Name and function Initial value
Unit Setting range
Control mode
Control mode, regenerative brake option selection Used to select the control mode and regenerative brake option.
Select the control mode.0:Position1:Position and speed2:Speed3:Speed and torque4:Torque5:Torque and position
0 0
Selection of regenerative brake option0:Not used1:FR-RC, FR-BU2:MR-RB0323:MR-RB124:MR-RB325:MR-RB306:MR-RB508:MR-RB319:MR-RB51
POINT
Wrong setting may cause the regenerative brake option to burn. If the regenerative brake option selected is not for use with the servo amplifier, parameter error (AL.37) occurs.
0 *STY
0000 Refer to
Name
and
function
column.
P S T
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1 *OP1 Function selection 1 Used to select the input signal filter, pin CN1B-19 function and absolute position detection system.
Input signal filterIf external input signal causes chattering due to noise, etc., input filter is used to suppress it.0:None1:1.777[ms]2:3.555[ms]3:5.333[ms]
CN1B-pin 19's function selection0:Zero Speed detection signal1:Electromagnetic brake interlock signal
Selection of absolute position detection system(Refer to Chapter 15)0: Used in incremental system1: Used in absolute position detection system
0
0002 Refer to
Name
and
function
column.
P S T
(4)The parameter surely set up according to machine specification and an operation pattern if these parameters are wrong in a setup, the amount of movements of machine maybe out the range under a setting value. Please be sure to set up according to specification.
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(a) No. 3, 4 (CMX, CDV ; Electronic gear) The ratio is set up by making parameter No.4 into a denominator, making parameter No. 3 as a numerator. Since the relation between machine specification and a ratio is indicated in detail in the Section 2.5.1.
Class No. Symbol Name and Function Initial value Unit Setting Range
Control Mode
3
4
CMW
CDV
Electronic gear (command pulse magnification molecule) :
The multiplier over a command pulse input is set up.
Command pulse input CMX position command f1 CDV
f2 =f1 *
1 CMX Note. < <500 is the setting range.
50 CDV
A setup of the number of input pulses per servo motor 1
rotation can be changed by the following formula.
(For example, HC-MFS servomotor : 131072pulse/rev )
CMX 131072 * [pulse/rev] CDV
Electronic gear (Command pulse magnification
denominator):
Used to set the electronic gear denominator value
1
1
1 ~ 65535
1 ~ 65535
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CMX CDV
Caution Wrong setting can lead to unexpected fast rotation, causing injury.
!
(5) The parameter set up if needed
(a) Parameter No. 8, 9 10 (SC1, SC2, SC3; Internal speed command 1, 2, 3) Used to set the internal speed command. It is unnecessary when carrying out an analog setup from the outside.
Class No Symbol Name and Function Initial value
unit Setting range
Control mode
8 SC1 Internal speed command 1. The 1st velocity of internal speed instructions is set up.
100 r/min 0 ↓
S
Internal speed command 1. The 1st velocity of internal speed instructions is set up.
Instant permission
rotation speed
T
9 SC2 Internal speed command 2. The 1st velocity of internal speed instructions is set up.
500 r/min 0 ↓
S
Internal speed command 2. The 1st velocity of internal speed instructions is set up.
Instant permission
rotation speed T
10
SC3 Internal speed command 3. The 1st velocity of internal speed instructions is set up.
1000 r/min 0 ↓
S
Internal speed command 3. The 1st velocity of internal speed instructions is set up.
Instant permission
rotation speed T
Basic Param
eter
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(b) Parameter No. 11,12 (STA, STB; Acceleration time constant) Used to set the acceleration time required to reach the rated speed from 0 r/m in response to the analog speed command and internal speed commands 1 to 7. (Contents)
Acceleration time until it reaches rated speed, or slowdown time until it stops from rated speed is set up to speed instructions (exterior and inside 3 speed).
If the preset command speed is lower
than the rated speed, the acceleration/
Deceleration time will be shorter.
time S T B
Parameter No. 12 setting
0 r/min
Rated speed
Speed
S T A Parameter No. 11 setting
Class No
Symbol Name and function Initial value
Unit Setting Range
Control Mode
11
STA Acceleration time constant
Acceleration time until it reaches rated rotation speed from zero speed is set up to analog speed instructions and the internal speed command 1-3.
If the preset command speed is lower
than the rated speed, the acceleration/
Deceleration time will be shorter.
time S T B
Parameter No. 12 setting
0 r/min
Rated speed
Speed
S T A Parameter No. 11 setting
Example:
For the servomotor HC – MFS of 3000r/m rated speed, set 3000 (3S) to increase speed from 0r/m to 1000r/m in 1 second.
0 ms 0 ~ 20000 S, T
12 STB Deceleration time constant
Deceleration time until it reaches zero speed from
rated rotation speed is set up to analog speed
instructions and the internal speed instructions 1-3.
0
Basic Param
eter
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
© Parameter No.13 (STC; S-pattern acceleration/deceleration)
Class No Symbol Name and function Initial value
Unit Setting range
Control mode
13 STC S-pattern acceleration/ deceleration time constant:
Used to smooth start/stop of the servo motor
STA : Acceleration time constant (Parameter No.11) STB : deceleration time constant (Parameter No.12) STC : S-pattern acceleration/deceleration time constant (Parameter No.13)
0 ms 0 ~ 1000 S, T
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Command speed
0r/min
Speed Servomotor
STA STC Time STC
STBSTC STC
>the range of STC if used to set
Long setting may produce an error in the time of the arc part for the setting of the S-pattern acceleration/deceleration constant. The upper limit value of the actual arc part time is limited by (Example) At setting STA=20000, STB=5000, STC=200 During acceleration: = 100[ms] < 200[ms] During deceleration: = 400[ms] > 200[ms]
STA or STB 2,000,000
2,000,000 STA or STB
2,000,000
2,000,00020000
5000
(d) Parameter No. 14 (TQC; Torque command time constant)
Class No. Symbol Name and function Initial value
Unit Setting range
Control mode
14 TQC Torque command time constant Used to set the constant of a low pass filter in response to the torque command.
Torque command
TQC TQC Time
Afterfiltered
TQC: Torque command time constant
Torque
0 ms 0 to
20000
T
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(e) Parameter No. 21 (* OP3: Function selection 3 ) Used to select the input from of the pulse train input signal.
Class No Symbol Name and function Initial value
Unit Setting Range
Control Mode
21 * OP3 Function selection 3 (Command pulse selection) : Used to select the input from of the pulse train input signal
Command pulse train input from 0: Forward/reverse rotation pulse train 1: Signed pulse train 2: A/B phase pulse train
Pulse train logic selection 0: Positive Logic 1: Negative logic
0000 0000 H ~
0012 H
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Pulse train form Waveform of input The input signal of pulse system
Forward rotation Reverse rotation Open collector Differential line drive
Forward rotation pulse train PP - SG PP - PG
Reverse rotation pulse tr in a
(Setting value: 0010) NP - SG NP - NG
Pulse train + sign PP - SG PP - PG
(Setting value: 0011) NP - SG NP - NG
A phase pulse train PP - SG PP - PG
B phase pulse train
(Setting value: 0012) NP - SG NP - NG
Forward rotation pulse train PP - SG PP - PG
Reverse rotation pulse train
(Setting value: 0000) NP - SG NP - NG
Pulse train + sign PP - SG PP - PG
(Setting value: 0001) NP - SG NP - NG
A phase pulse train PP - SG PP - PG
B phase pulse train
(setting value: 0002) NP - SG NP - NG
PP
NP
PP
NP L H
PP
NP
PP
NP
PP
NP H L
PP
NP
Positive logic N
egative logic
0 0
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(6) The parameter set up while operating a machine (adjustment)
(a) Parameter No.2 (* ATU; auto tuning)
Used to set the response level, etc. for execution of auto tuning.
Class No Symbol
Name and function Initial Value
Unit Setting Control mode
2 ATU Auto tuning: Used to set the response level, for execution of auto tuning.
Auto tuning response level setting
* If the machine hunts or generates
large gear sound, decrease the set value.
* To improve performance, e. g. shorten the setting time, increase the set value.
Auto tuning selection
0105 0001H ~
040FH
P, S
Set
value
Response
level
Machine resonance frequency
guideline
1 15Hz 2 20Hz
3 25Hz
4 30Hz
5 35Hz
6 45Hz 7 55Hz 8 70Hz 9 85Hz A 105Hz B 130Hz C 160Hz D 200Hz E 240Hz F
Low response
Middle response
High response
300Hz
Set value Gain adjustment Description 0 Interpolation mode Fixes position control gain (parameter No. 6) 1 Auto tuning mode
1 Ordinary auto tuning.
2 Auto tuning mode 2
Fixes the load inertia moment ratio set in parameter No. 34. Response level setting can be change.
3 Manual mode 1 Simple manual adjustment. 4 Manual mode 2 Manual adjustment of all gain.
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(7) The parameter which makes a setting change of the extended parameter
(a) Parameter No. 19 (* BLK; Parameter Block) Used to select the reference and write ranges of the parameters. If the parameter block after an adjustment end is applied, incorrect operation prevention can be performed. Since only a basic parameter (No.0-- No. 19) can be written in at the time of factory shipments, a setup is required when an extended parameter needs to be set up.
Class No Symbol Name and function Initial Value
Unit Setting range
Control mode
19 *BLK Used to select the reference and write ranges of the parameters.
The reference range and the write-in range of a parameter are chosen.
0000 0000H ~
000CH .
000EH .
100BH .
100CH .
100EH
P, S, T
Basic Param
eter
Set value Reference Write 0000 No. 0 ~ 19 No. 0 ~ 19 000A No. 19 only No. 19 only 000B No. 0 ~ 49 No. 0 ~ 19 000C No. 0 ~ 49 No. 0 ~ 49 000E No. 0 ~ 84 No. 0 ~ 84 100B No. 0 ~ 19 No. 19 only 100C No. 0 ~ 49 No. 19 only 100E No. 0 ~ 84 No. 19 only
[Reference] Parameter package initialization Doing this work changes all parameters to an initial value. Since it becomes impossible to return to the parameter before operation, it is necessary to carry
out after cautions enough. (1) pr.19 are set as "ABCD." (2) Circled Off/on the power supply. (3) Pr. 182 are set as “0112”. (4) If circled OFF/ON the power supply, package conversion of pr.0-pr.84 (foundations and
extended parameter) will be carried out at the value at the time of shipment (Table 4.7). (5) Pr. 19 are set as “0000”.
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
4.3.8 Parameter setting
Initial setting of the parameter value according to the conditions of operation is carried out after a power supply turned on. Since there is a parameter stated by the section 4.3.7, please set up based on design specification.
Please be sure to check about the parameter stated especially by the section 4.3.7(2).
[Operation procedure ] If the <MODE> button is further pushed from alarm mode, basic parameter mode will be displayed.
If a button<UP> is pushed, parameter No. will shift to 19 sequentially from 0 of Table 4.7. If a button<DOWN> is pushed, it will shift conversely.
Please perform the following operation to change the contents of a parameter. (a) <MODE> Display mode is united with parameter mode with this button. ↓
(b) <UP> , <DOWN> It unites with the position of parameter No. to change with this button. ↓
(C) <SET> A button is pushed twice. The setting value of specified parameter No. blinks ↓ (d) <UP> , <DOWN> The setting value under blink can be changed with a button.
↓ (e) <SET> A button is pushed and it decides.
↓ (f) OFF ⇒ ON [ a power supply ]. When a setting change of parameter No.0, 1, 15, 16, 18, and 19 is made, it is surely required refer to the section 4.3.7(1).
The following example shows the operation procedure performed after power-on to change the control mode
(parameter No. 0) to the speed control mode. Using the "MODE" button, show the basic parameter screen.
The set value of the specified parameter number flickers.
UP DOWN
The parameter number is displayed.
Press or to change the number.
Press SET twice.
Press UP once.During flickering, the set value can be changed.
Use or .
Press SET to enter.
( 2: Speed control mode)UP DOWN
To shift to the next parameter, press the UP DOWN/
button. When changing the parameter No. 0 setting, change its set value, then switch power off once and switch it on again to make the new value valid.
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
4.3.9 External I/O signal display
It checks to see the input-and-output signal of Servo amplifier is connected with the operation board, the circumference relay, etc. as the wiring diagram, before beginning operation.
The ON/OFF states of the digital I/O signals connected to the servo amplifier can be confirmed. (1) Operation
Call the display screen shown after power-on. Using the "MODE" button, show the diagnostic screen.
Press UP once.
External I/O signal display screen
(2) Display definition
CN1B7
CN1B9
CN1B8
CN1A14
CN1A8
CN1B4
CN1B18
CN1B14
CN1B5
CN1B17
CN1B16
CN1B19
CN1B6
CN1A19
CN1A18
Lit: ONExtinguished: OFF
Input signals
Output signals
CN1B15
Always lit
The 7-segment LED shown above indicates ON/OFF. Each segment at top indicates the input signal and each segment at bottom indicates the output signal. The signals corresponding to the pins in the respective control modes are indicated below:
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(a) Control modes and I/O signals
(Note 2) Symbols of I/O signals in control modes Connector Pin No.
Signal input/output (Note 1) I/O P P/S S S/T T T/P
Related parameter
8 I CR CR/SP1 SP1 SP1 SP1 SP1/CR No.43 to 48 14 O OP OP OP OP OP OP 18 O INP INP/SA SA SA/ /INP No.49
CN1A
19 O RD RD RD RD RD RD No.49 (Note 3) 4 O DO1 DO1 DO1 DO1 DO1 DO1
5 I SON SON SON SON SON SON No.43 to 48 6 O TLC TLC TLC TLC/VLC VLC VLC/TLC No.49 7 I LOP SP2 LOP SP2 LOP No.43 to 48 8 I PC PC/ST1 ST1 ST1/RS2 RS2 RS2/PC No.43 to 48 9 I TL TL/ST2 ST2 ST2/RS1 RS1 RS1/TL No.43 to 48
14 I RES RES RES RES RES RES No.43 to 48 15 I EMG EMG EMG EMG EMG EMG 16 I LSP LSP LSP LSP/ /LSP 17 I LSN LSN LSN LSN/ /LSN 18 O ALM ALM ALM ALM ALM ALM No.49
CN1B
19 O ZSP ZSP ZSP ZSP ZSP ZSP No.1 49
Note: 1. I: Input signal, O: Output signal 2. P: Position control mode, S: Speed control mode, T: Torque control mode, P/S: Position/speed control change mode, S/T: Speed/torque
control change mode, T/P: Torque/position control change mode 3. The signal of CN1A-18 is always output.
(b) Symbol and signal names
Symbol Signal name Symbol Signal name
SON Servo-on EMG Emergency stop LSP Forward rotation stroke end LOP Control change LSN Reverse rotation stroke end TLC Limiting torque CR Clear VLC Limiting speed SP1 Speed selection 1 RD Ready SP2 Speed selection 2 ZSP Zero speed PC Proportion control INP In position ST1 Forward rotation start SA Speed reached ST2 Reverse rotation start ALM Trouble RS1 Forward rotation selection WNG Warning RS2 Reverse rotation selection OP Encoder Z-phase pulse (open collector) TL Torque limit BWNG Battery warning RES Reset
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(3) Default signal indications (a) Position control mode
Lit: ONExtinguished:OFF
Input signals
Output signals
TL (CN 1 B-9) Torque limitPC (CN 1 B-8) Proportional control
CR (CN 1 A-8) ClearRES (CN 1 B-14) Reset
SON(CN 1 B-5) Servo-onLSN (CN 1 B-17) Reverse rotation stroke end
LSP (CN 1 B-16) Forward rotation stroke end
RD (CN 1 A-19) ReadyLNP (CN 1 A-18) In position
ZSP (CN 1 B-19) Zero speedTLC (CN 1 B-6) Limiting torque
DO1 (CN 1 B-4) In positionALM (CN 1 B-18) Trouble
OP (CN 1 A-14) Encoder Z-phase pulse
EMG(CN 1 B-15) Emergency stop
(b) Speed control mode
SP1 (CN 1 A-8) Speed selection 1RES (CN 1 B-14) Reset
SON (CN 1 B-5) Servo-onLSN (CN 1 B-17) External emergency stop
LSP (CN 1 B-16) Forward rotation stroke endLit: ONExtinguished: OFF
RD (CN 1 A-19) ReadySA (CN 1 A-18) Limiting speed
ZSP (CN 1 B-19) Zero speedTLC (CN 1 B-6) Limiting torque
DO1 (CN 1 B-4) Limiting speedALM (CN 1 B-18) Trouble
OP (CN 1 A-14) Encoder Z-phase pulse
Input signals
Output signals
SP2 (CN 1 B-7) Speed selection 2ST1 (CN 1 B-8) For ward rotation start
ST2 (CN 1 B-9) Reverse rotation startEMG(CN 1 B-15) Emergency stop
(c) Torque control mode
RS1 (CN 1 B-9) Forward rotation selectionRS2 (CN 1 B-8) Reverse rotation selection
SP2 (CN 1 B-7) Speed selection 2SP1 (CN 1 A-8) Speed selection 1
RES (CN 1 B-14) ResetSON (CN 1 B-5) Servo-on
Lit: ONExtinguished: OFF
RD (CN 1 A-19) ReadyZSP (CN 1 B-19) Zero speed
VLC (CN 1 B-6) Speed reachedALM (CN 1 B-18) Trouble
Input signals
Output signals
OP (CN 1 A-14) Encoder Z-phase pulse
EMG(CN 1 B-15) Emergency stop
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
4.3.10 Manual operation
Perform manual operation by using the machine operation board and check the machine status and signal such as the stroke end, etc. Carry out troubleshooting and corrections if necessary. Pay special attention to the following points during the checked.
