Controller

SIEMENS AG 20.01.
02
Workshop mold & die / 5-axis-milling

These script is not a start-up manual!!!
1. Optimisation of the control loops:
The following machine-data should be fixed before optimisation.
Computational resolution for linear positions (internal increments per millimetre):

10200 INT_INCR_PER_MM 100000.0
10210 INT_INCR_PER_DEG 100000.0
Fine interpolator type and drive interpolator:
33000 FIPO_TYPE 3
1004 CTRL_CONFIG 4096 (= 1000H = Bit 12)
Shift of setpoint transfer time of the position controller:
10082 CTRLOUT_LEAD_TIME 0.0 (makes the adaption of the FFW data easier)
Current controller adaption:
1183 CURRCTRL_ADAPT_ENABLE 0
1180 CURRCTRL_ADAPT_CURRENT_1 10.0
1182 REDUCE_ARMATURE_INDUCTANCE 35.0
Lookahead and Buffer:
29000 LOOKAH_NUM_CHECKED_BLOCKS 100

28060 MM_IPO_BUFFER_SIZE 100
18360 MM_EXT_PROG_BUFFER_SIZE 50
28070 MM_NUM_BLOCKS_IN_PREP 100
Path velocity data:
20490 IGNORE_OVL_FACTOR_FOR_ADIS 1
20170 COMPRESS_BLOCK_PATH_LIMIT 50.0
20602 CURV_EFFECT_ON_PATH_ACCEL 0.8
20603 CURV_EFFECT_ON_PATH_JERK 1
28530 MM_PATH_VELO_SEGMENTS 5
28520 MM_MAX_AXISPOLY_PER_BLOCK 3
28540 MM_ARCLENGTH_SEGMENTS 10
11400 TRACE_SELECT 0
42470 CRIT_SPLINE_ANGLE 36.0
Then NCK-Reset.
Th. Reichel, A&D MC E55 Controller.doc Page 1 of 22

SIEMENS AG 20.01.02
Current controller:
The following parameters are relevant:
1000 CURRCTRL_CYCLE_TIME (2) 62.5µs

1120 CURRCTRL_GAIN 25.0
1121 CURRCTRL_INTEGRATOR_TIME 2000.0
1183 CURRCTRL_ADAPT_ENABLE 0
1182 REDUCE_ARMATURE_INDUCTANCE 35.0
• Current control filters do not influence the measurements and therefore they must not be deactivated.
Normally the current control parameters are adjusted very well with the operation "Calculate control data" and
need not further be optimised. However, an inspection of the frequency response is always reasonable,
particularly when little motors are used.
Example: Optimised current controller:
Speed controller:
-Dynamic (equivalent time constant) of the inner current control loop and therefore the MD who are relevant for
the current control loop.
and additional:
Controller and cycle data:
1001 SPEEDCTRL_CYCLE_TIME (4) 125µs

