Control Systems

and
Circuits – Part 2
 What we will learn today
 What are Servos?
 What is a CNC?
 Basic operation of the above
 Key parameters related to above
 Some applications
 What is Servo?
 Origin of the word - Late 19th century: from Latin servus ‘slave’.
 Slaves faithfully obey the commands of the master

 ‘the servos should faithfully follow the input commands’

 It is also used as a short for servomechanism or servomotor

 It works on the principle of controlling the position based on error

correction between the commanded position and the negative
feedback from the position sensor.

 Typical servo loop scan times are around 125 microseconds. It

means that the loop is corrected about 8000 times per second.

 PARI gantry X axis max. speed is 3 m/s. That translates to 3mm/ms.

 Types of Servo systems

 Servo systems can be of many types.

 Pneumatic
 Hydraulic
 Electro-Mechanical
 Most popular are the electromechanical systems due to their high
speeds , quick response and fine control.
 Servo systems can be controlled by a PLC or a CNC.

 If used with PLC , a positioning module is required to generate the

positioning commands.
 The CNC system is designed for positioning applications and has all
the necessary components required for positioning.
 What is a CNC System?

 A CNC stands for Computerised Numerical Control. The

system typically consists of:
 NC CPU
 PLC CPU
 HMI + Keyboard
 Teach Pendant
 Machine Panel
 Servo drives
 Servo motors
 Feedback system
 Some manufactures of CNC and Servo
Systems
 Siemens There are many more.
 Fanuc
 Bosch Rexroth But Siemens and Fanuc are the
most popular brands today and
 Mitsubishi
have the major market share.
 NUM
 Fagor
In our discussion today we will stick
 Fidia with Siemens CNC for convenience
 Heidenhain and since those are used in larger
 Parker volumes.
 Baumuller
 Beckhoff Other CNCs used at PARI are:
 Lenze Fanuc 0 series
Rexroth Bosch MTX series
 History of Siemens CNC
 SIemens NUMERIK control

 1960 first SIEMENS controller launched

 1967 SINUMERIK SYSTEM 200
 1975 microcontroller based SINUMERIK SYSTEM 7
 1981 SINUMERIK SYSTEM 3
 1984 SINUMERIK 810M and 810T were developed.
 1986 SINUMERIK 880
 1990 SINUMERIK 840C
 1994 SINUMERIK 840D was designed continued
 1996 SINUMERIK 810D
 2001 SINUMERIK 802D
 2006 SINUMERIK 802Dsl
 2009 SINUMERIK 828D
 What is a CNC System?

 NCU Unit 7x0.3PN

(e.g. Siemens 840Dsl)
 The NCU contains both the
NC processor and the PLC
CPU.
 What is a CNC System?

 CNC HMI – OP12 with TCU50

 What is a CNC System?

 Teach Pendant – HT8 + PN Box

 What is a CNC System?

 Machine Panel
What is a CNC System?

 Servo drives
Siemens Sinamics S120
 What is a CNC System?

 A.C. Servo Motors with built in encoders

 3-phase permanent magnet synchronous motors
Typical Network Diagram for a
Gantry Application
 NC-PLC Communication
· Part Program
· NC Parameters
Controls the · Safety Part Program
Axes positioning · Compensations
and speed · User Interface
control · Axes Interpolation

NC-PLC
NC Exchange Area
in from of
Data Blocks
(DB)

Controls the
Pneumatic and PLC
Hydraulically
operated
cylinders, · PLC Program
Induction motors · Digital and Analog I/Os
of conveyors, · Messaging
Lubrication, etc.
 Closed Loop System – Servo Loop
MOTION
COMMAND
NOMINAL NOMINAL NOMINAL
POSITION SPEED TORQUE
ROTARY
POSITION
POSITION SPEED CURRENT PWM ENCODER FOR
SETPOINT +- CONTROLLER +- CONTROLLER +- CONTROLLER INVERTER ROTOR SPEED (&
GENERATOR
AXIS POSITION)
CURRENT LOOP
POSITION LOOP
POSITION SPEED LOOP
MEASUREMENT
USING LINEAR
ENCODER
SLIDE NUT AND BELT & ELASTIC
BALL SCREW
MOTION LOAD PULLEY COUPLING