(1) Give a low speed command to the motor and check the direction of rotation, sound,
and vibration of the motor itself; (2) Check the machine operation, paying attention to smoothness of travel,
directions of travel, looseness and abnormal sound. (3) Check the motor sound; (4) Check that the machine speed matches the set speed; (5) Check if the stoke end signals are issued correctly. Check if there are any
collisions between machine parts; (6) Check if the machine operations follow the I/O signals issued from the operation
panel correctly; (7) Check tightened parts for losseness. (8) Check the connecting cables between moving parts for insufficient or excessive
length.
* Refer to the Manul for practicing with a Training Machine for details on operations with a training machine.
4.3.11 Home Position Return After checking the machine operations by performing manul operation, execute a home position return and align the machine home position with the home position for the positioning control unit. * Refer to the Manul for practicing with a Training Machine for details on operations with a training machine.
4.3.12 Automatic Operation
Perform manual operation with a positioning program prepared for testing purposed. Check if the operations follow the program. After checking, perform continuous operation and check the load factor and machine movement.
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
4.3.13 Test operation mode
Motor operation without wiring to the command unit, simulated operation with the command unit and the servo amplifier but no motor, are both possible using the display of the servo amplifier. (1) Test operation I: Run the motor without commands and check the machine operations; (2) Test operation II: Input commands to the servo amplifier with no motor connected so that
monitoring is executed as if the motor were rotating. This test allows checking of the electrical system and program.
CAUTION
The test operation mode is designed to confirm servo operation and not to confirm machine operation. In this mode, do not use the servo motor with the machine. Always use the servo motor alone. If any operational fault has occurred, stop operation using the forced stop (EMG) signal.
POINT
The test operation mode cannot be used in the absolute position detection system. Use it after choosing "Incremental system" in parameter No. 1. The servo configuration software is required to perform positioning operation. Test operation cannot be performed if the servo-on (SON) signal is not turned OFF.
(1) Mode change
Call the display screen shown after power-on. Choose jog operation/motor-less operation in the following procedure. Using the "MODE" button, show the diagnostic screen.
When this screen appears, jog feed can be performed.
Press UP three times.
Press SET for morethan 2s.
Flickers in the test operation mode.
Press UP five times.
Press SET for more than 2s.
When this screen is displayed, motor-less operation can be performed.
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(2) Jog operation
Jog operation can be performed when there is no command from the external command device.
(a) Operation Connect EMG-SG to start jog operation and connect VDD-COM to use the internal power supply. Hold down the "UP" or "DOWN" button to run the servo motor. Release it to stop. When using the servo configuration software, you can change the operation conditions. The initial conditions and setting ranges for operation are listed below:
Item Initial setting Setting range
Speed [r/min] 200 0 to instantaneous permissible speed Acceleration/deceleration time constant [ms] 1000 0 to 50000
How to use the buttons is explained below:
Button Description
"UP" Press to start CCW rotation. Release to stop.
"DOWN" Press to start CW rotation. Release to stop.
If the communication cable is disconnected during jog operation performed by using the servo configuration software, the servo motor will be decelerated to a stop.
(b) Status display You can confirm the servo status during jog operation. Pressing the "MODE" button in the jog operation-ready status calls the status display screen. With this screen being shown, perform jog operation with the "UP" or "DOWN" button. Every time you press the "MODE" button, the next status display screen appears, and on completion of a screen cycle, pressing that button returns to the jog operation-ready status screen. For full information of the status display, refer to Section 4.4.2. In the test operation mode, you cannot use the "UP" and "DOWN" buttons to change the status display screen from one to another.
(c) Termination of jog operation
To end the jog operation, switch power off once or press the "MODE" button to switch to the next screen and then hold down the "SET" button for 2 or more seconds.
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(3) Positioning operation
POINT
The servo configuration software is required to perform positioning operation.
Positioning operation can be performed once when there is no command from the external command device.
(a) Operation Connect EMG-SG to start positioning operation and connect VDD-COM to use the internal power supply. Pressing the "Forward" or "Reverse" button on the servo configuration software starts the servo motor, which will then stop after moving the preset travel distance. You can change the operation conditions on the servo configuration software. The initial conditions and setting ranges for operation are listed below:
Item Initial setting Setting range
Travel distance [pulse] 10000 0 to 9999999 Speed [r/min] 200 0 to instantaneous permissible speed Acceleration/deceleration time constant [ms] 1000 0 to 50000
How to use the keys is explained below:
Key Description
"Forward" Press to start positioning operation CCW. "Reverse" Press to start positioning operation CW.
"Pause"
Press during operation to make a temporary stop. Pressing the "Pause" button again erases the remaining distance. To resume operation, press the button that was pressed to start the operation.
If the communication cable is disconnected during positioning operation, the servo motor will come to a sudden stop.
(b) Status display You can monitor the status display even during positioning operation.
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(4) Motor-less operation
Without connecting the servomotor, you can provide output signals or monitor the status display as if the servo motor is running in response to external input signals. This operation can be used to check the sequence of a host programmable controller or the like. (a) Operation
After turning off the signal across SON-SG, choose motor-less operation. After that, perform external operation as in ordinary operation.
(b) Status display You can confirm the servo status during motor-less operation. Pressing the "MODE" button in the motor-less operation-ready status calls the status display screen. With this screen being shown, perform motor-less operation. Every time you press the "MODE" button, the next status display screen appears, and on completion of a screen cycle, pressing that button returns to the motor-less operation-ready status screen. For full information of the status display, refer to Section 4.3.8. In the test operation mode, you cannot use the "UP" and "DOWN" buttons to change the status display screen from one to another.
(c) Termination of motor-less operation To terminate the motor-less operation, switch power off.
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
4.3.14 The operation procedure in each operation mode (conclusion) (1) Position control mode
Please separate a machine from a servo motor, and connect with a machine after checking operating normally.
P o w e r o n (a) The Servo-On signal (SON) is turned off.
(b) After switches on power supply (NFB), displaying data that "C (return pulse accumulation)" is displayed after 2 seconds on a display part.
Please check that a servomotor operates using JOG operation in test operation mode. (Refer to section 4.3.13(1)) Parameter is set up according to the composition and specification of a machine. (Refer to section 4.3.8) * example
If a Servo on signal (SON) is turned on, it will be in the state which can be operated and a servo motor axis will lock. (Servo lock state) When not carrying out a Servo lock, it is not in the Servo on state. Please check an external sequence by diagnostic display. • If a pulse sequence is inputted from positioning, a servo motor will rotate.
Please check the rotation direction etc. in the beginning at a low speed. Please check an incoming signal, when you do not move in the direction to mean.
• Please check the rotation speed, the command pulse frequency, the rate of load of the servo motor by state display.
• If the check of a machine of operation finishes, automatic operation will be checked by the program of positioning controller.
• This Servo amplifier contains the real-time auto tuning function by model adaptive control. Execution of operation adjusts a gain automatically. The optimal tuning result can be obtained by the thing that suited the machine by parameter No.2 and to do for a response setup.
If the following operations are performed, operation will be interrupted and it will stop. (a) Servo on signal OFF ... Becoming base interception, a servomotor carries
out a free run stop. (b) A stroke end signal ....... The sudden stop of the servomotor is carried o
ut, and it carries out a Servo lock. It can operate to an opposite direction. (c) Alarm generating .....If alarm is generated, it will become base interception,
and the dynamic brake will operate and carry out the sudden stop of the servomotor.
(d) Emergency stop OFF (EMG) .... It becomes base interception, and dynamic brake operates and carries out the sudden stop of the servo motor. AL E6 occurs.
S t o p
Parameter Setting value content Automatic setup Servo amplifier : MR-J2S-40A Automatic setup Servo motor : HC-MFS43
No.0
0 3 0 0 Select the control mode: Position Selection of regenerative brake option: MR-RB12
No.1
0 0 0 2 Input signal filter : 3.555ms Electromagnetism brake interlock signal: -- it is not used Selection of position detection system --- Incremental system
No.2
0 1 0 1 Auto tuning response level setting: Low response Auto tuning selection.
No.3 2 No.4 1
Electronic gear (CMX/CDV ) : 2/1
P o w e r O n
Command pulse input
S e r v o O n
P a r a m e t e r s e t u p
T e s t o p e r a t i o n
MODE
SON ON
Servo on state
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(2) Speed control mode Please separate a machine from a servomotor, and connect with a machine after checking operating normally.
P o w e r O n (a) The Servo-On signal (SON) is turned off. (b) After switches on the power supply (NFB), displaying data that "C (return
pulse accumulation)" is displayed after 2 seconds on a display part. Please check that a servomotor operates using JOG operation in test operation mode. (Refer to section 4.3.13(1)) Parameter is set up according to the composition and specification of machine. (Refer to section 4.3.8) • Example
If a Servo on signal (SON) is turned on, it will be in the state which can be operated and a servo motor axis will lock. (Servo lock state) When not carrying out a Servo lock, it is not in the Servo on state. Please check an external sequence by diagnostic display. • Servo motor rotation speed is chosen by speed selection 1 (SP1) and the
speed selection 2 (SP2). If forward rotation start (ST1) is turned on and the forward rotation(CCW) direction and inversion starting (ST2) will be turned ON, it will rotate in the inversion (CW) direction. Please set rotation speed as a low speed and check the rotation direction in the beginning. Please check an incoming signal, when you do not move in the direction to mean.
• Please check the servomotor rotation speed, the rate of load, etc. • If the check of a machine of operation finishes, automatic operation will b
e checked with the control device of a higher rank etc. • This Servo amplifier contains the real-time auto tuning function by model
adaptive control. Execution of operation adjusts a gain automatically. The optimal tuning result can be obtained by the thing that suited the machine by parameter No.2 and to do for a response setup.
If the following operations are performed, operation will be interrupted and it will stop. (a) Servo on signal OFF ... Becoming base interception, the servomotor carries
out a free run stop. (b) A stroke end signal ....... The sudden stop of the servomotor is carried o
ut, and it carries out a Servo lock. It can operate to an opposite direction. (c) Alarm generating ....If alarm is generated, it will become base interception,
and a dynamic brake will operate and carry out the sudden stop of the servomotor.
(d) Emergency stop OFF (EMG) .... It becomes base interception, and dynamic brake operates and carries out the sudden stop of the servo motor. The ALE6 occurs.
Parameter Setting value Contents Automatic setup Servo Amplifier :MR-J2S-40A Automatic setup Servomotor :HC-MFS43
No.0
0 0 0 2 Select the control mode : Speed Selection of regenerative brake option: no use
No.1
0 0 1 2 Input signal filter : 3.555ms Electromagnetism brake interlock signal: it is used
No.2
0 1 0 5 Auto tuning response level setting: Middle response Auto tuning selection: Auto tuning mode 1
No.8 1000 Internal speed command 1 : 1000r/min No.9 1500 Internal speed command 1 : 1500r/min
No.10 2000 Internal speed command 1 : 2000r/min No.11 1000 Acceleration time constant : 1s No.12 500 Deceleration time constant : 0.5s No.13 0 S-pattern acceleration/deceleration time constant: 0 S
S t o p
S t a r t
S e r v o O n
Parameter setup
Test operation
P o w e r O n
MODE
SON ON
Servo on state
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
(3) Torque control mode Please separate a machine from a servomotor, and connect with a machine after checking operating normally.
P o w e r O n
(a) The Servo-On signal (SON) is turned off. (b) After switches on power supply (NFB), displaying data that "C (return
pulse accumulation)" is displayed after 2 seconds on a display part. Please check that a servomotor operates using JOG operation in test operation mode. (Refer to section 4.3.13(1)) Parameter is set up according to the composition and specification of the machine. (Refer to section 4.3.8)
Example
If a Servo on signal (SON) is turned on, it will be in the state which can be operated and a servo motor axis will lock. (Servo lock state) When not carrying out a Servo lock, it is not in the Servo on state. Please check an external sequence by diagnostic display.
• Servo motor rotation speed is chosen by speed selection 1 (SP1) and the speed selection 2 (SP2). If forward rotation start (RS1) is turned on and the forward rotation (CCW) direction and inversion starting (RS2) will be turned ON, it will rotate in the inversion(CW) direction. Please set rotation speed as a low speed and check the rotation direction in the beginning. Please check an incoming signal, when you do not move in the direction to mean.
• Please check the servomotor rotation speed, the rate of load, etc. by state display.
• If the check of a machine of operation finishes, automatic operation will be checked with the control device of a higher rank etc.
If the following operations are performed, operation will be interrupted and it will stop. (a) Servo on signal OFF ... Becoming base interception, a servomotor carries
out a free run stop. (b)Alarm generating .....If alarm is generated, it will become base interception,
and a dynamic brake will operate and carry out the sudden stop of the servomotor.
(c) Emergency stop OFF (EMG) ....It becomes base interception, and dynamic brake operates and carries out the sudden stop of the servo motor. The AL E6 occurs.
(d) Simultaneous ON or the simultaneous off-servo motor of a forward rota-tion start (RS1) signal and an inversion selection (RS2) signal becomes a free run.
Parameter Setting value Contents Automatic setup Servo Amplifier : MR-J2S-40A Automatic setup Servomotor : HC-MFS43
No.0
0 0 0 4 Select the control mode : Torque Selection of regenerative brake option: no use.
No.1
0 0 0 2 Input signal filter : 3.555ms Electromagnetism brake interlock signal: it is used
No.8 1000 Internal speed command 1 : 1000r/min No.9 1500 Internal speed command 2 : 1500r/min No.10 2000 Internal speed command 3 : 2000r/min No.11 1000 Acceleration time constant : 1s No.12 500 Deceleration time constant : 0.5s No.13 0 S-pattern acceleration/deceleration time constant: 0 S No.14 2000 Torque command time constant : 2s No.28 50 Internal torque limit 1 : Restrict to 50% of output.
S t o p
S t a r t
S e r v o O n
Parameter setup
Test operation
P o w e r O n
MODE
SON ON
Servo lock state
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
4.3.15 A function convenient for starting and diagnosis
Also besides the Section 4.3.9 "an external input-and-output signal check" and the section 4.3.13 "test operation", MR-J2S-A Servo amplifier rose and has arranged the function convenient to diagnose. The main item is listed below.
(1) Auto tuning .... According to the inertia moment of load, a Servo gain is adjusted
automatically. According to the conditions of a machine, the low, middle and high response can be chosen into quantity.
(2) VC automatic offset .... Offset of analog incoming signals, such as speed instructions, is rectified automatically.
(3) Reason display for a stop .... The factor is expressed with the segment of a display part when the motor has stopped. It is convenient for troubleshooting.
(4) DO forcible output .... The forcible output of the digital output signal of amplifier is carried out. Since the check of an external relay, a lamp, etc. is made to convenient.
(5) Machine simulation ..... Based on a machine analyzer's result, the simulation of the motion of a machine can be carried out on the screen of a personal computer.
(6) Gain search function .... A personal computer is automatic set gain that does not have an exaggerated shot for a short time is discovered while changing a gain.
(Note) Setup S/W is needed when performing a machine simulation and a gain search function.
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4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS
Memo
4-66
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
5.1 Basic Performance and Function As shown in the following figure, MR-H-N series Servo amplifier has come to be able to do all of connection with external apparatus, and a monitor from the front of amplifier, and can do those work easily also in the state of wearing in a board. As an input-and-output signal connected with an operation board, it is together put by a terminal stand and connectors CN1 and CN3 (only for monitor outputs). The converter unit is needed for 3 phase AC400V class mass type [ 30-55kW ].
C N
4
Servo Configuration Software
Personal Computor
+
Parameter Unit
Or
Programmable controller
Junction terminal Block MR-TB50
(note 2) Power supply3- phase AC, 200~230 V
No-fuse Breaker (NFB) or fuse
Magnetic contactor (MC)
Regenerative brake option Servo Amplifier
MR-H AN Analog Meter
To CN3
To CN4
To CN1 To CN2
(Note1)MR-HCN2
W V U
P
C
N
R
S
T
R1
S1
U
V
W
Ground
Servomotor
Note 1, Required when using the HC-MF, HA-FF OR HC-UF 3000 rpm servomotor 2. Depends on the servo amplifier capacity.
CHARGE
CN3
CN4
CN1 CN2
The parameterunit or Servo Configuration software is required for parameter setting
5-1
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
The composition of 3 phase AC400V class mass type [ 30-55kW ]
No-fuse Breaker (NFB)
Converter unit( MR-HP55KA4 )
Servo Amplifier
3 phase AC 380 – 460V
No-fuse Breaker (NFB)
Magnetic contactor
(MC)
Line noise Filter ( FR-BLF )
R S T
Servomotor HA-LF series
Regenerative breaker ( MR-RB -4 )
(note 2)
Power update DC Reactor( MR-DCL K-4 )
(Control circuit)
Servo configurationSoftware
Personal computer
+
Parameter unit
OR
CN4
(MR-H AN4 )
( MR-HSCBL M )
(MR-J2HBUSM)
The parameter unit or Servo Configuration software is required For parameter setting.
Note 1. The converter unit that connect with Servo amplifier are standard accessories.
2. The above-mentioned example of connection is the case of MR-RB 136-4. In MR-RB 138-4, it is in three sets (parallel connection).
3. The converter unit is required for this system.
5-2
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
5.2 Parameter functions
A parameter is the function to prescribe the operation conditions of Servo that the section 4.3.7 that described beforehand, in the case of MR-H-N series, consists of a user parameter (No.00-No.19) and
an extended parameter (No.20-No.64).
(1) Parameter setting table
Position control
Speed control
Torque control
Remarks
The parameter surely set up or checked
before operation. 0, 1, 2, 0, 1, 2, 0, 1, 2, 1. There are parameters other
than the following and an item
which carries out a setting
check according to an operating
condition.
The parameter surely set up according to
machine specification and an operation
pattern.
4, 5
The parameter set up if needed. 21 9~ 14 15 2. After setting the parameter
The parameter set up while operating a
machine (adjustment). 20 20
No. 19 value, switch power
off, then on to make that
When a setting change of the extended
parameter is made
19 19 setting valid .
5-3
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
(2) The parameter surely set up or checked before operation If a setup is wrong, a motor will not move, or the parameter explained here becomes alarm. Please be sure to check before operation, and when you differ from an initial value, change the setup.