1004 CTRL_CONFIG 4096 (= 1000H = Bit 12)
1407 SPEEDCTRL_GAIN_1 5.500000

1409 SPEEDCTRL_INTEGRATOR_TIME_1 3.0
1414 SPEEDCTRL_REF_MODEL_FREQ 0.0

1415 SPEEDCTRL_REF_MODEL_DAMPING 1.0
1421 SPEEDCTRL_INTEGRATOR_FEEDBK 0.0

SIEMENS AG 20.01.02
Current setpoint filter and speed setpoint filter:
1200 NUM_CURRENT_FILTERS 1
1201 CURRENT_FILTER_CONFIG E
-------------------- ------
1202 CURRENT_FILTER_1_FREQUENCY 2000.0
1203 CURRENT_FILTER_1_DAMPING 0.700000
-------------------- ------
1204 CURRENT_FILTER_2_FREQUENCY 0.0
1205 CURRENT_FILTER_2_DAMPING 1.0
-------------------- ------
1210 CURRENT_FILTER_1_SUPPR_FREQ 1400.0
1211 CURRENT_FILTER_1_BANDWIDTH 600.0
1212 CURRENT_FILTER_1_BW_NUM 0.0
1222 CURRENT_FILTER_1_BS_FREQ 100.0
-------------------- ------
-------------------- ------
-------------------- ------
-------------------- ------
1500 NUM_SPEED_FILTERS 2
1501 SPEED_FILTER_TYPE 200
1503 SPEED_FILTER_2_TIME 2.400000
1508 SPEED_FILTER_2_FREQUENCY 2000.0
1509 SPEED_FILTER_2_DAMPING 0.700000
-------------------- ------
1514 SPEED_FILTER_1_SUPPR_FREQ 3500.0
1515 SPEED_FILTER_1_BANDWIDTH 500.0
1516 SPEED_FILTER_1_BW_NUMERATOR 0.0
Effectiveness of the Current setpoint filter and speed setpoint filter at low frequencies in dependence of the
cycle time:
speed controller cycle time: Effectiveness of the band stop filt.: Effectiveness of the low pass
62.5 µs > 80 Hz >50 Hz
125 µs > 30 Hz >30 Hz
250 µs > 15 Hz > 15 Hz
• For optimisation and frequency response measurements of the speed control loop the speed setpoint filter
must be switched of. They have no influence on stability of the speed control loop but they have a big
influence on measuring results.

SIEMENS AG 20.01.02
Optimisation of the speed control loop:
Overview of the measuring points for frequency responses
Frequency response of the Controlled System:
Do the frequency response of the controlled system for better estimation of the poles and zeros.
• Transfer function: actual speed motor / actual current motor
Advantage of these measuring: Poles and Zeros of the controlled system can be examined without any
influence of the controller. E.g. at linear motors: sometimes the motor makes a noise already with standard data.
So the measuring result is very noisy and inapplicable.
Remedy: reduce speed controller gain - make frequency response of the controlled system - identify critical
poles - place band stop filters - increase controller gain. Over a specific controller gain the frequency response
of the closed speed controller loop brings good results again.
TIP: For very clean and good frequency responses of the controlled system at lower frequencies it is very
helpful to reduce the speed controller gain and increase the integrator time extremely.
Controller parameters for Controlled_System_0 (green): 1407 SPEEDCTRL_GAIN_1 0.100000

Controller parameters for Controlled_System_1 (blue): 1407 SPEEDCTRL_GAIN_1 5.5


SIEMENS AG 20.01.02
Mechanical frequency response:
• Transfer function: actual speed direct measuring system / actual speed motor measuring system
Advantage of these measuring: Comprehensive classification of the performance of an axis at a glance. As

higher the first pole of mechanic frequency response is (mostly natural frequency of the axis, locked rotor
frequency) as higher is the performance of the axis. The first pole limits the dynamic of the axis, normally the
max. reachable Kv-factor, the acceleration and the max. acceptable jerk (jerk limitation).
Here: Natural frequency of the X-axis ≈ 30 Hz.

SIEMENS AG 20.01.02
Maximum allowed jerk in dependence of the natural frequency:
speed feedforward control : Max. Jerk [m/s³] at X_Delta = ...µ
10000.0
1000.0
100.0
100 µ
10 µ
1µ
10.0
1.0
0.1
1 10 100 1000
Natural frequency [Hz]
Reference: Dr. Tröndle, A&D MC E55, Siemens AG
Max. reachable Kv-factor in dependence of the natural frequency:
Reachable KV-Factor:
100,0
1 ms
2 ms
10,0
4 ms
1,0
0,1
1 10 100 1000 10000
Min. natural frequency / Hz

Reference: Dr. Tröndle, A&D MC E55, Siemens AG

SIEMENS AG 20.01.02
Frequency response of the closed speed control loop:
Frequ_Resp_0 (green): 1407 SPEEDCTRL_GAIN_1 2

Frequ_Resp_1 (blue): 1407 SPEEDCTRL_GAIN_1 5.5

Frequ_Resp_1 (green): 1407 SPEEDCTRL_GAIN_1 5.5



SIEMENS AG 20.01.02
Reference model:
With the reference model different respond to setpoint changes or disturbance changes can be achieved.