MECHANICAL TRANSMISSION COMPONENTS

Note:
Open loop - No Feedback
Semi Closed loop - Feedback from Motor Shaft only
Closed loop - Feedback from External Encoder coupled to the actual
moving part whose position is to be measured
 Current Loop
 This is the innermost loop.
 It monitors the current of the motor and maintains the current
according to the torque setpoint. Hence maintains the steady torque
of the motor.
 The Torque of the motor is directly proportional to the current through
the motor. Hence constant force can be maintained.
 Therefore limiting the current in the motor, the torque of the motor
can be limited.
 This feature can be used to limit the damages in case of crashes.
 Speed Loop
 This is middle loop.
 It monitors the Speed of the motor and maintains a constant speed.
 It uses the encoder feedback to measure the speed of the rotor. The
encoder is mounted directly on the motor shaft.
 The speed is directly proportional to the voltage applied to the motor.
 The variation in motor speed due to supply voltage variations is also
corrected by the loop and the programmed speed is maintained.
 Position Loop
 This is the outer most loop.
 It monitors the position of the axis and maintains is position and
trajectory.
 It uses the position feedback from either the motor mounted encoder
or an external encoder depending on the system configuration.
 The feedback can be from an incremental encoder or an absolute
encoder. They could be rotary or linear type.
A.C. Servo Motor Construction

Linear servo motor 

3 Phase Induction Motor with VFD
A.C. Servo Motor Characteristics
 Important considerations when
selecting a servo motor
 Rated Torque (Mn) – Torque (Nm) at the rated speed
 Static Torque (M0) - Torque (Nm) at the zero speed
 Rated Speed – Max. speed of motor without field weakening (almost
constant torque)
 Max. Mechanical Speed – Max. speed of motor with field weakening (Torque
reduces significantly) It is limited by the bearing RPM.
 Motor rotor inertia – Rotor to reflected load inertia ratios are important for
good controllability. 1:1 is the best for the finest control. For less demanding
applications like point to point positioning 1: 10 is ok. Ratios greater than this
need detailed study of the application and the resulting implications.
 Shaft type – plain, with key, tapered
 Frame size
 Speed Torque characteristics – to determine the torque available at the
speed required for the application
 Features of a A.C. Servomotor
 The various features of A.C. servomotor are:
 Light in weight cylindrical construction is with smaller diameter as
compared to the length, hence the rotor inertia is small allowing
quicker response to changes in speed
 Robust in construction.
 It is reliable and its operation is stable in nature.
 Smooth and noise free operation.
 Large torque to weight ratio.
 No brushes or slip rings are required. Hence maintenance free.
 Driving circuits are simple to design.
 The negative slope of the torque-slip characteristics adds more
friction improving the damping. This improves the stability of the
motor. This features is called internal electric damping of two
phase A.C. servomotor.
Absolute Rotary Encoders
Incremental Rotary Encoders
Principle of operation of a drive
 Fundamental operation of a drive
A PWM inverter is a voltage-source DC link converter with a constant DC
link voltage, which is converted into a three-phase voltage that is almost
sinusoidal with a variable voltage and frequency using a PWM inverter.
 Drive operation