(a) No. 00 (M*MSR ; Motor series)
Used to choose the servo motor series.
Class. No. Code Name and Function Control
Mode
Initial
Value
Unit Setting
Range
1 *MSR Motor series Used to choose the servo motor series. When using the HC-MF,HA-FF, HC-SF, HC-RF, HC-UF series servomotor, this parameter need not be set since it is automatically judged by merely connecting the motor encoder and servo amplifier. At this time, this parameter is changed but may be used as it is.
P S T
_
0000 ~
0003 ~
0005
Bas
ic P
aram
eter
(b) No. 01 (MTY; Motor Type) The rating of the motor to operate is set up. The rated output and rated rotation speed of the motor are set up in four digits.
Classif
ication
No
.
Code Name and Function Control
Mode
Initial
Value
Unit Setting
Range
1 *MTY Motor series: Used to set the parameter(servomotor capacity) according to the motor used. The servomotor and servo amplifier to be set should be any of their combinations having the parameter in the table. When using the HC-MF,HA-FF, HC-SF, HC-RF, HC-UF series servomotor, this parameter need not be set since it is automatically judged by merely connecting the motor encoder and servo amplifier. At this time, this parameter is changed but may be used as it is.
Rated speed (Unit: 1000r/min)
Rated output (Unit: 100 W)
P S T
Setting Servomotor series
0000 HA -- SH
0001 HA -- LH
0002 HA -- UH
0003 HA -- FH
0005 HA -- MH
Servo amplifier MR-HN
Servomotor Capa.
(W)
10 20 40 60 100 200 350 500 700 11K 15K 22K
HA-MH053 50 053
HA-MH13 100 13
HA-UH152 1500 152
HA-UH222 2200 222
HA-UH352 3500 352
HA-UH452 4500 452
! Caution Servo amplifier and servomotor cannot be set up other than the combination in which the parameter setting value of a top table exists. It becomes the cause of a fire.
It ca
lls a
t a
left
tabl
e.
It ca
lls a
t a
left
tabl
e.
B
asic
Par
amet
er
5-4
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
(c) No. 02 (*STY; Servo Type) used to choose the control mode and the regenerative brake option.
Class. No. Code Name and Function Control mode
Initial value
Unit Setting range
2 *
STY
Servo type: Used to choose the control mode and regenerative brake option
Control mode selection 0. Position 1. Position and speed 2. Speed
3. Speed and torque 4. Torque 5. Torque and position Position : Pulse train Speed : The analog, internal 3 speed, and internal 7 speed. Torque : The analog.
Select the regenerative brake option. 0. Set 0 when the servo amplifier of less than 11kW capacity has
no external option or when the servo amplifier of 11kW or more uses the supplied regenerative brake resistor.
1. FR-RC, FR-BU brake unit 2. MR-RB013 3. MR-RB033 5. MR-RB32
6. MR-RB34 7. MR-RB54 8. MR-RB30 9. MR-RB50 B. MR-RB31 C. MR-RB51
E. When the servo amplifier is 11kW or more and the supplier regenerative brake resistor is cooled by a fan to improve its capacity.
0001 0000 ~
0E05h 0 0
Bas
ic P
aram
eter
With the following table, please select the regeneration option corresponding to each Servo amplifier, and set up a parameter.
Built-in External Regeneration option (W) (note 2)
Servo amplifier model
Brake( w )
Regenerative brake resistor
( W ) (Accessories)
MR- RB013
MR- RB033
MR- RB30
MR- RB31
MR- RB32
MR- RB34
(Note 1) MR-RB50
(Note 1) MR-RB51
(Note 1) MR-RB54
Special option ( W )
MR-H10AN, MR-H20AN - - 10 30 - - - - - - - -
MR-H40AN, MR-H60AN
50 - - - - - 300 - - - - -
MR-H100AN 80 - - - - - 300 - - - - -
MR-H200AN 80 - - - - - - 300 - - 500 -
MR-H350AN, MR-H500AN
130 - - - 300 - - - 500 - - -
MR-H700AN 170 - - - - 300 - - - 500 - -
MR-H11KAN - 500 - - - - - - - - - 800
MR-H15KAN, MR-H22KAN - 850 - - - - - - - - - 1300
Note 1.Please install a cooling fan; 2.It corresponds by change of parameter No.2, and resistor cooling fan installation.
5-5
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
(3) The parameter must be set up according to machine specification and an operation pattern If the parameter dealt with here is not setup correctly, the actual distance moved by the moving part will not be those specified by the values set. It is therefore essential to set these parameters in accordance with the specifications.
(a) No. 4, 5 (CMX, CDV; Electronic gear) required only at the time of position Servo.
The setting for Parameter No. 4 is the numerator of the ratio and No. 5 is its denominator.
Since the relation between machine specification and a ratio is indicated in detail refer to section 2.5.1.
Class No Code Name and Function Control
mode
Initial
value
Unit Setting
Range
4 CMX Command pulse magnification (numerator) : Set the multiplier for the command pulse input.
Command pulse input CMX Position command fc CDV
fc1 = fc 1 CMX
Note. < <50(set the value within this range) 50 CDV
For the setting, refer to Section 2.5.1 command pulse magnification can be switched with an external signal. (Refer to the parameter No.24)
P 1 1 ~
50000
5 CDV Electronic gear denominator.
P 1 1 ~
50000
CMX CDV
Bas
ic P
aram
eter
(4) The parameter set up if needed
(a) No. 9, 10, 11 (Internal speed command 1 – 3)
Used to set internal speed command. It is unnecessary when carrying out an analog setup from the outside.
Class No Code Name and function Control
mode
Initial
setting
Unit Setting
Range
9 SC1 Internal speed 1:
Used to set speed 1 of the internal speed command
S, T 100.0 r/min 0 ~ max. speed
10 SC2 Internal speed 2:
Used to set speed 2 of the internal speed command S, T 500.0 r/min 0 ~
max. speed
11 SC3 Internal speed 3:
Used to set speed 3 of the internal speed command
S, T 1000.0 r/min 0~ max. speed
Bas
ic P
aram
eter
5-6
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
(b) No. 12, No. 13 (STA, STB; Acceleration/deceleration time constant)
Acceleration time and slowdown time are set up according to an operation pattern. It is effective also to external analog instructions. Acceleration time until it reaches rated speed, or slowdown time until it stops from rated speed is set up to speed command (external and internal 3 speed).
Class No. Code Name and Function Control Mode Initial
value Unit
Setting Range
12 STA Acceleration time constant: This Parameter is used to set the acceleration time until the rated speed is reached from 0 rpm.
S 0 ms 0 ~ 50000
13 STB Deceleration time constant: This Parameter is used to set the deceleration time until the zero speed is reached from the rated speed.
S 0 ms 0 ~ 50000
Bas
ic p
aram
eter
If set command speed is lower than rated speed, acceleration/deceleration time will be shorter.
Time STB Setting value
0 r/min
Rated speed
Speed
STA Setting value
(c) STC; (Parameter No. 14; S-pattern acceleration/deceleration time constant)
Class No. Code Name and Function Control
Mode Initial
Value
Unit Setting
Range
14 STC S-pattern acceleration/deceleration time constant. Used to smooth the start/stop of the servomotor. When a constant is enlarged at the time of acceleration and
a slowdown, the time of a circle portion may stop suiting a setting value.
S 0 ms 0 ~ 5000
Bas
ic p
aram
eter
(d) No. 21 (* OP2; Function selection 3)
Pulse sequence input I/F at the time of position Servo operation is set up. Moreover, a low noise function is also chosen.
5-7
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
Class No Code Name and Function Control
mode Initial
setting
Unit Setting
Range
21 *OP2 Function selection 3:
Used to select the option function.
Low acoustic noise mode selection
0: non-low acoustic noise
3: low acoustic noise
Note: By choosing the low acoustic noise mode,
electromagnetic sound generated by the
servomotor can be reduced by about 20dB
Command pulse input form
0: forward, reverse rotation pulse train
1: signed pulse train
2: A/B- phase pulse
Command pulse logic selection
0: Positive logic
1: Negative logic
0000 ms 0000 ~ 0123h
Extension Parameter
0
5-8
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
(5) The parameter set up while operating a machine (adjustment)
(a) No. 20 (Function selection 2) Used to select automatic restart after instantaneous power failure and servo lock in the auto tuning/speed control mode.
Class No. Code Name and Function Control Mode Initial
Value Unit
Setting Range
20 OP1 Function selection 2: Used to choose automatic restart after instantaneous power failure and
servo lock in the auto tuning/speed control mode.
Auto tuning selection 0: auto tuning selected for use of interpolation axis
control, etc, in position control (valid) 1: auto tuning for ordinary operation(valid) 2: No auto tuning (Invalid)
Auto-restart after instantaneous power failure ( speed control Mode) Restart can be made without an alarm (AL 10) stop when power is restored after instantaneous power failure. 0: Invalid 1: valid
Response setting (When auto tuning is valid) Optimum response can be selected according to the rigidity of the machine. As the machine has higher rigidity, faster response can be set to improve tracking performance in response to a command and to reduce setting time.
Note) When changing the value, always increase the setting from lower to higher response levels while simultaneously checking the vibration and setting of servo motor and machine immediately before a stop and during a stop. Speed control servo lock selection. 0: Valid 1: Invalid
Note) When the function is made valid, the servomotor shaft attempts to
return to the original position if it is turned by external force.
When this function is invalid, counterforce matching the external
force is produce but the shaft does not return to the original position.
P, S 0001 0000 ~ 1C12
0
Ex
tens
ion
Para
met
er
Machine Description Guideline of position setting time
Type Set value
Response Guide of corres
ponding rigidity
GDL2/GDM2
Guideline of load inertia(GDL2/GDM2
= within 5 times)
Initial 0 Low Low to high 1 ~ 5 times -
Ordinary
1 2 3 4 5
Low
Middle
High
Low rigidity
~ Medium rigidity
~ High rigidity
50 ~ 300ms
10 ~ 70ms
10 ~ 30ms
Large friction
8 9 A B C
Low
Middle
High
Low rigidity
~ Medium rigidity
~ High rigidity
70 ~ 400ms
10 ~ 100ms
10 ~ 50ms
1 ~ 10 times
5-9
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
(6) The Parameter you are recommended to set under some operating conditions (a) No. 19 (*BLK; Parameter block)
Used to restrict the reference and write ranges of parameters. By executing a parameter block operation after completing adjustment, the system can be protected against incorrect operations. Only the basic parameter (No. 00 to No. 19) can be written in the factory-set condition. Parameter No. 19 has to be set in order to set expansion parameters.
Class No Code Name and Function Control
mode Initial
setting
Unit Setting
Range
19 *BLK
Parameter write disable
Used to limit parameter write.
0000 0000 ~
000E
Basic Param
eter
Setting Referred Parameter Written Parameter
0000 Basic parameter Basic parameter
000A Parameter No.19 Parameter No.19
000C Basic parameter +
expansion parameter
Basic parameter
000E Basic parameter +
expansion parameter
Basic parameter +
expansion parameter
<Reference> Parameter package initialization Doing this work changes all parameters to an initial value. Since it becomes impossible to return to the parameter before operation, it is necessary to carry out after cautions enough. 1) pr.19 are set as "ABCD." 2) turn off power supply and on again 3) pr.85 are set as "0001." 4) If OFF/ON the power supply, package conversion of pr.0-pr.79 (basic and extended
parameter) will be carried out at the initial value (Table 5.1). 5) pr.19 are returned to the original value "0000." Cautions: Since pr.0-pr.3 is initialized, please re-set it as the motor and Servo type that surely correspond.
5-10
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
(7) Converter unit Parameter of MR-HP55kA4
No. Code Name and Function Initial
setting
Unit Setting
Range
0 *STY Control mode and regeneration option selection Control mode and a regeneration option are chosen. 0 0 0 Selection of a regeneration option 0: It is not used. 1: MR-RB136-4 2: MR-RB128-4 (3 No.s)
0000 0000h
~
0002h
1 *MCC Machine maker setup 0000
2 *D01 Machine maker setup 0000
3 MOD Machine maker setup 0001
4 *DMD State display selection
The state display displayed at the time of a power supply turn on is chosen.
0 0 0 The converter unit at the time of a power supply up The state display of a display part 0: Bus voltage(initial value) 1: The rate of effective load 2: The rate of peak load 3: The rate of regeneration load
0000 0000h
~
0003h
5 *ACL Alarm history clearance
An alarm history clearance is chosen.
0 0 0
Alarm history clearance 0: Invalid (it does not clear) 1: Valid (it clears)
When an alarm history clearance is confirmed, it is rear to clear about an alarm history next time at the time of a power supply turned on. It automatically invalid after an alarm history clearance if it is set to (0)
6 Spare
7 Spare
8 Spare
9 *BLK For a machine maker setup 0000
* . It becomes effective by power supply OFF->ON after parameter setting change.
5-11
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
5.3 Display and Diagnosis Functions
5.3.1 MR—PRU01A Parameter Unit This unit has an LCD (13 characters X 4 lines) used for condition display and alarm diagnosis. It can be used to set data, perform test operation, set parameters, monitor the operating status, and display alarm definition.
(1) MR—PRU01A Structure
Operation Key : Help mode select key.
Used to set the monitor or parameter in a list.
: SHIFT Key Used to make the typing of the corresponding shift character valid.Used to switch the screen.Example: use to alternate between the current alarm and the concurrent alarm.
: Cancel Key Used to return to the previous screen.
: Scroll Keys Used to scroll the screen
Hold down the key for more than 1 second to increase the scroll speed. Used to move the cursor on the screen.
HELP
SHIFT
CAN
: Forward rotation start key. Used to start forward rotation in the test run mode
- / Reserve rotation start key Used to enter the –(negative) sign Used to start reverse rotation in the test run mode
: Stop/ reset Key Used to stop the test run temporarily.
Used to reset an alarm or clear data entered.
FWD
REV
--
STOP
RESET
: Definition Key Used to define the parameter data after it is entered
Used to choose the necessary operation on the corresponding function menu screen.
Definition Key
: Numerals (0 to F) Used to enter the set value of the parameter. To type F, Press the [F/9] after pressing the [SHIFT] key.
: Decimal point
F 9 0
1STEP .
Numeral key
: Monitoring mode select key. Used to change the screen display to the monitoring mode.
: Alarm/diagnostics mode select key. Used to change the screen display to the alarm/diagnostic mode.
: Parameter mode select key. Used to change the screen display to the parameter mode.
: Test mode select key. Used to change the screen mode to the test mode.
MONI- TOR
ALM/ DGN
PARAM DATA MITSUBISHI MELSERVO-PRU01A
MONI-TOR
ALM/DGN
PARAMDATA TEST
HELP SHIFT CAN
Test Run Key
FWD
REV
-
STOPRESET
D7 E
8 F
9 A
4 B
5 C
6
1 2 3
0 1STEP
・
Mode Key—Used to switch between modes display
~
Display—Liquid crystal screen(13 characters by 4 digits)Interactive parameter setting Help function, troubleshooting guidance Monitoring
TEST
5-12
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
(2) Operation of the MR—PRU01A
SERVO Initializing --Servo being initialized
COMMUNICATION Initializing
--Being initialized by communication.
CONTROL POSITION --Control mode display
(for about 3 seconds)
Position Position/Speed
SpeedSpeed/torque Torque
Torque/position
1 Speed F/B 0. 0 r/ min
MONI- TOR Monitoring mode
1 1st AL--No Alarm
ALM/ DGN Alarm diagnostic mode
<TEST mode> : On test 0 → Finish 1 Jog feed
TEST Test mode
1 → Speed F/B 2 Ref. Speed 3 Droop 4 Ref. pulse
HELP Screen 1 → ALARM2 Not Rot3 ALM Hist.4 I/O Sig.
HELP Screen
<PARAM mode>Pr. Read : No. Pr. List : Help Copy: SFT + 3
PARAMDATA Parameter mode
<PARAM HELP>→ List All
List Chg
HELP Screen
00 MTR Ser. 0003
0 ~100 B
0Parameter No. 0 Call screen
→ JAPANESE ENGLISH
MONITOR ALM/DIAG. PARAMETER TEST MODE
Characters displayed on the screen are switched between English and Japanese.
Japanese-English select screen
→ Monitor AlM/DIAG ParameterTest Mode
Press the HELP key to move to the HELP screen in the mode indicated by the cursor
HOME screen
CAN
HELP screen
HELP
CAN
CAN
: POSITIO : POSITION/SPEED : SPEED : SPEED/TORQUE : TORQUE : TORQUE/POSITION
(3) Function
There is a function in monitor mode, alarm mode, parameter mode, and test operation mode in a parameter unit.
Please refer to the manual for the specification handling description about the contents of each function, and the flow of operation.
5-13
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
5.3.2 Monitor (1) The monitor by parameter unit MR-PRU01A
Name Status Display Indication
Range
Unit Description Positi
on
Spee
d
Torq
ue
Feedback pulse
value
Pulse F/B
-999999
~999999
Pulse
Feedback pulse from the servomotor encoder are counted and displayed. When the value exceeds 9999999, it starts with 0. Press “reset” to reset the value to 0
O
O
-
Servomotor Speed Speed F/B -4600.0
~4600.0 r/min
The speed of the servomotor is displayed. Reverse rotation is indicated by “-“. O O O
Command Speed Ref. Speed -4600.0
~4600.0 r/min
Command speed input to the servo amplifier is shown. For the internal speed command, the value set in the selected parameter is display.