Frequ_Resp_3_Ref_Mod (blue): 1407 SPEEDCTRL_GAIN_1 5.500000

(with reference model) 1409 SPEEDCTRL_INTEGRATOR_TIME_1 3.0
Speed filter:
Speed filters do not help for stability in the closed speed control loop because they are outside in front of the
closed loop. They smooth the desired speed of the speed controller who comes from the position controller and
can stabilise the position controller.


(with speed filter) 1409 SPEEDCTRL_INTEGRATOR_TIME_1 3.0
1414 SPEEDCTRL_REF_MODEL_FREQ 0
1503 SPEED_FILTER_2_TIME 6

SIEMENS AG 20.01.02
Longer integrator time of the speed controller:
Comparison of the speed control loop with long and short integrator time. A longer integrator time reduce the
noise reduction, this is remarkable particularly at the quadrant change (friction).

(longer integrator time) 1409 SPEEDCTRL_INTEGRATOR_TIME_1 10.0


SIEMENS AG 20.01.02
Mechanic plus disturbance optimal speed controller loop as controlled system for the position controller without
reference model
Frequ_Resp_2_250 (green): Closed speed controller loop up to 250 Hz

Mechanic (blue): Mechanical frequency response
Mechanic plus disturbance optimal speed controller loop as controlled system for the position controller with
reference model 150 Hz.
Frequ_Resp_3_Ref_250 (green): 1407 SPEEDCTRL_GAIN_1 5.500000

(with reference model) 1409 SPEEDCTRL_INTEGRATOR_TIME_1 3.0
Mechanic (blue): Mechanical frequency response

SIEMENS AG 20.01.02
Comparison closed speed controller loop up to 250 Hz with and without speed filter 6 ms
Frequ_Resp_2_250 (green): 1407 SPEEDCTRL_GAIN_1 5.5

Frequ_Resp_4_SF (blue): 1407 SPEEDCTRL_GAIN_1 5.500000

(with speed filter) 1409 SPEEDCTRL_INTEGRATOR_TIME_1 3.0
1503 SPEED_FILTER_2_TIME 6
Position controller loop
-Dynamic (equivalent time constant) of the inner speed and current control loop and therefore the MD who are
relevant for the speed and the current control loop.
10050 SYSCLOCK_CYCLE_TIME 0.001000

10060 POSCTRL_SYSCLOCK_TIME_RATIO 1
10082 CTRLOUT_LEAD_TIME 0.0
----------------------------------- ------
32640 STIFFNESS_CONTROL_ENABLE 0
32930 POSCTRL_OUT_FILTER_ENABLE 0
32940 POSCTRL_OUT_FILTER_TIME 0.0
32200 POSCTRL_GAIN 1.0
----------------------------------- ------
The following MD have an influence to the result but they have no influence on the stability of the closed
position controller loop. Therefore they must be deactivated.
32620 FFW_MODE 0
32900 DYN_MATCH_ENABLE 0
32910 DYN_MATCH_TIME 0.000500
32400 AX_JERK_ENABLE 0
32402 AX_JERK_MODE 2
32410 AX_JERK_TIME 0.030000
Before optimisation of the position controller the optimal IPO- and position controller cycle time must be
measured out (10 000 block program) because the cycle times have an influence on the max. reachable Kv-
factor.

SIEMENS AG 20.01.02
Optimisation position controller:
1. With disturbance optimal speed controller loop:

Clearly visible is the pole at ca. 30 Hz which was measured as lowest natural frequency in the mechanical
frequency response too. It limits the max. reachable Kv-factor with disturbance optimal speed controller if no
additional actions are taken.
Pos_Control_1 (green): 32200 POSCTRL_GAIN 1.0

Pos_Control_2 (blue): 32200 POSCTRL_GAIN 2.0
With a reference model at 150 Hz the Amplitude at 30 Hz is reduced already in the speed control loop
(Compare picture Frequ_Resp_3_Ref_250 with Frequ_Resp_2_250). With the same Kv-Factor as in the picture
before some amplitude margin stands for disposal so the Kv-factor can be increased.
Pos_Control_4: 32200 POSCTRL_GAIN 2.0