 animation- How a VFD or variable frequency d

rive works.mp4

 construction of servo motor.mp4

 Kinematics Data
GL300 Gantry model

Parameter
Parameter Name Unit value value value
Number Comparison with Kinematics data sheet
Axis name - X Z1 Z2
In Gantry kinematics data maximum speed given is in mm/sec.For X axis speed
mm/ given is 3000 and for Z axis it is 2000.
Maximum Speed 18000 12000 12000
min we have to multiply these by 60 to set value in parameter 32000
32000 $MA_MAX_AX_VELO which is in mm/min
Acceleration Time Sec 1 0.67 0.67
32300 Acceleration (Maximum) m/sec2 3 3 3
32410 Jerk Parameter Sec 0.4 0.27 0.27
$MA_DRIVE_AX_RATIO_DEN
100 100 100
31050 OM[0] In Gantry kinematics data gear box reduction ration value give for X axis 7.25.
So we set this as Paramour 31050 DRIVE_AX_RATIO_DENOM[0]=100 and
$MA_DRIVE_AX_RATIO_NUM 31060 DRIVE_AX_RATIO_numera[0]=725
725 1025 1025 In Gantry kinematics data gear box reduction ration value give for Z axis 10.25.
ERA[0]
So we set this as Parameter 31050 DRIVE_AX_RATIO_DENOM[0]=100 and
31060 31060 DRIVE_AX_RATIO_numera[0]=1025
299.8 In Gantry kinematics data PCD of Pinion value given is
$MA_LEADSCREW_PITCH mm 299.83 299.83 95.49. 31030 Leadscrew pitch parameter must be set with value PCD of pinion
3
31030 multilied by Pi value (3.14)
Linear Travel per rev. of motor 41.37
mm 29.267 29.267
shaft 8
4350. In Gantry kinematics data these values given as Maximum motor operational
$MA_RATED_VELO RPM 4100.15 4100.15
32260 15 speed
Motor Brake torque Nm 43 43 43
6.695
Inertia Ratio to load - 0.8844 0.8844
6
Load inertia reflected on motor
Kg-m2 0.079 0.01044 0.01044
shaft
P1520 Torque limit upper Nm 75 55 55 In Gantry kinematics data these values given as maximum power
P1521 Torque limit lower Nm -75 -55 -55 In Gantry kinematics data these values given as maximum Torque
P2177 Motor locked Delay Time Sec 0.4 0.4 0.4 In Gantry kinematics data these values given as Max Torque Time
 Basic NC Parameters
GL300 Gantry model
Parameter
Parameter Name Unit Comparison with Kinematics data sheet
Number
In Gantry kinematics data maximum speed given is in
mm/sec.For X axis speed given is 3000 and for Z axis it
is 2000.
32000 Maximum Speed mm/min
we have to multiply these by 60 to set value in
parameter 32000 $MA_MAX_AX_VELO which is in
mm/min
32300 Acceleration (Maximum) m/sec2
32410 Jerk Parameter Sec
31050 $MA_DRIVE_AX_RATIO_DENOM[0] In Gantry kinematics data gear box reduction ration
value give for X axis 7.25.
So we set this as Parameter 31050
DRIVE_AX_RATIO_DENOM[0]=100 and
31060 DRIVE_AX_RATIO_numera[0]=725
In Gantry kinematics data gear box reduction ration
31060 $MA_DRIVE_AX_RATIO_NUMERA[0] value give for Z axis 10.25.
So we set this as Parameter 31050
DRIVE_AX_RATIO_DENOM[0]=100 and
31060 DRIVE_AX_RATIO_numera[0]=1025
In Gantry kinematics data PCD of Pinion value given is
31030 $MA_LEADSCREW_PITCH mm 95.49. 31030 Leadscrew pitch parameter must be set
with value PCD of pinion multilied by Pi value (3.14)
Linear Travel per rev. of motor shaft mm
In Gantry kinematics data these values given as
32260 $MA_RATED_VELO RPM
Maximum motor operational speed
 Basic Drive Parameters
GL300 Gantry model

Parameter
Parameter Name Unit Comparison with Kinematics data sheet
Number

In Gantry kinematics data these values given as

P1520 Torque limit upper Nm
maximum power

In Gantry kinematics data these values given as

P1521 Torque limit lower Nm
maximum Torque

In Gantry kinematics data these values given as Max

P2177 Motor locked Delay Time Sec
Torque Time
 Overview of Coordinate Systems
 We distinguish between the
following coordinate systems:
 The machine coordinate
system with the machine
zero M

 The workpiece coordinate

system with the workpiece
zero W
 The current workpiece
coordinate system with the
current offset workpiece
zero Wa
 Part Programming
 The CNC is programmed using a part program.
 There are basic codes that are used in the programming – M, S, G, T, F
(there are many more special codes)
 The M codes are used to trigger peripheral actions like operating cylinders,
control the flow of the program, etc.
 The S code is for spindle speed (in case of metal cutting machines)
 The G codes have special functions that control the contour, interpolation,
feed type, corner rounding, jerk control, and many more
 The T codes are for calling tools from the magazine (in metal cutting
machines)
 The F codes specify the federate of the axis
 Part Programming
 Examples:
 G90 G00 X2000 will move the X axis in Rapid to the absolute position 2000

 G04 F5 will add a delay of 5 second

 G01 X200 Z-500 F2000 will move both X and Z axes simultaneously with a feed
of 2 m/min
 M40 used to move a pneumatic slide forward

 M00 program stop

 840DSL Programming Manual.pdf

 Servo Applications
 PARI Applications  Other Applications
 Gantry Robots  Metal Cutting
 Servo slides  Profile cutting machines
 Servo lifters  Printing machines
 Turn over inspection  Packaging machines
 Articulated robots  Wood working machines
 Servo based ASRS  Rolling mills
 Indexers  Satellite tracking
 Pick and Place
 Number (VIN) marking There are many other
machines applications where servo are
 Gauging Machines used.
 Videos
 Servo Basic Concepts.mp4
Thank you