O O O
Droop Pulse Value Droop -999999
~999999 Pulse
The pulse value of the deviation counted is displayed. Reverse rotation pulse value is indicated by “—“. O - -
Command Pulse
Value
Ref. Pulse
-999999
~999999
Pulse
Position command input pulses are counted and displayed. Since the value displayed is not yet multiplied by the electronic gear, it may not match the indication of the feedback pulse value. When the value exceeds 9999999, it starts with 0. Press “reset” to reset the value to 0
O
-
-
Command Pulse
frequency
Ref. freq
-400~400
Kpps
Position command input pulse frequency is displayed. The value displayed is not yet multiplied by the electronic gear. Reverse rotation pulse value is indicated by “—“
O
-
-
Speed Command
Voltage
Ref SPDV -10.00~
+10.00
Volt
(1) For Position or torque control mode, the Analog speed limited (VC) voltage is displayed.
(2) For speed control mode, the Analog speed command (VC) voltage is displayed.
-
O
O
Reverse rotation
analog torque
command voltage
- TQ LMTV 0.00~
-10.00
Volt
Reverse rotation analog torque command(TLAP) voltage is displayed. Indication range: 0.00 to -8.00 V
O
O
O
Reverse rotation
analog torque
command voltage
+TQ LMTV 0.00~
10.00 Volt Forward rotation analog torque command. O O -
Regenerative load
factor
Reg. load
0~100
%
The percentage of regenerative power to the permissible regenerative value is displayed.
O
O
O
Effective load
factor
Effc. Load 0~300 % Continuous effective load torque is displayed. The effective value is displayed relative to the rated torque of 100%.
O O O
Peak load factor Peak load 0~300 % Max. generated torque is displayed. The peak value in the past 15seconds is displayed relative to the rated torque of 100%.
O O O
Within one
revolution position
1 cycle Pos 0~16383 Pulse The position within one revolution is displayed in terms of encoder pulse.
O O O
A B S counter ABS count 0~65535 rev Moving distance from the home position in the absolute position detection system is displayed in the counter value of the absolute position encoder.
O O O
Machine speed Mach. SPD 0~999.00 m/min Speed multiplied by the machine speed conversion
constant is displayed. O O
O
Bus voltage P/N Volt 0~ 400 Volt The voltage (across P-N) of the main circuit converter is
displayed.
O O O
5-14
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
(2) The monitor in the main part of Servo amplifier The monitor (Table 5.3) of an operation state is based on a parameter unit, and also it can be seen by 4-figure LED of the Servo amplifier. The rotary switch (0-C) of a main part performed selection of the contents of a monitor, and it has been independent of the contents of selection by MR-PRU01A.
Table 5.3 The setup of the contents of the monitor and the rotary switch
Rotary switch(CS1)
Status Display
Setting Position Control Speed Control Torque Control
0
Parameter No. 18 setting
1
2
3
4
5
6
7
8
9
A
B
C
Fr
Cr
E
P
PA
F
Up
Un
Ld
JA
Jb
Cy
Pn
Servomotor speed
Command speed
Droop pulse value
Command pulse value
Command pulse frequency
------- Reverse rotation torque limit voltage
Forward rotation torque limit voltage
Regenerative load factor
Effective load factor
Peak load factor Within one revolution position
Bus voltage
Servomotor speed
Command speed
-------
-------
-------
Speed command voltage Reverse rotation torque limit voltage Forward rotation torque limit voltage
Regenerative load factor
Effective load factor
Peak load factor Within one revolution position
Bus voltage
Servomotor speed
-------
-------
-------
-------
Torque command voltage Reverse rotation torque limit voltage Forward rotation torque limit voltage
Regenerative load factor
Effective load factor
Peak load factor Within one revolution position
Bus voltage
Code
5-15
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
5.4 The setup and operation
5.4.1 Hard Ware setup (1) The setup of rotary switch(CS1)
Please be sure to check never turn the power on with the rotary switch of amplifier unites set at D, E, F. Since it will become a display error. The contents of a L.E.D. monitor of the front of amplifier (refer to Table 5.3) are chosen in the position of a scale 0 - C.
(2) Wearing of a battery When you use a motor with a position detection machine absolutely, please equip amplifier with an exclusive option (MR-BAT) for memory preservation.
5.4.2 Turned on Power Please switch on a power supply in the same check and same procedure as the case of MR-J2S (Refer to section 4.3.5).
5.4.3 Parameter setup Initial setting of the parameter value according to the conditions of operation is carried out after power supply on. Since there is a parameter stated by the section 5.2, please set up based on design specification. Please be sure to check about the parameter stated especially by section 5.2 (3) and (4).
5-16
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
(1) The outline of the parameter setup
When setting up an extended parameter (No.20 or subsequent ones), a parameter block (No.19) needs to be reset.
Please perform the parameter block after a setting end for the parameter rewriting rate prevention by incorrect operation.
There are some which a power supply once and become effective in a parameter after a setup. Please be based on power supply OFF->ON after a setup.
(2) Release of the parameter block The range of a parameter that can be setup is limited to the basic parameter (No.00-No.19) at the time of factory shipments. Please reset the parameter block, when you make a setting change of the extended parameter. Release of a parameter block is based on a setup of parameter No.19.
Setting value Parameter can be reference Parameter can be write
0000 (Initial setting) Basic parameter Basic parameter
000A Parameter block No.19 Parameter block No.19
000C Basic parameter + extended parameter Basic parameter
000E Basic parameter + extended parameter Basic parameter + extended parameter
(d) Power supply OFF- On
(a) Release of a parameter block
(b) Parameter setup
(c) Parameter block
Start
5-17
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
(3) The Setting operation of a parameter Setup of a parameter and read-out are performed using parameter unit MR-PRU01A of exclusive use. For any parameter whose symbol is preceded by *, set the parameter value and switch power off once, then switch it on again to make that parameter setting valid.
[the operation procedure and contents] [Key operation] [Screen display]
(a) The parameter mode
of MR-PRU01A is
chosen.
<Setting mode> Pr. No. 0 Read:
Key is pressed
Key in is carried out.
Key is pressed
key in is carried out.
Key is pressed.
Key in is carried out.
P A R A M
0
1
3
0 Motor series 3 Power-off then ON Pr Read: No.
0 motor series 0 0 ~5
<Parameter mode> Pr Read : No. Pr List : Help Copy : SFT + 3
(All the data of a repetition and a parameter list is set up) (Main Power Supply OFF)
(b) The key in of
parameter No. to
set up is carried
out.
(c) The key in of
the setting data is
carried out.
(d) The key in of fol-
lowing parameter
No is carried out. <Setting mode>
Pr. No. 1 Read
(Main Power Supply On)
5-18
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
5.4.4 Input-and-output signal check The monitor of the ON/OFF state of the input-and-output signal of the connector CN1 for control signals can be carried out using parameter unit MR-PRU01A. Please check the connection state of the switches of operation board before putting in operation instructions.
(An operation procedure and contents) (Key operation) (Screen display)
(a) The alarm and diagnostic mode of MR-PRU01A are chosen.
(Third screen)
DI D I 1 D I 2
D I 3 D I 4
E M G
DI SON TL
PC RES
LSP LSN
CR DIO
(Second screen)
4 DIO Signal : On : Off Read :
Key is pressed
Key is pressed 3 times.
Key is pressed
(First screen)
ALM/DGN
∇
1 1st Alarm No Alarm
(b) The DIO diagnostic function is called.
(c) The ON/OFF state
is checked on a DIO diagnostic screen.
∇ Key is pressed
∇ Key is pressed D O RD PF
ZSP TLC
ALM OP
Note 1. “ ” of a screen expresses ON state and “” expresses an OFF state.
2. The number of DIO signals and a name change with Servo loop form.
5-19
5. MELSERVO – H PERFORMANCE AND FUNCTIONS
Memo
5-20
6. SELECTION
6.1 Provisional selection of motor capacity
The rough guidelines for selecting the capacity of AC Servo that is appropriate for a given mechanical drive system is as follows: (1) The Guideline relating to the stability of a control loop
Moment of load inertia (JL) ≤ Moment of motor rotor inertia (Jm) X recommendation load inertia moment ratio
(2) The allowance for load torque Load torque (TL) ≤ motor rated torque(TM) x (0.5-0.8)
6.1.1 Load inertia moment (JL) The term “load inertia moment” means of the moment of inertia of the mechanical locking
element which is connected to the motor output shaft and that of the drive system beyond the coupling; both act as loads on the motor. The moment of inertia of magnetic brake of the motor and that of the reduction gears should also be included. The unit which should be used to express the moment of load inertia.
In addition, by AC servo system, the unit of the load inertia moment JL uses [kg.cm2], and the formula used to calculate the moment of load inertia is given in Table 6.1.
6.1.2 Load torque TL A thrust, friction power, imbalanced torque, etc. which work in the movable part of the
machine used as the load of a motor are said. In addition, the unit of the load torque TL uses [N-m], and shows the formula of load torque
in Table 6.2.
Note The Symbols of a formula are based on Appendices 1.
6-1
6. SELECTION
6.1.3 Formulae to calculate load inertia moment and load torque (1) Formulae used to calculate load inertia moment
The formulae used to calculate moment of inertia in typical cases are presented in Table 6.1
Table 6.1 Calculation of Load inertia moment
TYPE Mechanism Formula
1. Cylinder
π•ρ•L W JL= • (D1 – D2 ) = • (D1 + D2 ) ………( 6 –1) 32 8
JL :Moment of load inertia [•cm2 ] ρ :Density of material [/cm3] L :Length of cylinder [cm] D 1 :Outside diameter of cylinder [cm] D 2 :inside diameter of cylinder [cm] W :Mass of cylinder [kg]
Reference: Density of material: steel --------7.8 •10- 3 [kg/cm3] Aluminum --------2.7 •10 – 3 [ /cm3 ] Copper ----------8.96 •10 – 3 [ /cm3 ]
2.Prism
a 2+ b 2
J=W • + R 2 ------------- (6-2) 3
a, b, R : see the diagram in the left. [cm]
3. A
n ob
ject
mov
ing
alon
g th
e lin
er
axis
4. A
susp
ende
d ob
ject
5.C
onve
rted
mom
ent
of l
oad
iner
tia
appl
ied
to th
e m
otor
shaf
t.
2
2 4 4
Axis of rotation
)(
Axis of rotation
V 2 1 V 2 ∆ S 2JL = W・ =W• • = W • -(6-3) 600 ω 2πn 10 2 π
J L : Converted moment of load inertia applied to the Motor shaft [ •cm2 ]
V : Speed of moving object [mm/min] N : Motor rotation speed [r/min]
Z 1 ∆ S = P B • Z 1, Z 2 : No. of teeth of gears. Z 2
W J L = • D 2 + J p (6 – 4) 4
JP : Moment of inertia of pulley [ •cm2 ]
D : Diameter of pulley [ ]
N 2 2
J L = J 11 + ( J 21 + J22 + J A )・ ( ) N 1
N 3 2
+ ( J 31 + J B ) • (--------) ---------( 6-5)
( ))(
Load ALoad B
N 1
J A , J B : Converted moment of load A,B 〔・cm2〕
J11 ~ J 31 : Moment of inertia of gears [ •cm2 ]
N 1 ~ N 3 : Rotational speed of shafts [r / min]
6-2
6. SELECTION
(2) Formulae used to calculate load torque
The formulae used to calculate load torque in typical cases are presented in Table 6.2
Table 6.2 Calculation of Load Torque
Type Mechanism Formula
Line
r mot
ion
F V F • ∆ S T L = * = - ---------(6-6) 2 X10 3 π η N 2 X 10 3 π η
F : Axis force of machine moving along linear axis [ N] η : Efficiency of drive system
The force required to move the table as illustrated in the diagram To the left is calculated using the following formula.
F = F c + µ ( W • g + F c ) -------------------(6 – 7) Fc : Thrust applied to the movable part ( N) F G : Table guide way clamping force ( N ) µ : Friction coefficient V : Speed of object moving along liner axis [mm / min ] N : Motor rotational speed ( r /min) W : Mass of object. [ kg] g : Gravitational acceleration [ 9.8 m /s 2 ] ∆ S : Object feed distance per motor revolution (mm)
Rot
atio
n
Z
T1 1
L = • • T L O + T F ( 6 - 8) Z 2 η
TL o : Load torque applied to the shaft (N• m)
T L : Converted friction load torque applied to the motor
shaft (N• m)
T F : movable friction torque (N • m)
Ver
tical
mot
ion
For upward motion
T L = T U + T F ------------------------------- (6 –9 )
For upward motion
T L = - η 2 • T U + T F ------------------------------------------(6 - 10)
T U : Imbalance (N•m)
T F : movable friction torque (N•m)
( W - W )•g V (W 1 2 T = • =
1 – W 2)•g •∆S U
2 X 10 3 πη N 2X 10 3π η ----------- (6-11)
µ • ( W + W ) • g • ∆S 1 2
( )
Motor
Load
Mass of count-
T = ------------------------------- (6 - 12) F 2 X10 3 π η
W1 : Mass of load [kg ]
W2 : Mass of counterweight [kg]
η : Efficiency of drive system
µ : Friction coefficient (on sheave)
6-3
6. SELECTION
6.2 Reduction Ratio To make the most of the servomotor’s performance, it is important to draw power from the servomotor in the most efficient way and to keep the servo system, including the machine, operating stably and at high responsibility. An important factor in achieving this is the reduction ratio of the mechanism between the servomotor and the machine. The conditions necessary for selecting the reduction ratio correctly are discussed below. (1) Select the reduction ratio so that the motor runs at the rated rotational speed when the
machine is operating at the fastest speed. This allows you to utilize the motor output (power) most efficiently.
(a) The max. output(rated output) of a servomotor is obtained when it runs at the rated rotational speed.
(b) The converted load torque and converted moment of load inertia applied to the motor shaft of the machine become smaller as the selected reduction ratio is increased. In other words, the load on the motor is smallest when the reduction ratio is selected so that the motor runs at the rated rotational speed.
(2) Select the reduction ratio and motor capacity so that moment of load inertia ratio will be 5 to 10 . This ensures good servo system responsibility while maintaining stable operation.
Moment of load inertia ratio m
Converted load applied to the motor shaft J L M = Motor JM < (5 to 10 )
The smaller the moment ratio of load inertia is, the greater the possibility of increasing the responsibility of the servo system. For systems with a high incidence of starting and stopping, select as small a ratio (m < 2) as permitted.
(3) To ensure high positioning accuracy, the feed distance (∆l0) per pulse should be as small as possible.
The following is a rough guideline for the relationship between machine accuracy (∆ε) and feed distance per pulse (∆l0). (∆l0) < ∆ε X [ (1/5) to (1/10) ] Note: For the relationship between ∆l0 and the reduction ratio, refer to section 2.5.1. MEMO
1. The power during acceleration will be smallest when m=1. This is achieved by setting the reduction as 1/n = (√ Jm / JL). This reduction ratio is generally called the optimum reduction ratio.
2. When spur gears and pulleys are used to reduce motor speeds, if the diameter of the driven pulley is enlarged to increase the reduction ratio, the moment of load inertia may become large due to speed reduction.
6.3 Operation Patterns and Required Motor Torque
6-4
6. SELECTION
An operation pattern is usually assessed by dividing a cycle into accelerating time, Tpsa; fixed speed operation time, tc; decelerating time, Tpsd; setting time, ts, and stop time ts
The energy necessary for accelerating an object which has a load inertia moment(JL) is called the acceleration torque, Ta, and that necessary for deceleration is called the deceleration torque, Td.
During the period from the start of deceleration in the fixed speed operation state to the settling time, ts, the friction torque, TL, acts in the same manner as it does during fixed speed operation.
6.3.1 Acceleration torque (Ta)
The formula used to calculate the acceleration torque Ta is formulae (6-17)
(JL + JM) • No - Ta= • ( 1- ε ) (N•m) ---------------------- (6-17)
T PSAT p
9.55 X10 4 •Tpsa
Formulae (6-18) is also used to calculate the approximate acceleration torque Ta.
(Jl + JM) • No Ta= (N•m) ------------------------------------------(6-18) 9.55X10 4 • Tpsa
6.3.2 Deceleration torque (Td)
The formulae used to calculate the deceleration torque(Td) is formulae (6-20).
(JL + JM) • No - Td = • (1- ε ) (N•m) (6-20)
T PsaT p
9.55X104 • Tpsd
Formulae (6-21) is also used to calculate the approximate deceleration torque(Td).
(JL +JM) • No Td = (N • m) ----------------------------------------------- (6-21) 9.55 X104 • Tpsd
If Tpsa = Tpsd, the acceleration torque and the deceleration torque have the same value; Ta = - (Td )
6-5
6. SELECTION
6.3.3 Driving pattern
The discussion above can be summarized as follows: (a) The motor torque required for fixed speed operation is the converted load torque applied to motor shaft, TL . (b) The converted load torque applied to the motor shaft, TL, may have a negative value under certain conditions if the
motor is used for up/down motion; (c) The motor torque necessary for acceleration and deceleration are:
Motor torque necessary for acceleration Tma = Load torque TL + Acceleration torque Ta Motor torque necessary for deceleration Tmd = Load torque TL - deceleration torque Td
(d) The condition Tmd = TL – Td > 0 indicates a power deceleration state in which the motor decelerates while supplying energy to the machine;
(e) The condition Tmd = TL – Td < 0 indicates the regenerative braking(the regenerative mode) in which the motor decelerates while applying a braking force to the machine. In this mode, regenerative power flows from motor to amplifier.
(f) Fig. 6.1 shows the deceleration pattern and torque pattern.
Power mode
Regenerative mode
The acceleration/ deceleration torque follows the pattern illustrated in (a) in the diagram to the left due to lag in the control system. However, to simply calculation, Ta and Td in (b) may be used.
Acceleration/deceleration torque
Required Motor torque
Acceleration/deceleration torque
Load torque
Motor speed
Pulse frequency
Motor speed
Input pulse frequency (PPS)
(Remark)
tst Stop time [s] tf 1 operation cycle [s]
tf
t0
tC
Fig. 6.1 Driving Pattern and Torque Pattern at Each Interval
6-6
6. SELECTION
6.3.4 Determining motor capacity
Whether a specific motor may be used for the required application should be determined by
assessing if it can produce the required motor torque shown in Fig. 6.1. In addition to the torque,
the temperature rise of the motor and heat capacity of the regenerative brake must also be
assessed in the case of motors subjected to frequent use.