SIEMENS AG 20.01.02


A similar effect can reached with the speed filters. However the time constant (MD 1503) should be not too big
(ca. < 10 ms). If this time constant is too big, the sum of the little time constants can lead to a exorbitant
adjustment of the position controller and this can lead to a bad positioning behaviour.
Besides big time constants in the speed filters have the negative effect that they filter the desired values too
who come from the feed forward control (because of their arrangement in the controller loop). The same
SIEMENS AG 20.01.02
damping effect can be reached alternative with the filter MD 32930 POSCTRL_OUT_FILTER_ENABLE and the
corresponding time constant MD 32940 POSCTRL_OUT_FILTER_TIME. These low pass has no effect on the
feed forward channel.
Pos_Control_5 32200 POSCTRL_GAIN 2.0



SIEMENS AG 20.01.02

2. With a "more damping optimal" adapted speed controller
In the next picture the speed controller integrator time was increased to 10 ms. It can not yet be the speech from
a damping optimal adaption, but it goes into this direction. If the mechanical characteristics of the axis allow
these adjustment (quadrant error, friction....) in this way can be reached the highest Kv-factors (compare picture
Pos_Control_2 and Pos_Control_3). These adjustment should not be used with software versions < 5 on milling
machines.


SIEMENS AG 20.01.02
Once again to compare:
Pos_Control_3 (green): 32200 POSCTRL_GAIN 2.0

Pos_Control_2 (blue): 32200 POSCTRL_GAIN 2.0


The practice shows, that a absolute necessary requirement for a good surface and contour precision is a good
circularity test. A "good" circularity test is - in dependence on the machine dynamic - a radius- and shape
deviation < 10 µm.

SIEMENS AG 20.01.02
With the numerous Functions of the 840 D it is nearly always possible to fulfil this criteria.
The easiest way to program the circle is as follows:
G91 ;Incremental
G17 ;X/Y-plane
G02 I10 J0 F10000 TURN=1000 ;Radius 10 mm, 1000 repeats
M30
• In the practice a circularity test with Radius = 10 mm and F = 5 ... 10 m/min is useful.
Without any further effort the following circles can be reached in dependence of the described 3 optimisation
methods (Reference model, speed filter, long integrator time). All circles with Kv = 3.8 m/min/mm.
All Circles without Feed Forward Control!!
All circles in this document are made with 5000 mm/min = F5000 even if in the field ’feedrate" in the circularity
test is a different value!!!!!!
Data from picture Pos_Control_8 :
Radius 25 µm too small (mean R = 9.975)!
Reference model should be the same for each axis!

R = 10 mm, F5000!!
Radius 22 µm too big (mean R = 10.22)
Speed filter should be the same for each axis!

R = 10 mm, F5000!!
Radius 62 µm too small.
Integrator time can be a little bit different!

• Attention: Bigger Delta R because of longer

integrator time!
R = 10 mm, F5000!!

SIEMENS AG 20.01.02
In all 3 Cases a good circularity shape can be reached. However the actual radius is very different to the desired
radius. Because the use of the speed filter leads to an expand of the radius, this filter can be combined with the
two other methods to reach a good circle radius.
E.g. Combination of longer Integrator time and speed

filter to expand the radius:

With this combination of longer Integrator time and speed filter the position controller loop can become
unbalanced. Therefore the frequency response has to be checked again after the circularity test.
Pos_Control_11(green): 1409 SPEEDCTRL_INTEGRATOR_TIME_1 10.0

(Radius o.k.) 1503 SPEED_FILTER_2_TIME 5.800000
Pos_Control_6(blue): 1409 SPEEDCTRL_INTEGRATOR_TIME_1 10.0

(Radius too small) 1503 SPEED_FILTER_2_TIME 0

SIEMENS AG 20.01.02
Because the speed filter has a damping effect to the position controller, it is now possible to reduce the
integrator time a little bit. If the radius of the circle changes slightly, the speed filter has to be adjusted a little bit
again. So it is possible to get a very accurate Radius and a nearly perfect frequency response of the position
controller loop.