The motor provisionally selected may be used if it satisfies the following three conditions.
(1) Motor torque required for acceleration Tma in Fig. 4.1
Tma = TL + Ta < Max. motor torque Tma ---------------------------------(6-23)
(2) Motor torque required for deceleration Tmd
Tmd = TL – Ta < Max. motor torque Tmax -------------------------------(6-24)
(3) Continuous effective torque Trms
Trms < Motor rated torque Tm --------------------------------------------(6-25)
The load torque at which the temperature rise of a motor operated intermittently is equal to its
temperature rise when operated continuously is called the continuous effective load
torque, Trms. Therefore, if Trms < Tm, it indicates that the motor maybe used without heat
generation problems.
In the case shown in fig. 6. 1, the continuous effective load torque, Trms, may be calculated
by using the following formula.
Trms = √ Tma • Tpsa + TL • (tc + ts) + Tmd • Tpsd
tf
6-7
6. SELECTION
If any one of the conditions (1), ( 2) and (3) indicated above is not satisfied. Review the conditions at the machine, the operation, motor capacity, etc. and evaluated the selection motor again using the procedure. If all of the conditions(1), (2), (3)indicated above are satisfied, the provisionally selected motor can be used for the required application using the planned speed pattern and cycle time without encountering problems relating to torque or temperature rise. If negative torque is generated in the torque pattern, the performance of the regenerative brake of servo amplifier must be examined.
6-8
6. SELECTION
6 - 9
6.4 Example of Capacity Selection Procedure (1) Table feed
Shaft
Servomotor Coupling
System configuration figure
Table mass Load mass Load resistance power force of a table guidance side Slowdown ratio (NL/NM) Slowdown machine inertia moment Coupling inertia moment Output axis conversion inertia moment Ball screw lead Ball screw diameter Ball screw length Drive part efficiency Friction coefficient Rapid-traverse speed Positioning length / time Positioning time 1 cycle time
WT : W L : FC : FG : 1/n : JG : JC: JO: PB: DB: LB: η: µ: VO: L: To: t f :
kg kg N N kg• cm 2
kg• cm 2
kg• cm 2
mm mm mm/ min mm S S
200.0 50.0 0.01 0.01 1/1 0.20 2.00 0.10 10.00 20.00 1500.00 0.90 0.10 20000.00 400.00 1.50 2.00
Mechanical
ITEM
REMARKCALCULATION The load inertia moment can be computed by machine makers. However, with the system illustrated above, the moment of load inertia can be calculated as indicated below. Note when computing a load inertia moment, the value must be converted into the moment applied to the motor shaft . ① Ball screw
JB LB DB= × × × × ⎛⎝⎜
⎞⎠⎟
132
0 007810 10
4
π . = 13 2
3 1 4 1 6 0 0 0 7 8 1 5 0 01 0
2 01 0
4× × × × ⎛
⎝⎜⎞⎠⎟
. .
[k 2]
Calculation
The calculation of movements per motor rotation (the motor to which the slowdown machine is 1 1
nm= )
∆s PBn nm
= × ×1 1= = [mm/rev]
Motor rotation speed calculation
N VS
0 0=∆
= = [r/min]
<Reference>: Since operation is impossible when calculated NO surpasses the motor maximum rotation speed, it is necessary to make the highest machine speed VO small, or to enlarge amount of sending ∆S per motor rotation.
The positioning time of machine side specification and positioning speed (the highest machine speed) are asked for acceleration and deceleration time of servomotor. Generally, a motor is straight line acceleration anddeceleration , and since acceleration and deceleration time are set up equally, it asks for an operation pattern by thepremise also by this example. (The position loop gain Kp is taken as the initial value 35 of MR-J2S.) The acceleration and deceleration time is found in the following ways from a front figure. Stop setting time calculation
tsKp
= ×3 1 = = [s]
The acceleration and deceleration time calculation
Tsa Tsd t LV
ts= = − × +⎛⎝⎜
⎞⎠⎟
=00
60
= [s]
0.214
1.5-(400/20000 X60+0.086)
ITEM
1. Calculation of Load data
2. Motor Rotation Speed at Time of Highest Machine Speed
3. Operation Pattern
3 X 1/35 0.086
20000/10.0 2000
10.0 10X1X1
REMARK
6. SELECTION
6 - 10
HC-MFS73 MR-J2S-70A
0.433
10.471 0+0+6.333+ 0.2+2+0.1+1.838 X(1)2 X12
6.333
1.838
> TL = 0.433 Ttyp = 2.4
JM = 0.6 JL/30 = 0.349 >
( . . ). .
.10 471 0 6 20009 55 10000 0 214
0 433+ ×× ×
+
1.516 7.2
− + ×× ×
+( . . ). .
.10 471 0 6 20009 55 10000 0 214
0 433
-0.650 7.2
6. SELECTION
6 - 11
CALCULATION Calculate the continuous effective load torque from the driving pattern and the required motor torque, calculated above. The calculated continuous effective load torque must not exceed the rated torque of the provisionally selected motor. Continuation effective load torque
( )Tr ms
Tma Tsa TL t Tsa Tsd ts TMd Tsdtf
=× + × − − − + ×2 2 20
=
= [N.m] <Motor Rated torque Type
Determine if the regenerative brake option is necessary, on the basis of the brake duty. Acceleration energy Ea N TMa Tsa= × × ×01047 0
2.
= = [J]
Deceleration energy Ed N TMd Tsd= × × ×01047 02
.
= = [J]
Working energy ( )Ef N TL to Tsa Tsd ts− −= × × × −01047 0.= = [J]
Absolute value of the negative energy sum total = = [J]
Regenerative: Pr =× − × −ηm Em Wa t Ec
tf=
= [W]
Regeneration brake option unused Regeneration brake option used
The result selected from the above examination is as follows. Servomotor
Servo amplifier Regeneration option
Motor rotational speed corresponding to the maximum machine speed : 2000 (r/min) Acceleration/ deceleration time : 0.214 (s) Motor torque required for acceleration : 1.516 (N・m) Motor torque required for deceleration : -0.650 (N・m) Continuous effective load torque : 0.619 (N・m)
The regeneration brake more than regeneration power is used. Model name
Unused
0.1047 X2000/2X1.516X0.214 33.967
0.1047X2000/2X(-0.650)X0.214 -14.564
89.401 0.1047X2000X0.433X0.986
14.564 |-14.564|
Built-in regeneration power 20 [W] < -3.1744
HC-MFS73
MR-J2S-70A
1516 0 214 0 433 15 0 214 0 214 0 086 0 650 0 2142
2 2 2. . . ( . . . . ) ( . ) .× + × − − − + − ×
REMARK ITEM
8. Calculation of
continuous effective load torque
9. Evaluation of
whether the regenerative brake option should be used or not
10.Result of
selection
2.4 0.619
< unused 、 >:used
( / ) . .80 100 14 5 0 0 214 18
2× −64× −
6. SELECTION
6 - 12
(2)Lift applications
coupling
Motor Shaft
System configuration figure
Table mass Load mass Counter weight mass Load resistance power Force of the table guidance side Slowdown ratio(NL/NM) Slowdown machine inertia moment Coupling inertia moment Other output conversion inertia moment Ball screw lead Ball screw diameter Ball screw length Drive part efficiency Friction coefficient Rapid-traverse speed Positioning length / time Positioning time 1 cycle time
WT: WL: WC: Fc: FG: 1/n: JG: JC: J0: PB: DB: LB: η: μ: V0: L: t0: tf:
kg kg kg N N kg・cm2 kg・cm2 kg・cm2 mm mm mm mm/min mm s s
80.00 50.00 100.00 0.01 0.01 1/2 0.20 2.00 0.10 10.00 20.00 1500.00 0.90 0.10 10000.00 400.00 2.60 6.00
Mechanical Specification
ITEM
1. Calculation of Load Data
2. Motor rotation speed at time of highest machine speed
3. operation Pattern
CALCULATION
The calculation of movements per motor rotation ( the slowdown machine 1 1nm
= )
∆s PBn nm
= × ×1 1= = [mm/rev]
Motor rotation speed calculation
N VS
0 0=∆
= = [r/min]
<Note>:Since operation is impossible when calculated NO surpasses the motor maximum rotation speed, it is necessary to make the highest machine speed VO small, or to enlarge amount of sending ∆S per motor rotation.
The positioning time of machine side specification and positioning speed (the highest machine speed) are askedfor acceleration and deceleration time of servomotor. Generally, a motor is straight line acceleration anddeceleration , and since acceleration and deceleration time are set up equally, it asks for an operation pattern by thepremise also by this example. (The position loop gain Kp is taken as the initial value 35 of MR-J2S.)
The acceleration and deceleration time is found in the following ways from a front figure.
Setting time calculation
tsKp
= ×3 1 = = [s]
The acceleration and deceleration time calculation
Tsa Tsd t LV
ts= = − × +⎛⎝⎜
⎞⎠⎟
00
60 =
= [s]
0.114
2.6-(400/10000X60+0.086)
3X1/35 0.086
10000/5.0 2000
5 10X0.5X1
REMARK
6. SELECTION
CALCULATION The load inertia moment can be computed by machine makers. However, with the system illustrated above, the moment of load inertia can be calculated as indicated below. Note when computing a load inertia moment, the value must be converted into the moment applied to the motor shaft .
① Ball screw
6 - 13
JB LB DB= × × × × ⎛⎝⎜
⎞⎠⎟
132
0 007810 10
4
π .
( )
=
= [kg・cm2]
② The straight-line motion object
JF WT WL WC S= + + ××
⎛⎝⎜
⎞⎠⎟
∆10 2
2
π=
= [kg・cm2]
③ Motor shaft conversion load inertia moment (the motor which the slowdown machine is not attached, JMG=0
JL JMG JMB JF JG JC J JB= + + + + + + × ⎛⎜ ⎞⎟
⎧⎨⎪ ⎫
⎬⎪ × ⎛⎜ ⎞
⎟0 1 12 2
( )
n nm⎝ ⎠⎩⎪ ⎭⎪ ⎝ ⎠
= = [kg・cm2]
<note>:Since all the objects moved when a motor rotates are applicable, an inertia moment needs to take all them into
consideration.. The load inertia moment can be computed by machine makers. However, with the system illustrated above, the moment of load inertia can be calculated as indicated below. Note when computing a load inertia moment, the value must be converted into the moment applied to the motor shaft . (Gravity acceleration g= 9.8)
Imbalanced torque
TUFc WT WL WC g S=
+ + − ×× ∆
( )
1000 2π=
= [N.m]
Friction torque
TFWT WL WC g FG S=
× + + × +µ ∆
( )
×π1000 2
=
= [N.m]
TLuTU TF
=+η
= = [N.m]
the motor shaft conversion load torque at the time of descent. ・(-TU+TF)>0
TLd TU TF− +=η
( )TLd TU TF= − + ×
= = [N.m]
・(-TU+TF)<0
η = = [N.m]
Once the load torque and a load inertia moment can be found, it is possible to select an approximate motor capacity., as the standard of provisional selection.
① The motor rated torque Ttyp should be more than load torque. (A margin is usually given to about 50 - 80% of the rated torque Ttyp.)
② The load inertia moment of the motor itself, Jm, must be at least 1/10(HC-KFS) of Jl ; ③ The motor of a perpendicu ts with a safety top brake. lar axis selec
Provisional selection motor、 a servo nd amplifier
JM = 0.42
REMARK
(-0.234+0.179)X0.9 -0.05
CALCULATION
Now the load torque, the load inertia moment, and the operation pattern of motor have been obtained. The next step is to assess whether the torque required for accelerating and deceleration by the provisionally selected motor is less than the max. torque of this motor. If the torque required for acceleration/deceleration exceeds the max. torque of the motor, the motor cannot follow the pattern within the acceleration/deceleration time calculated in the preceding step, and a servo error will result. Acceleration torque at the time of rise
( )JL JM N+ ×⎧ ⎫0
HC-KFS43B MR-J2S-40A
Ttyp = 0.64 TLu = 0.459
REMARKITEM
4. Calculation of Load Inertia Moment
5. Calculation of Load Torque
6. Provisional selection of a motor
0 01 50 100 9 81000
52 31416
. (80 ) ..
+ + − ××
×
0.234
01 80 50 100. (× + + 9 8 0 011000
52 3146
) . ..
× +×
×
0.179
0.459 0 234 0179. .+
0 9.
ITEM
>
TLd = -0.05 > Ttyp = 0.64
> JL/15 = 0.2837
0+0.040+1.456+ 0.2+2+0.1+1.838x(0.5)2x12 4.256
1.456
( ) ..
80 50 100 5 010 2 3 1416
2+ + ×
× ×⎛⎝⎜
⎞⎠⎟
1.838
1 0 0078 150010
2010
4× × ⎛
⎝⎜⎞⎠⎟
. .32
3 1416× ×
6. SELECTION
6 - 14
-0.909
)05.0(114.01000055.92000)420.0256.4(
−+⎭⎬⎫
⎩⎨⎧
×××+
−
)05.0(114.01000055.92000)420.0256.4(
−+⎭⎬⎫
⎩⎨⎧
×××+
1.9
0.809
1.9 -0.400
459.0114.01000055.92000)420.0256.4(
+⎭⎬⎫
⎩⎨⎧
×××+
−
( . . ). .
.4 266 0 670 20009 55 10000 0114
0 459+ ×× ×
⎧⎨⎩
⎫⎬⎭
+
1.9
1.9
1.366
2.6-0.114-0.114-0.086
2.286
tc to Tsa Tsd ts= − − −
Trmst
TMau TMad Tsa TMdu TMdd Tsd TLu TLd tc TU tf t tsf
= )+ × + + × + + × + × − × + ×( ) ( ) ( ) (2 2 2 2 2 2 2 2 0 2
0.393 0.64
6
)086.026.226(2
234.0286.2)2
)05.0(2
459.0(114.0)2
)909.0(2
)400.0((114.0)2
809.02
366.1( ×+×−×+×−++×−+−+×+
6. SELECTION
6 - 15
CALAULATION Determine if the regenerative brake option is necessary, on the basis of the brake duty. Acceleration energy at the time of rise
Eau N TMau Tsa= × × ×010472
0. =
= [J]
Deceleration energy at the time of rise
Edu N TMdu Tsd×= × ×010472
0. =
= [J]
working energy at the time of rise Efu N TLu tc= × × ×01047 0. = = [J]
Acceleration energy at the time of descent Ead N TMad Tsa= × × ×0 1047
20. =
= [J]
Deceleration energy at the time of descent Edd N TMdd Tsd×= × ×01047
20. =
= [J]
working energy at the time of descent Efd N TLd tc= × × ×01047 0. = = [J]
The absolute value of the negative energy sum total Em=|(Eau,Edu,Efu,Ead,Edd,Efd Sum total|
= = [J]
Regenerative:
Pr = × − × −ηm Em Wa t Ectf
=
= [W]
Regeneration brake option unused Regeneration brake option used
15.731
114.0)400.0(20002
1047.0 ×−××
-4.774
219.718 0.1047X2000X0.459X2.286
114.0809.1047.0 020002
×××
9.656
114.0)909.0(20002
1047.0 ×−××
-10.850
0.1047X2000X(-0.05)X2.286 -23.934
|(-4.774)+(-10.850)+(-23.934)| 39.558
69514.20558.39)100/70( −×−×
Built-in regeneration power 10 [W]
< 3.115
114.0318.120002
1047.0 ×××
<unused 、 >:use
The regeneration brake more than regeneration power is used. Model name
ITEM
10. Evaluation of whether the regenerative brake option should be used or not
REMARK
6. SELECTION
6 - 16
CALAULATION The result selected from the above examination is as follows.
Servomotor
Servo amplifier
Regeneration option
Motor rotational speed corresponding to the maximum machine speed : 2000 (r/min) Acceleration time : 0.114 [s]
Motor torque required for acceleration at the time of rise : 1.318 [N・m]
Motor torque required for deceleration at the time of rise : 0.809 [N・m]
Motor torque required for acceleration at the time of descent : -0.400 [N・m]
Motor torque required for deceleration at the time of descent : -0.909 [N・m]
Continuous effective load torque : 0.393 [N・m]
HC-KFS23B
MR-J2S-20A
unused
ITEM
11.Result of selection
REMARK
7. The Measure Against Noise, Leak Current, Harmonics
7.1 The measure against a noise
Servo amplifier is controlling the servomotor by switching rectification and the direct-current power supply of
about 300 V that carried out flat and smooth for a commercial power supply. Therefore, Servo amplifier may serve
as a noise generation source to peripheral equipment, and may generate the trouble of a noise with the amount of -
proof [noise] of Servo amplifier, the cloth line affair of the power line between servomotors, the grounding method,
and Servo peripheral equipment.
The signal line of that on which the noise generated from Servo amplifier is radiated from the electric wire
connected to the main part of Servo amplifier, and a Servo amplifier main circuit (ON and output), and the
peripheral equipment close to the main circuit electric wire -- electromagnetism -- it can divide roughly into a target,
the thing to guide in static electric, and the thing transmitted in power supply circuit.
Servo amplifier
Generating noise
Noise transmitted in
the air
Noise radiated directly
from Servo amplifier
Noise radiated from the
power supply cable
Noise radiated from the
motor connection cable Electromagnetism
induction Noise
Static electric induction
Noise
----Route (4), (5)
----Route (6)
The Noise transmitted
through electric channels
Noise transmitted through
power supply cable
Noise from the grounding
cable due to leak current.
---- Route (1)
----Route (2)
----Route (3)
----Route (7)
----Route (8)
Telephone
Sensor power supply
Servomotor Sensor
Servo Amp. Instrument Receiver
7-1
7. The measure against a noise, leak current, harmonics
Noise propagation Measure
(1) (2) (3)
Feeble signals, such as a measuring instrument, a receiver, and a sensor, are treated, and since
apparatus may incorrect-operate by air propagation of a noise when it is influenced of a noise, and it is
contained in the same board as Servo amplifier, or the apparatus which is easy to operate, and its signal
cable approach and are wired, it is necessary to take the following measures.
(1) The apparatus which is easy to be influenced is separated from Servo amplifier as much as
possible, and is installed.
(2) From the input-and-output cable of Servo amplifier, the signal cable which is easy to be
influenced is detached as much as possible, and is patterned.
(3) Wiring is avoided in parallel routing and the bunch of a signal cable and a power line (Servo
amplifier input-and-output cable).
(4) If a cable noise filter and an input can insert a radio noise filter in an input-and-output cable, the
radiation noise from an electric wire can be controlled.
(5) It is still more effective, if the shield cable is used for the signal cable or the power cable or it
puts into a respectively individual metal duct.
(4) (5) (6)
When parallel routing of the signal cable is carried out or it is bundled by the power cable together
with the power cable, it electromagnetism induction. Since a noise may spread and incorrect-operate
on a signal line by the noise and the static electricity induction noise.
It is necessary to take the following measures.
(1) The apparatus that is easy to be influenced is separated from Servo amplifier as much as
possible, and is installed.
(2) From the input-and-output cable of Servo amplifier, the signal cable that is easy to be influenced
is detached as much as possible.
(3) Wiring is avoided in parallel route and the bunch of a signal cable and a power cable (Servo
amplifier input-and-output cable).
(4) It is still more effective, if the shield cable is used for a signal cable or the power cable or it puts
into a respectively individual metal duct.
(5) A data line filter is attached in the signal cable.
(7)
The case where the power supply of peripheral equipment is connected with the power supply of the
same system as Servo amplifier since apparatus may incorrect-operate from the noise in which the
generated noise flows backwards the power supply cable, it is necessary to take the following
measures:
(1) A radio noise filter (FR-BIF) is installed in the power cable(input-and-output cable) of Servo
amplifier.
(2) A radio noise filter (FR-BLF, FR-BSF01) is installed in the power cable of Servo amplifier.
(3) A data cable filter is attached in the power supply cable of peripheral equipment.
7-2
7. The measure against a noise, leak current, harmonics
(8)
When wiring of peripheral equipment is having the closed loop circuit constituted by wiring Servo
amplifier, it leaks from the grounding cable of Servo amplifier, current flows in, and apparatus may
incorrect-operate.
When such, if the grounding cable of apparatus is removed, there is a case where it stops incorrect-
operating.
7.2 Leak current
To AC Servo, the chopper current of the harmonics by which PWM control was carried out flows. It leaks and current becomes
large compared with the motor containing a part for harmonics operated with a commercial power supply.
A short circuit breaker should select a lower formula to reference, and a Servo amplifier, servomotor etc. should ground
certainly.
Moreover, please the route distance of the electric wire of input and output be short as much as possible to reduce leak current,
detach as much as possible between the grounds, and carry out electrical route (about 30cm).
Rated sensitivity current >=10X(lg1+lgn+lga+KX(lg2+lgm)) (mA)
K: The constant in consideration of a part for harmonics
Short circuit breaker
Type Elegance of
our
company
Harmonics and a serge
correspondence article
NV - SF
NV - CF 1
Common article
NV - CA
NV - CS
NV - SS
3
Wire length
Servo amplifier
7-3
7. The measure against a noise, leak current, harmonics
Ig1 :Leak current of the circuit from a short circuit breaker to a Servo amplifier input terminal (It asks from
Fig. 7.1.)
Ig2 :Leak current of the circuit from a Servo amplifier output terminal to the servo motor (It asks from
Fig. 7.1.)
Ign :Leak current at the time of connecting an input side filter etc. (In FR-BIF, it is 4.4mA per piece.)
Iga :Leak current of Servo amplifier (It asks from Table 7.2.)
Igm :Leak current of a servomotor (it asks from Table 7.1)
Leak current of a servo motor (it asks from Table 7.1)
Fig. 7.2 Example of leak current per km
at the time of carrying out metal wiring
of CV cable (Ig1, Ig2)
Table 7.1 Servo motor’s
eak current (Igm) l
Servo motor output (kW)
Leak current(mA)
0.05 ~0.5 0.1
0.6 ~0.1 0.1
1.2 ~2.2 0.2
3, 3.5 0.3
Table 7.2 Servo amplifier’s leak
urrent (Iga) c
Servo Amplifier
capacity (kW)
Leak current (mA)
0.1 ~ 0.6 0.1
0.7 ~ 3.5 0.15
Leakage current
Cable size
7-4
7. The measure against a noise, leak current, harmonics
7.3 Harmonics
7.3.1 A basic wave and harmonics It is defined as the thing with the frequency of the integral multiple of a basic wave (generally power supply
frequency), and it is distorted and what compounded one basic wave and two or more harmonics is called
harmonics with the wave. (Refer to Fig. 7.3)
Although the distortion wave is generally included to the harmonics (kHz-MHz) of a harmonics domain, it differs
in character with the problem of the harmonics domain which the 40-50th (-3kHz) usually deal with it as harmonics
of a power distribution system, and generally presents a random aspect. For example, problems with a personal
computer, such as an electric wave obstacle and a noise (refer to section 7.1), are local problems stuck to apparatus
hard, and the influence and a correspondence means differ from the harmonics for an electric power network. It is
necessary to clarify this first.
∞ I = Io + Σ In •sin (2πfnt + ϕn)-------------------------- (7.1) n=1
n = 1, 2, 3……….
f = Basic frequency
Merger wave
3 times harmonics
2 times harmonics
Basic Wave
Fig. 7.2 Basic wave and harmonics Fig. 7.3 Distortion wave
7-5
7. The measure against a noise, leak current, harmonics
Table 7.3 The harmonics and noise as following
ITEM Harmonics Noise
Frequency Usually, the 40-50th 3kHz or less Harmonics (several 10 kHz-MHz order)
Environment Depended on track and power supply impedance
Depended on space, distance, a routing course
Quantity grasp Theoretical calculation is possible. They are generating and quantity grasp difficulty at random.
The amount of generating
It is proportional to load capacity mostly.
It is based on a current rate of change (size like high-speed switching).
The amount of -proof of damage apparatus
It writes clearly by the standard for every apparatus.
It changes with a maker's apparatus specifications.
The example of a measure
A reactor (L) is attached. Distance (l) is extended.
7.3.2 The characteristic of a rectification circuit and generating harmonics As a generation source of harmonics, there are a rectifier, an exchange electric power adjustment machine, etc. The converter
part of general-purpose Servo consists of the rectifier circuit, and has generated many harmonics.
As shown in Table 7.4, there are two kinds of things in a rectifier circuit with the main circuit system, and most 3 phase bridge
systems are adopted in general-purpose Servo.
Table 7.4 Rectifier circuit system and harmonics
Circuit name Basic circuit diagram Harmonics degree Harmonics content
Single bridge
N = 4k + 1
K = 1, 2……
Kn X 1/n
3 phase Bridge
N = 6k + 1
K = 1, 2 ……
Kn X 1/n
Kn: The coefficient decided by the control delay angle, the running style overlap angle, etc.
7.3.3 The measure against harmonics The Ministry of International Trade and Industry enacted the harmonics control measure guideline about the
measure against harmonics control in September, 94.
The Servo amplifier of 4.0 or less kW becomes the object product of "household electric appliances and a general-purpose
article harmonics control measure guideline." In accordance with these guidelines, the gradual regulation level was decided in
Japan Electrical Manufacturers' Association.
Since this regulation level is suited, the Servo amplifier 4.0kW or less installed on and after January 1,
97 needs to connect a power improvement reactor (FR-BAL).
7-6
8. Maintenance and Inspection
8.1 Maintenance and Inspection
Although AC Servo amplifier is stillness apparatus constituted focusing on the semiconductor element, in order to
prevent beforehand the trouble generated from the influence of use environment, such as temperature, humidity,
and vibration, secular change of use parts, a life, etc., it is necessary to perform everyday check.
8.1.1 Notes at the maintenance and inspection Please carry out after checking with a tester etc. that the voltage between main circuit terminal P-N is 0V waiting
and after that until a charge lamp puts out the light, since a flat and smooth capacitor is in a high-voltage state for a
while after intercepting a power supply, when checking the inside of AC Servo amplifier.
8.1.2 Item of inspection
1 Daily inspection Basically, it checks for no following abnormalities during operation.
(1) Does the motor move as the setting?
(2) Is it normal by the environment of the installation place?
(3) Is it normal for the cooling system?
(4) Aren't there unusual vibration and unusual sound?
(5) Aren't there unusual overheating and discoloration?
It is usually with a tester during operation, and the input voltage of AC Servo is checked.
2 Scheduled inspection The part which cannot be checked unless it stops operation, and the part which requires a scheduled
inspection are checked.
(1) Is it normal for a cooling system? .... Cleaning of an air filter etc.
(2) It increases with a check with a bundle and fastens. .... Under the influence of vibration,
temperature change, etc., since connector, such as a screw and a bolt, may loosen, it often carries
out after a check.
(3) Aren't corrosion and breakage in the conduct and an insulator?
(4) Measurement of insulation resistance
(5) The check and exchange of the cooling fan, the smooth capacitor, and the relay.
8-1
8. Maintenance and Inspection
8-2
Table 8.1 Daily check and scheduled inspection
Check item
Check matter
Dai-
ly
Per-
iod
The check method
Judgment standard
Meter
Circumference
environment
Circumference
temperature, humidity, dirt,
etc. are checked.
X A thermometer,
a hygrometer, a
recorder
Who
le u
nit
Preservation
environment
Circumference
temperature, humidity, dirt,
etc. are checked.
X It measures with
temperature, a hygrometer,
etc.
(1) motor: -- below -10 degrees
C - +70 degree-C(there needs to
be no freeze) RH [ 90%] (there
needs to be no dew
condensation) amplifier: --
below -20 degrees C - +65
degree-C(there needs to be no
freeze) 90%RH (there needs to
be no dew condensation)
A thermometer,
a hygrometer, a
recorder
Entire Equipment Aren't there unusual
vibration and unusual
sound?
X It is based on viewing and
hearing.
If normal. -
Power supply
voltage
The main circuit voltage is
normal.
X Voltage measurement
between phase to phase of
the Servo amplifier terminal
stands R, S, and T
Standard specification is referred
to.
Multi-meter
Whole unit (1) Isn't there any slack of
Connector?
(2) After overheating into
each portion, is there
nothing?
(3) Cleaning
X
X
(1) Carry out an increase
bundle.
(2) It is based on viewing.
There are no abnormalities in (1)
and (2).
Mai
n ci
rcui
t Connection
conduct
Wire or cable
(1) Isn't there any
distortion in conduct?
(2) Isn't there any tear of
electric wire covering?
X (1) (2) It is based on
viewing.
There are no abnormalities in (1)
and (2).
Terminal stand Isn't it damaged? X It is based on viewing.
Are normal.
Flat and smooth
capacitor
(1) Isn't there any liquid
leak?
(2) Has not (safety valve)
come out or doesn't a
swelling have it?
X
(1) and (2) is based on
viewing.
(1)(2). There are no
abnormalities
Capacity meter
8. Maintenance and Inspection
8-3
swelling have it?
(3) Measurement of static
electricity capacity
X (3) Measure with a capacity
measuring instrument.
(3) 85% or more of rated
capacity
Mai
n ci
rcui
t
Relay (1) Isn't there any Beeper
sound at the time of
operation?
(2) The check of the time
of a timer of operation
(3) Isn't there that any in a
point of contact?
X
X
X
(1) It is based on a feeling of
listening
(2) Time from a power
supply ON to relay suction
(3) It is based on viewing.
(1) Are normal.
(2) Operate in 0.1 - 0.15
seconds.
(3) Are normal.
Multi-meter
Resistor
(1) Isn't there any Wire of
a resistor insulator?
(2) The check of
disconnection existence
X
X
(1) It is based on
viewing. Cement
resistance and
winding form
resistance
(2)
Remove connection
of one side and they
are measurement
cement resistance
and winding form
resistance with a
tester.
(1) Are normal.
(2) It is less than 10% of error
of display resistance.
8. Maintenance and Inspection
Check Item
Check matter
Daily
Period
Check method
Judgment standard
Meter
Con
trol c
ircui
t and
pro
tect
ion
circ
uit To check of
operation
(1) By Servo simple
substance (no-load)
operation, it is the check of
balance of each phase of
output voltage.
(2) Sequence protection
operation is performed and
there are no abnormalities
in protection / display
circuit.
X
X
(1) Measure the Servo
amplifier output terminals U
and V and the voltage
between W phase.
(2) Short-circuit the
protection circuit output of
Servo amplifier in imitation.
(1) The voltage balance between
phase to phase is less than
[ 4V ].
(2) Abnormalities operate on a
sequence.
Rectified type
voltmeter
Coo
ling
syst
em Cooling fan (1) Aren't there unusual
vibration and unusual
sound?
(2) Isn't there any slack
of a connection part?
X
X
(1) It turns by hand in the
state of no power supply.
(2) Carry out an increase
bundle.
(1) Rotate smoothly.
(2) Are normal.
Dis
play
Display Aren't there a charge
lamp and a piece of a 7
segment Light Emitting
Diode display?
X The lamp and display
machine of the amplifier
face of a board are shown.
Lighting is checked.
Serv
omot
or Whole unit (1) Aren't there unusual
vibration and unusual
sound?
(2) Isn't there any nasty
smell?
X
X
(1) It is based on a feeling
of listening, a physical
feeling, and viewing.
(2) The nasty smell check
by overheating, damage,
etc.
There are no abnormalities in
(1) and (2).
Encoder Aren't there unusual
vibration and unusual
sound?
X It is based on a feeling of
listening, and a physical
feeling.
Are normal.
Cooling fan (1) Aren't there unusual
vibration and unusual
sound?
(2) Have not the foreign
substance, etc. adhered?
X (1) It turns by hand in the
state of no power supply.
(2) It is based on viewing.
(1) Rotate smoothly.
(2) Are normal.
Bearing Aren't there unusual
vibration and unusual
sound?
X It is based on a feeling of
listening, and a physical
feeling.
Are normal.
8-4
8. Maintenance and Inspection
8.1.3 Parts exchanged
The following parts have secular degradation on mechanical wear or physical properties, and since the
performance fall of a unit and failure may be affected, while performing a scheduled inspection for preventive
maintenance, it is necessary to carry out periodical exchange.
(1) Flat and smooth capacitor : As for a flat and smooth capacitor, the characteristic deteriorates under the
influence of ripple current etc. Although greatly influenced by
circumference temperature and the operating condition, the life of a
capacitor will turn into a life in ten years, when continuation operation is
carried out on the air-conditioned usual environmental conditions.
(2) Relays : Poor contact occurs in the point-of-contact wear by opening-and-closing
current. Although influenced by power supply capacity, it becomes a life
by the 100,000 hours of accumulation opening and closing (opening-and-
closing life).
(3) Servo amplifier cooling fan : It is 10,000 - 35,000 hours from a cooling fan's bearing life. Therefore, in
continuation operation, it is necessary to usually exchange it the whole
fan, using the 2 - 3 year as a standard. Moreover, when unusual sound
and unusual vibration are discovered at the time of check, it is necessary
to exchange.
(4) Servo motor bearing : Please exchange 20,000 - 30,000 hours for a standard by rated speed and
rated load operation. Since it is influenced by the operation situation,
when unusual sound and unusual vibration are discovered, exchange is
required at the time of check.
(5) Servo motor oil seal, V ring: Exchange is needed by making 5000Hr(s) into a standard at rated speed.
Exchange is needed, when an oil leak etc. is discovered at the time of
check, since it was influenced by operation conditions.
(6) Battery : It will become a life from a manufacture day in five years.
8-5
8. Maintenance and Inspection
8-6
Table 8.2 Standard exchange years of parts
Parts Standard exchange time Remark
Flat and smooth capacitor 10 Years
Servo amplifier Relay -
Cooling Fan 10,000 ~30,000hours (2~3 Years)
Bearing 20,000 -- 30,000 hours
Servo motor Encoder 20,000 -- 30,000 hours
Oil seal, V Ring 5000 hours
Battery It is for five years from a manufacture day.
8. Maintenance and Inspection
8.1.4 Troubleshooting
If alarm is generated, a failure signal (ALM) will be turned off that displayed alarm on a display part.
A servo motor stops. Please remove the cause of alarm according to which kind of Alarm . A
generating factor can be referred to if the setup software of an option is used. Only in the case of
MR-J2S, an alarm code is outputted. In MR-H, use of a parameter unit can refer a generating factor.
(Note2)Alarm Code Alarm deactivation
Display CN1B 19
CN1A 18
CN1A 19
Name Power OFF→
ON
Press “set” on current Alarm screen
Alarm reset (RES) signal
AL.10 0 1 0 Undervoltage o o o AL.12 0 0 0 Memory error1 o AL.13 0 0 0 Clock error o AL.15 0 0 0 Memory error 2 o AL.16 1 1 0 Encoder error 1 o AL.17 0 0 0 Board error 2 o AL.19 0 0 0 Memory error 3 o AL.1A 1 1 0 Motor combination error o AL.20 1 1 0 Encoder error 2 o AL.24 1 0 0 Motor output ground fault o AL.25 1 1 0 Absolute position erase o AL.30 0 0 1 Regenerative error o o o
AL.31 1 0 1 overspeed o o o
AL.32 1 0 0 overcurrent o o o
AL.33 0 0 1 overvoltage o AL.35 1 0 1 Command pulse frequency error o o o
AL.37 0 0 0 Parameter error o AL.45 0 1 1 Main circuit device overheat o o o
AL.46 0 1 1 Servomotor overheat o o o
AL.50 0 1 1 Overload 1 (note1) o (note1) o (note1) o
AL.51 0 1 1 Overload 2 (note1) o (note1) o (note1) o
AL.52 1 0 1 Error excessive o o o
AL.8A 0 0 0 Series communication time-out o o o
AL.8E 0 0 0 Series communication error o o o
8.8.8.8.8. 0 0 0 Watchdog o AL.92 Open battery cable warning
AL.96 Home position setting warning
AL.9F Battery warning
AL.E0 Regenerative warning
AL.E1 Overload warning
AL.E3 Absolute position counter
warning
AL.E5 ABS time-out warning
AL.E6 Servo emergency stop
AL.E9 Main circuit off warning
AL.EA
ABS servo-on warning
Removing the cause of occurrence deactivates the alarm automatically.
Note 1. Deactivate the alarm about 30 minutes of cooling time after removing the cause of occurrence. 2. If the value of a parameter 49 is set to "01", an alarm code can be outputted at the time of alarm generating. 0:
It becomes an OFF 1:ON signal.
8-7
8. Maintenance and Inspection
Dis- play Name Defination Cause Action
1. Power supply voltage is low.
2. There was an instant power failure for 15ms or more.
3. Shortage of Power supply capacity caused the power supply voltage to drop at start,
etc. 4. It turned on within 5s after the power
supply OFF.
Review the power supply. AL.10 Undervoltage Power supply voltage dropped. MR-J2S-A:160V or less
5. Faulty parts in the servo Amplifier
Alarm(AL. 10) occurs if power is switched on after N1A,CN1B and CN3 connectors are disconnected
Checking Method
Change the servo amplifier
AL.12 Memoty error1 RAM, Memory fault
AL.13 Clock error Print board fault
AL.15 Memory error2 EEP-ROM fault
Faulty parts in the servo amplifier
Alarm(any of AL12,13 and 15) occurs if power is switched on after CN1A,CN1B and CN3 all connectors are disconnected.
Check Method
Change the servo amplifier.
1. CN2 connector disconnected. Connect correctly
2. Encoder fault Changed the servo motor.
3. Encoder cable faulty (Wire breakage or shorted)
AL.16 Encoder error1 Communication error occurred between encoder and servo amplifier
4. The combination of Servo amplifier and a servo motor is different.
Cable repair or exchange.
Note
At the time of alarm generating, please re-operate after removing a cause and securing safety. It becomes the cause of an injury.
When the following alarm is generated, please carry out alarm release repeatedly by control circuit power supply OFF->ON, and do not resume operation. It becomes the cause of failure of Servo amplifier, a servomotor, and a regeneration option. Please resume operation after setting the cooling time for about 30 minutes at the same time it removes the cause of generating.
* Regenerative error(AL.30) * Overload 1 (AL.50) * Overload 2 (AL.51)
Wa rning
8-8
8. Maintenance and Inspection
Display Name Definition Cause Action
AL.17 Board error 2 CPU/parts fault AL.19 Memory error 3 ROM memory fault
Faulty parts in the servo amplifier Checking method
Alarm (AL.17 or AL.19) occurs i f power is switched on after CN1A,CN1B and CN3 connectors aredisconnected.
Change the servo amplifier.
AL.1A Motor combination error
Wrong combination of servo anplifier and servo motor.
Wrong combination of servo amplifier and servomotor connected.
Use correct combination.
1. Encoder connector (CN2) disconnected. Connect correctly. AL.20 Encoder error 2 Communication error occurred between encoder and servo amplifier.
2. Encoder cable faulty (Wire breakage or shorted)
Repair or change the cable.
1. Power input wires and servo motor output wires are in contact at main circuit terminal block (TE1).
Connect correctly.
2. Sheathes of servo motor power cables deteriorated, resulting in ground fault.
Change the cable.
AL.24 Main circuit error Ground fault occurred at the servo motor outputs (U,V and W phases) of the servo amplififer.
3. Main circuit of servo amplifier failed. Checking method
AL.24 occurs i f the servo isswitched on after disconnect ingthe U, V, W power cables fromthe servo ampli fier .
Change the servo amplifier.
1. Reduced voltage of super capacitor in encoder
After leaving the alarm occurring for a few minutes, switch power off, then on again. Always make home position setting again.
2. Battery voltage low
Absolute position data in error
3. Battery cable or battery is faulty. Change battery. Always make home position setting again.
AL.25 Absolute position erase
Power was switched on for the first time in the absolute position detection system.
4. Super capacitor of the absolute position encoder is not charged
After leaving the alarm occurring for a few minutes, switch power off, then on again. Always make home position setting again.
1. Wrong setting of parameter No. 0 Set correctly. 2. Built-in regenerative brake resistor or
regenerative brake option is not connected.
Connect correctly
3. High-duty operation or continuous regenerative operation caused the permissible regenerative power of the regenerative brake option to be exceeded.
Checking methodCal l the status display and checkthe regenerat ive load rat io.
1. Reduce the frequency of positioning. 2. Use the regenerative brake option of larger
capacity. 3. Reduce the load.
4. Power supply voltage is abnormal. MR-J2S- A:260V or more MR-J2S- A1:135V or more
Review power supply
Permissible regenerative power of the built-in regenerative brake resistor or regenerative brake option is exceeded.
5. Built-in regenerative brake resistor or regenerative brake option faulty.
Change servo amplifier or regenerative brake option.
AL.30 Regenerative alarm
Regenerative transistor fault
6. Regenerative transistor faulty. Checking method
1) The regenerat ive brake opt ion has overheated abnormally.2) The alarm occurs even after removal of the bui l t -in regenerat ive brake resistor or regenerat ive brake opt ion.
Change the servo amplifier.
8-9
8. Maintenance and Inspection
Display Name Definition Cause Action
1. Input command pulse frequency exceeded the permissible instantaneous speed frequency.
Set command pulses correctly.
2. Small acceleration/deceleration time constant caused overshoot to be large.
Increase acceleration/deceleration time constant.
3. Servo system is instable to cause overshoot.
1. Re-set servo gain to proper value. 2. If servo gain cannot be set to proper value:
1) Reduce load inertia moment ratio; or 2) Reexamine acceleration/
deceleration time constant. 4. Electronic gear ratio is large
(parameters No. 3, 4) Set correctly.
AL.31 Overspeed Speed has exceeded the instantaneous permissible speed.
5. Encoder faulty. Change the servomotor. 1. Short occurred in servo amplifier output
phases U, V and W. Correct the wiring. AL.32 Overcurrent Current that flew is
higher than the permissible current of the servo amplifier.
2. Transistor (IPM) of the servo amplifier faulty.
Checking methodAlarm (AL.32) occurs if power isswitched on after U,V and Ware disconnected.
Change the servo amplifier.
3. Ground fault occurred in servo amplifier output phases U, V and W.
Correct the wiring.
4. External noise caused the overcurrent detection circuit to misoperate.
Take noise suppression measures.
1. Lead of built-in regenerative brake resistor or regenerative brake option is open or disconnected.
1. Change lead. 2. Connect correctly.
2. Regenerative transistor faulty. Change servo amplifier 3. Wire breakage of built-in regenerative
brake resistor or regenerative brake option
1. For wire breakage of built-in regenerative brake resistor, change servo amplifier.
2. For wire breakage of regenerative brake option, change regenerative brake option.
4. Capacity of built-in regenerative brake resistor or regenerative brake option is insufficient.
Add regenerative brake option or increase capacity.
AL.33 Overvoltage Converter bus voltage exceeded 400V.
5. Power supply voltage high. Review the power supply.
8-10
8. Maintenance and Inspection
Display Name Definition Cause Action
1. Pulse frequency of the command pulse is too high.
Change the command pulse frequency to a proper value.
2. Noise entered command pulses. Take action against noise.
AL.35 Command pulse frequency error
Input pulse frequency of the command pulse is too high.
3. Command device failure Change the command device. 1. Servo amplifier fault caused the
parameter setting to be rewritten. Change the servo amplifier. AL.37 Parameter error Parameter setting is
wrong. 2. Regenerative brake option not used with
servo amplifier was selected in parameter No.0.
Set parameter No.0 correctly.
1. Servo amplifier faulty. Change the servo amplifier. 2. The power supply was turned on and off
continuously by overloaded status. The drive method is reviewed.
AL.45 Main circuit device overheat
Main circuit device overheat
3. Air cooling fan of servo amplifier stops. 1. Exchange the cooling fan or the servo amplifier.2. Reduce ambient temperature.
1. Ambient temperature of servo motor is over 40 .
Review environment so that ambient temperature is 0 to 40 .
2. Servo motor is overloaded. 1. Reduce load. 2. Review operation pattern. 3. Use servo motor that provides larger output.
AL.46 Servo motor overheat
Servo motor temperature rise actuated the thermal protector.
3. Thermal protector in encoder is faulty. Change servo motor. 1. Servo amplifier is used in excess
of its continuous output current. 1. Reduce load. 2. Review operation pattern. 3. Use servo motor that provides larger output.
2. Servo system is instable and hunting. 1. Repeat acceleration/ deceleration to execute auto tuning.
2. Change auto tuning response setting. 3. Set auto tuning to OFF and make gain
adjustment manually. 3. Machine struck something. 1. Review operation pattern.
2. Install limit switches. 4. Wrong connection of servo motor. Servo
amplifier's output terminals U, V, W do not match servo motor's input terminals U, V, W.
Connect correctly.
AL.50 Overload 1 Load exceeded overload protection characteristic of servo amplifier. Load ratio 300%:
2.5s or more Load ratio 200%:
100s or more
5. Encoder faulty. Checking method
When the servo motor shaft isrotated slowly with the servo off,the cumulat ive feedback pulsesshould vary in propor t ion to therotary angle. I f the indicat ion skips or returns midway, the encoder is faulty.
Change the servomotor.
8-11
8. Maintenance and Inspection
Display Name Definition Cause Action
1. Machine struck something. 1. Review operation pattern. 2. Install limit switches.
2. Wrong connection of servomotor. Servo amplifier's output terminals U, V, W do not match servo motor's input terminals U, V, W.
Connect correctly.
3. Servo system is instable and hunting. 1. Repeat acceleration/deceleration to execute auto tuning.
2. Change auto tuning response setting. 3. Set auto tuning to OFF and make gain
adjustment manually.
AL.51
Overload 2 Machine collision or the like caused max. output current to flow successively for several seconds. Servo motor locked:
1s or more
4. Encoder faulty. Checking method
When the servo motor shaft isrotated slowly with the servo off,the cumulat ive feedback pulsesshould vary in propor t ion to therotary angle. I f the indicat ion skips or returns midway, the encoder is faulty.
Change the servomotor.
1. Acceleration/deceleration time constant is too small.
Increase the acceleration/deceleration time constant.
2. Torque limit value (parameter No.28) is too small.
Increase the torque limit value.
3. Motor cannot be started due to torque shortage caused by power supply voltage drop.
1. Review the power supply capacity. 2. Use servomotor which provides larger output.
4. Position control gain 1 (parameter No.6) value is small.
Increase set value and adjust to ensure proper operation.
5. Servo motor shaft was rotated by external force.
1. When torque is limited, increase the limit value.
2. Reduce load. 3. Use servomotor that provides larger output.
6. Machine struck something. 1. Review operation pattern. 2. Install limit switches.
7. Encoder faulty Change the servomotor.
AL.52 Error excessive The droop pulse value of the deviation counter exceeded the encoder resolution 10 [pulse].
8. Wrong connection of servomotor. Servo amplifier's output terminals U, V, W do not match servo motor's input terminals U, V, W.
Connect correctly.
1. Communication cable breakage. Repair or change communication cable 2. Communication cycle longer than
parameter No. 56 setting. Set correct value in parameter.
AL.8A Serial communication time-out error
RS-232C or RS-422 communication stopped for longer than the time set in parameter No.56. 3. Wrong protocol. Correct protocol.
1. Communication cable fault (Open cable or short circuit)
Repair or change the cable. AL.8E Serial communication error
Serial communication error occurred between servo amplifier and communication device (e.g. personal computer).
2. Communication device (e.g. personal computer) faulty
Change the communication device (e.g. personal computer).
8-12
8. Maintenance and Inspection
Display Name Definition Cause Action
88888 Watchdog CPU, parts faulty Fault of parts in servo amplifier Checking method
Alarm (88888) occurs i f poweris switched on after CN1A, CN1Band CN3 connectors aredisconnected.
Change servo amplifier.
8.1.5 Remedies for warnings
Display Name Definition Cause Action
1. Battery cable is open. Repair cable or changed. AL.92 Open battery cable warning
Absolute position detection system battery voltage is low. 2. Battery voltage dropped to 2.8V or less. Change battery.
1. Droop pulses remaining are greater than the in-position range setting.
Remove the cause of droop pulse occurrence
2. Command pulse entered after clearing of droop pulses.
Do not enter command pulse after clearing of droop pulses.
AL.96 Home position setting warning
Home position setting could not be made.
3. Creep speed high. Reduce creep speed. AL.9F Battery warning Voltage of battery for
absolute position detection system reduced.
Battery voltage fell to 3.2V or less. Change the battery.
AL.E0 Excessive regenerative warning
There is a possibility that regenerative power may exceed permissible regenerative power of built-in regenerative brake resistor or regenerative brake option.
Regenerative power increased to 85% or more of permissible regenerative power of built-in regenerative brake resistor or regenerative brake option.
Checking methodCall the status display and checkregenerat ive load rat io.
1. Reduce frequency of positioning. 2. Change regenerative brake option
for the one with larger capacity. 3. Reduce load.
AL.E1 Overload warning There is a possibility that overload alarm 1 or 2 may occur.
Load increased to 85% or more of overload alarm 1 or 2 occurrence level.
Cause, checking methodRefer to AL.50,51.
Refer to AL.50, AL.51.
1. Noise entered the encoder. Take noise suppression measures. AL.E3 Absolute position counter warning
Absolute position encoder pulses faulty. 2. Encoder faulty. Change servo motor.
1. PC lader program wrong. Contact the program. AL.E5 ABS time-out warning
2. ST2 TLC signal mis-wiring Connect properly.
AL.E6 Servo emergency stop warning
EMG-SG are open. External emergency stop was made valid. (EMG-SG opened.)
Ensure safety and deactivate emergency stop.
8-13
AL.E9 Main circuit off warning
Servo was switched on with main circuit power off.
Switch on main circuit power.
1. PC ladder program wrong. 1. Correct the program. AL.EA ABS servo-on warning
Servo-on signal (SON) turned on more than 1s after servo amplifier had entered absolute position data transfer mode.
2. SON signal mis-wiring. 2. Connect properly.
8. Maintenance and Inspection
8.1.6 The cause investigation method at the time of position gap generating Position Servo
8-14
In the above figure, “A” is the output pulse counter and “B” is the command pulse accumulation, “C” is the return pulse accumulation display, and “d” is the machine stop position are the check parts at the time of position gap generating. Moreover, the figure shows a position gap reason. For example, the noise having ridden on wiring of positioning equipment and Servo amplifier, and having carried out the mistake count of the pulse is shown. The next relation is materialized in the normal state where a position gap is not carried out.
(1) Q= P(Output counter = Servo amplifier instruction pulse accumulation of positioning equipment)
CMX (Parameter No.3) (2) P • CDX (Parameter No. 4)
= C (Command pulse accumulation x electronic gear = return accumulation)
(3) C •Δλ= (machine position = Amount of per pulse movements x return accumulation)
The position gap is checked in order of the following. (1) If Q ≠ P
The mistake count of noise riding and the pulse was carried out at wiring of the pulse sequence signal
of positioning equipment and Servo amplifier. (Reason A )
CMX
(2) If P • ≠ C
A outputPulse counter
Q
Electronic gear (Parameter No. 3, 4)
P
B Command pulse accumulation
C
C Return pulse accumulation
CMXCDV
Encoder
M
L Servomotor
D Servo on (SON)stroke and (LSP-LSN) an input
D Machine stop position (M)
A
B
C
Machine
CDV
A Servo On signal (SON), right running and an inversion stroke, and the signal (LSP-LSN) were
turned off during operation. Or the clear signal (CR) was turned on. (Reason D)
(3) If C •Δλ ≠ M
The noise rode on wiring of the Encoder cable, and the mistake count of the pulse was carried out. Or
8. Maintenance and Inspection
8-15
the mechanical slide was produced between the servomotor and the machine.
Appendices
Appendix 1 Symbols for the specifications T a
T d
T M a
T M d
T L
T u
T F
T lo
Trms
T m
T max
J L
J LO
J m
N r
N o
N
V o
V
P B
Z1
Z 2
: Acceleration time
: Deceleration torque
: Motor torque required for acceleration
: Motor torque required for acceleration
: Converted torque of inertia applied to the motor shaft
: Imbalance torque
: Torque of load friction
: Torque of load on load shaft
: Converted continuous effective load torque applied to the motor shaft
: Rated motor torque
: Max. motor torque
: Converted moment of load inertia applied to the motor shaft
: Converted moment of load inertia applied to the load shaft
: Moment of rotor inertia of the motor
: Rated motor rotational speed
: Motor rotational speed at the Max. machine speed
: Motor rotational speed
: Max. machine speed
: Machine speed
: Lead of ball screw
: No. of gear teeth on the motor shaft
: No. of gear teeth on the load shaft
[N•m]
[N•m]
[N•m]
[N•m]
[N•m]
[N•m]
[N•m]
[N•m]
[N•m]
[N•m]
[N•m]
[kg•cm 2]
[kg•cm2]
[kg•cm2]
[r/min]
[r/min]
[r/min]
[mm/min]
[mm/min]
[mm]
P I
F CI
F c
fo
Tpsa
Tpsd
K p
T P
∆λ o
∆λ c
λ
P
T f
t o
t st
tc
ts
m
ε
∆ ε
∆S
: No. of feedback pulses
: Electronic gear output pulse frequency
: Electronic gear input pulse frequency
: Input pulse frequency at the max. machine speed
: Acceleration time of command pulse frequency
: Deceleration time of command pulse frequency
: Position loop gain
: Position loop time constant (T P = 1 / K P )
: Feed distance per output pulse of electronic gear
: Feed distance per input pulse of electronic gear
: Feed distance per operation
: No. of input command pulses
: One operation cycle
: Position time
: Stop time
: Rated operation time
: Setting time
: Inertia ratio (m = J L / J M )
: No. of deviation counter pulses
: Positioning accuracy
: Feed distance per motor revolution
Example: Ball screw
[pulse/rev]
[pps]
[pps]
[pps]
[s]
[s]
[s- 1]
[s]
[mm/pulse]
[mm/pulse]
[mm]
[pulse]
[s]
[s]
[s]
[s]
[s]
[pulse]
[mm]
[mm]
Z1 Reduction ratio 1/n=
Z2 Speed decrease if 1/n < 1; Speed increase if 1/n > 1.
If direct connection ∆S = P B
If reduction ratio is 1/n ∆S = P B • (1/n)
Note 1. If the moment of inertia is expressed as G D 2, the relationship with J is GD 2 = 4X J.
2. 1kg •m2 = 10000kg • cm2
3. For the purposes of the specifications in the table above, “input” and “output” are defined in relation
to the servo amplifier. If input and output were defined in relation to the positioning controller, some
of the specifications above would have to be redefined. Two examples are given below:
Electronic gear input pulse frequency f c → Command output pulse frequency
Feed distance per input pulse of electronic gear ∆λ c → Feed distance per command per output pulse
(least command unit)
APP-1
APPENDICES
Appendix 2 Types of Drive System
(1) Classification of motion direction There are varieties of drive systems driven by an AC servomotor, and the system best fitting the intended purpose (required accuracy, feed accuracy in motion, travel distance, type of machine operation, etc.) can be selected. In order to examine the relationship between the mechanical system and the servomotor, the direction of machine motion is considered first. The command unit for linear motion is mm; for rotary motion, either the angle or the number of the servomotor must be assessed carefully since torque with a negative value is generated during operation.
Classification of Motion Direction
Horizontal Direction Vertical Direction
* The drive method most widely adopted for table feed of various machines, and transfer system, using a ball screw, rack and pinion, belt, etc.
* The drive method adopted for vertical motion in transfer systems and vertical motion axis of robot, etc. As shown in the illustration, a counterweight for balancing the load is often used. A motor equipped with a magnetic brake is also used to prevent the load from falling in the case of power failure.
SM
B
W Magnetic brake
Reduction gear Servo Motor
Counterweight
Chain
Ball screw
Encoder Servo Motor Reduction gear
Ball screw Table
Li
near
Mot
ion
The drive method adopted for rotary axes such as those of index table.
Generally, the rotational speed of the load axis(table rotating axis) is small and motor speed is reduced by gears or pulleys.
Worm gear
Bevel gears Example 1: Connection by gear
Servomotor
Servomotor
Example 2: Connection by belt
Timing belt
R
otar
y M
otio
n
APP-2
APPENDICES
(2) Example of drive methods For position control using a position loop, the basic element is the machine feed distance per pulse. To calculate this distance, it is necessary to determine the machine feed distance (symbol: ∆S, unit: mm) per motor revolution. The general configurations of the drive systems used for linear motion applications, shown in (1), are illustrated below, accompanied by details of basic formulae.
Classification of drive Methods Features and Basic Formula
* The typical drive method adopted for
accurate positioning in a relatively short
motion distance
Positioning accuracy and motion speed
are influenced by the ball screw lead; if
the ball screw lead is made smaller,
accuracy becomes higher and motion
speed becomes slower. (with the same
servomotor).
[ Basic formula]
Feed distance per motor revolution.
∆S (mm) = P B(mm)• (1/n)
If the coupling is directly connected without
using the reducer:
∆ S = P B
* The drive method adopted for positioning
over relatively long distance.
* Usually, the pinion is fixes and the rack
moves. In some applications, the rack is
fixed and the pinion side(including the
motor) moves.
[ Basic Formula ]
∆ S (mm) = P L (mm)• Z • (1/n)
or
∆S = PCΦ • π • (1/n)
Object to be driven
Lead of ball screw (symbol: Pb) Reduction ratio (1/n)
(1
) Bal
l scr
ew
Reduction ratio (1/n)
PC
Symbols for pinion
Module (Symbol: m)
Number of teeth (symbol: Z)
Rack pitch (symbol: PL)
Rack
Rac
k
Pini
on
Teeth are machine in fixed pitches on straight bar.
Gear with teeth machined in fixed pitches on its circumference.
Pinion
(2
) Rac
k an
d pi
nion
APP-3
APPENDICES
Classification of Drive Methods Features and Basic Formulas
* The drive method widely adopted for
various applications from large-sized
transfer systems to precision machines.
* In contrast to the situation with the V-
belts and flat belts often used for belt
drive systems, the teeth in the pulley and
those in the timing belt engage with each
other to ensure positive drive and there is
no error due to slip. However, with some
types of belt materials, deterioration in
accuracy is caused by aging, such as wear,
and careful maintenance is necessary. The
belt pitch is specified in “inch” system
dimensions. Therefore, if control is
executed in the “mm” system, fractions
are generated when setting the relationship
between the command pulse and the feed
distance.
[ Basic Formula ]
∆S (mm) = PT (mm)• Z • (1/n)
* The drive method generally adopted for
large-sized transfer systems.
* This method is suitable for feeding an
object at high-speed over a long distance.
* The chain pitch is specified in “inch”
system dimensions, as with the timing
belt. This means that some care is
required when setting the feed distance.
Another factor to be taken into
consideration is the initial elongation of
the chain that affects positioning
accuracy.
[ Basic Formula]
∆ S(mm) = Pc (mm)• Z • (1/n)
Belt pitch (Symbol: PT)
Reduction ratio (1/n) Number of pulley teeth (Symbol: Z)
Teeth on pulley
Timing pulley
Timing pulleyTiming belt
Timing Belt Enga
gem
ent b
etw
een
pulle
y an
d be
lt
(3
) Tim
ing
belt
No. of sprocket teeth (symbol: Z)
Reduction ratio (1/n)
Chain pitch (symbol: PC)
Chain
(4
) Cha
in
APP-4
APPENDICES
Classification of Drive Methods Features and Basic Formula
* The drive method in which workplaces
are fed by the friction force generation
force generated when a roll is rotated.
* This method is widely adopted for fixed-
pitch feed(the roll feeder for presses is a
typical example), and also for feeding film
sheet and paper(draw-control, cutters, etc.)
* To improve the positioning accuracy, it is
necessary to eliminate slip between the roll
and the material as well as to machine the
roll precisely to achieve a true circle.
* Since π is an irrational No. fractions
are inevitable when the command
pulse are converted into feed distance.
Compensation is therefore necessary.
[ Basic formula]
∆S (mm) = π • D(mm) • (1/n)
* The drive method used to drive a
cart with the servomotor mounted in
the cart as the drive power source
* The method of driving the wheels with
a servomotor, illustrated to the left, is
the one generally adopted. Careful
consideration is required to eliminate
slip between the rail and the wheels.
* The rack and pinion mechanism is
also used to drive carts. While the rack
is fixed, the pinion moves along the
rack.
[ Basic Formula] ( for the mechanism
illustrated to the left)
∆ S (mm) = π • D (mm) • (1/n)
Feed roll
Diameter of feed roll (Symbol : D)
Reduction ratio (1/n)
Workplace (material)
(5
) Rol
l fee
d
Cart
Cart drive mechanism
Drive wheels (right and left)
Diameter of drive wheel (symbol: D)
Gear reduction (1/n)
(6
) Driv
ing
cart
APP-5
APPENDICES
APPENDIX3. EXAMPLE APPLICATIONS
Several example applications using an AC servomotor are described below.
(1) X - Y Table a. A MELSEC-A series
programmable controller is used to run a program that executes high-speed and accurate positioning of the X-Y table driven by an AC servomotor.
* Devices used Servomotor: HC-KFS Servo amplifier: MR-J2S 2-axis positioning module AD75
(2) Transfer System (Vertical transfer)
Transfer and positioning of a lifter are controlled by the program of the FX-1 GM positioning module.
The servomotor equipped with an magnetic brake is used to prevent the load from falling in the event of a power failure.
* Devices used Servomotor(With brake): HC-SFS-B Servo Amplifier: MR-J2S Regeneration option: MR-RB Position Module: FX-10GM
AD75TAD75 HC-KFS
MR-J2S
Pulse train
HC-KFS
Lifter
HC-SFS-B
Pulse train
FX-10GM
MR-J2S Regeneration option
APP-6
APPENDICES
(3) Synchronous feed (coating line) The sensor is used to detect the
position of products and the encoder is used to control synchronous feed. After feeding a fixed distance, the mechanism returns to the home position and waits for the arrival of the next product.
Encoder for synchronous feed control
Positioning controller A171SH
MR-J2S-B HC-SFS
Sensor
* Devices used Servomotor: HC-SFS Servo Amplifier: MR-J2S-B Motion controller: A171SH Encoder for synchronous feed control.
Digital switches
MR-H-AC
Servomotor
Press
Roll feeder
(4) Press roll feeder
By driving the feed roll with an AC servomotor, a fixed length of material is supplied to the machine.
The material is supplied while the ram is moving up; the ram moves done to press the material after positioning of the supplied material has finished.
The feed distance is input from an external digital switch and transmitted to the servo amplifier.
* Devices used Servomotor: HC-SF Servo amplifier: MR-H-CAN(with built-in 1-axis positioning control function)
APP-7
APPENDICES
(5) Torque control (tension control) By combining a digital
servo system in the torque control mode with a tension sensor and tension control module, the tension is controlled during winding of sheet material.
Torque sensor
LX-TCServo amplifier
MR-H-AN
LA-10AT-SET
Tension control module
Input ofTorquecommand
* Devices used Servomotor: HC-SF Servo amplifier: MR-HAN Tension sensor: LX-TC Tension control module: LA-10AT-SET
APP-8
APPENDICES
APPR-9
Appendix 4 Positioning Controllers Performance Comparison
Controller positioning unit type Unit kind FX-1PG FX-1GM
FX-10GM FX-20GM AD75P1
A1SD75P1 AD75P2
A1SD75P2 AD75P3
A1SD75P3 The network CPU Positioning unit Servo amplifier
Syst
em c
onfig
urat
ion
Servomotor
(note) (1)The solid show the line bus connection. (2)Adashed line shows a pulse sequence.
C-C LINK(MNET/MINI) CPU
MNET( II), MNET/B(MNET/10)
I/F
spec
ifi-
catio
n
A positioning unit amplifier
A pulse sequence or bus connection
Pulse train Pulse train Pulse train Pulse train
Pulse train Pulse train
Instruction language (used language) *
Language + ladder Special language+ladder Data table system + ladder
Encoder specification INC/ABS System INC/ABS INC/ABS INC/ABS
The program for ABS communication is INC/(ABS), however it is necessity and difficulty at the time of ABS use.
The maximum controllable number of axes
One axis One axis Two axes One axis Two axes 3 axes
Output pulse frequency 100KPPS 100KPPS 200KPPS
(100KPPS) Differential system 400KPPS
Open collector system 200KPPS Pattern control function * * Linear/circular * Linear/circular
The main control functions Position/speed Position/speed Position/speedPosition/speed (position and speed )
change constant The number of control axes
small-scale axial control
small-scale axial control
For 2 axis control
For 1 axis control
For 2 axis control
For 3 axis control
Sequence Function (No.s of I/O)(Memory capacity)
All positioning
data is a ladder and
an object for small-scale I/O systems.
All positioning
data is a ladder and
an object for small-scale I/O systems.
I/O mark are an
object with I/O=8 /
eight points for small-
scale.
ACPU can be chosen arbitrarily. Position data is a data table system. (Even 100 point / axis is possible for the time of 600 point / axis, and a CPU write-in system)
SerContr
vo ol
function
For easy positioning
For easy positioning
two axes , more
function
1 axis
The straight line, circle assistant speed / position
control
The point and elated point of model selection of a positioning unit / controller group
Cost Performance Others
It is small and is a cheap system. It is used in combination with CPU.
It is small cheap system. Use is possible even when it is independent.
It is small cheap system. Use is possible even when it is independent.
Small (one 32 slot occupancy) and cheap. It is a FROM/TO command between CPUand position unit. Between positioning unitServo amplifier, they are a pulse sequenceand those with cable length restrictions. an electronic gear, both AD75P and Servoamplifier uses is possible electronic key position data -- a flash ROM --storing (battery -- unnecessary) AD75P andServo position data -- a flash ROM -- bothstoring (battery -- unnecessary) backup use ispossible
The Servo amplifier series group *
MR-J2-Jr MR-J2-A
MR-J2S-A MR-H-AN
In addition, all pulse sequence I/F systems can be used.
MR-J2-Jr MR-J2-A
MR-J2S-A MR-H-AN
In addition, all pulse sequence I/F systems can be used.
Perip
hera
l eq
uipm
ent
The programming tool for positioning, and a S/W package
* FX-PCS/WIN
* FX-PCS -KIT/98
* E-20TP * FX-PCF-KIT-GM/98
(DOS/V, PC98 personal computer) SW*NX-AD75P SW*IVD-AD75P
APPENDICES
APPR-10
AD75M1
A1SD75M1 AD75M2
A1SD75M2 AD75M3
A1SD75M3 AD778M
A1SD778M A171SH
CPU A172SH
CPU A173UH
CPU A273UH
CPU
MR-J2C
MR-H
ACN
MNET(Ⅱ)、MNET/B(MNET/10) CPU
Bus connection Bus connection
Bus connection --
Data table system + ladder Special
language ladder
Special language + ladder (NC language SV43 station)
Point table system /Point-of-contact input
INC/ABS ABS only
INC/ABS INC/ABS
1 axis 2 axes 3 axes 8 axes 4 axes 8 axes 32 axes 32 axes 1 axis 1 axis
High-speed serial communication system
High-speed serial
communication system
High-speed serial communication system --
* straight/ circle line straight/ circle
straight/ circle line *
A position / speed / position, and speed change
A position / speed /
position, and speed change
position/speed/-- a position, and speed change / position flattery control / cam Position Position
For 1 axiscontrol
For 2 axes control
For 3 axes control
For max 8 axes control
For max 8 axes control
For max 8 axes control
For max 32 axes control
For max 32 axes control For 1 axis
control For 1 axiscontrol
ACPU can be chosen arbitrarily. Position data is a data table system. (600 point / axis, even 100 point / axis is possible for the time of a CPU write-in system) (It is the program needlessness for communication also at the time of ABS use)
Combination is arbitrarily possible for ACPU.
They are I/O=512 point 14K step 0.25microsecond / step by A2SH.
A2SH-S1 about I/O=1024 point 30K step 0.25microsecond / step
A3U about I/O=2048 point 60K step 0.15microsecond / step
A3U about I/O=2048 point 60K step 0.15microsecond / step
All positioning data is built-in point table systems. For small-scale I/O systems.
For 1 axis control
A straight line, circle assistant control speed / position control, others
4 axis straight line 2 axis circle
4 axis straight lines, 2 axis circle assistant control speed / position, uniform control, position flattery control For easy
positioning For easy
positioningIt is a FROM/TO command between small (one 32 slot occupancy), cheapness, wiring easy CPU unit. A SSCNET bus and all the axial Servo-on signals Y15 are required between positioning unit and Servo amplifier. Infinite length positioning of ABS specification is impossible. The electronic gear in Servo amplifier cannot be used (pear). Electronic gear magnification is applied at the time of hand PA use. All parameter setup is performed from theAD75 side.
Motion language use. SSCNET bus connection ABS infinitelength positioning is possible.
(1) A motion language, NC language use (SV43) (2) SV13/SV22/SV43/SV51 Selection is possible. (3) It is a SSCNET system between controller and
Servo amplifier. (4) ABS infinite length positioning is possible.
It is small and is a cheap system. It is used independently.
It is small and is a cheap system. It is usedindependently.
MR-J2-B MR-J2S-B
MR-H-BN (full closed control is also possible)
<Terminus resistance important point>
same as left
same as left
MR-J2C MR-HACN
(DOS/V, PC98 personal computer) SW*NX-AD75P SW*IVD-AD75P
(DOS/V) SW0SRX- SV13ADL (Exclusive S/W)
(DOS/V, PC98 personal computer) (MS-DOS) OS : SW*SRX-SV13/SW*NX-SV13 : SW*SRX-GSV13/22 : SW*NX-GSV13/22 : SW**-CAMP
Main operation part of a general-purpose personal computer
General-purpose personal computer parameter unit
APPENDICES
<Special mention matter> 1. The Servo amplifier dealing with CC-Link serves as a MR-H-TN type. The number of
Servo amplifier connection becomes 21 sets in one master unit at the time of a maximum of 42 sets (at the time of one-game occupancy), and two-game occupancy.
2. FR-A500 series equips with built-in option FR-A5NC. The number of connection is a maximum of 42 sets (the number of connection changes with a remote device office and local broadcasting stations) at one master unit.
3. As for FR-E500 series, FR-E520-0.1 KN-FR-E520-7.5KN differs from a model name. 3. The basic base of A273UHCPU cannot be equipped with the special unit for sequencer A series.
4. the point of various system selections – (a) sequence function; (b) Servo function; (c) selection is required by the number of control axes; (d) cost performance; (e) programming nature; (f) system scale, extendibility, etc.
5. There is also the SFC (motion side) system Windows-NT version. In A171SH, correspondence is impossible.
6. The drive of MR-J2-A, Vector INV, the vector INV of the other company, etc. is also possible at use of an actuator I/F unit (analog output), and torque controls, such as tension control, are also possible.
7. Full Closed Loop Control is Possible to MR-H-AN and MR-H-BN at Option Built-in (Amplifier is Special).
8. Carry out from a positioning unit side altogether also including a Servo amplifier side parameter at the time of AD75M (A1SD75M) use. Therefore, it is easier for a program to use software-AD75P. Especially the parameter of fixation etc. recommends soft use.
APPR-11