Effect of different Parameters in interpolating Axis (all circles without feed forward control)
Axis 1 Axis 2
32200 POSCTRL_GAIN 3.8 3.80
1407 SPEEDCTRL_GAIN_1 5.5 5.0
1409 SPEEDCTRL_INTEGRATOR_TIME_1 3.0 3.0
1414 SPEEDCTRL_REF_MODEL_FREQ 0.0 0.0
1500 NUM_SPEED_FILTERS 2 2
1501 SPEED_FILTER_TYPE 200 200
1503 SPEED_FILTER_2_TIME 5.9 5.0
Axis 1 Axis 2

SIEMENS AG 20.01.02
Axis 1 Axis 2
Axis 1 Axis 2
32900 DYN_MATCH_ENABLE 1 1
32910 DYN_MATCH_TIME 0.0005 0.0
With the speed filter the equivalent time constant of the position controller loop did not change from the point of
view of the Interpolator. The speed filter lift only the amplitude of the position controller frequency response and
therefore the radius of the circle. With the Dynamic match time filter the equivalent time constant of the position
controller loop change, the phase relation changes, the circle changes to a ellipse or a ellipse will be corrected
to a circle.
Driving Corners and Contour precision with pure position control:
G64
Axis 1 Axis 2
32200 POSCTRL_GAIN 3.80 3.80
Scale: 10 µm/div.

SIEMENS AG 20.01.02
G64
Axis 1 Axis 2
32200 POSCTRL_GAIN 3.80 3.80
Scale: 10 µm/div.
G60
Axis 1 Axis 2
32200 POSCTRL_GAIN 3.80 3.80
Scale: 10 µm/div.
G60
Axis 1 Axis 2
32200 POSCTRL_GAIN 3.80 3.80
Scale: 10 µm/div.

SIEMENS AG 20.01.02
G64
Contour with corrected circle:
Axis 1 Axis 2
32200 POSCTRL_GAIN 3.80 3.80
Scale: 20 µm/div.
Contour with not corrected circle:
Axis 1 Axis 2
32200 POSCTRL_GAIN 3.80 3.80
Scale: 68 µm/div.

Controller

Загружено:

Сведения о документе

Исходное описание:

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Controller

Загружено:

Авторское право:

Доступные форматы

SIEMENS AG 20.01.

Workshop mold & die / 5-axis-milling

1. Optimisation of the control loops:

The following machine-data should be fixed before optimisation.

Computational resolution for linear positions (internal increments per millimetre):

Fine interpolator type and drive interpolator:

Shift of setpoint transfer time of the position controller:

Current controller adaption:

Lookahead and Buffer:

29000 LOOKAH_NUM_CHECKED_BLOCKS 100

Path velocity data:

Th. Reichel, A&D MC E55 Controller.doc Page 1 of 22

The following parameters are relevant:

1000 CURRCTRL_CYCLE_TIME (2) 62.5µs

Example: Optimised current controller:

The following parameters are relevant:

Controller and cycle data:

1001 SPEEDCTRL_CYCLE_TIME (4) 125µs

1407 SPEEDCTRL_GAIN_1 5.500000

1414 SPEEDCTRL_REF_MODEL_FREQ 0.0

1421 SPEEDCTRL_INTEGRATOR_FEEDBK 0.0

Th. Reichel, A&D MC E55 Controller.doc Page 2 of 22

Current setpoint filter and speed setpoint filter:

Th. Reichel, A&D MC E55 Controller.doc Page 3 of 22

Optimisation of the speed control loop:

Overview of the measuring points for frequency responses

Frequency response of the Controlled System:

• Transfer function: actual speed motor / actual current motor

Controller parameters for Controlled_System_0 (green): 1407 SPEEDCTRL_GAIN_1 0.100000

Controller parameters for Controlled_System_1 (blue): 1407 SPEEDCTRL_GAIN_1 5.5

Th. Reichel, A&D MC E55 Controller.doc Page 4 of 22

Mechanical frequency response:

Advantage of these measuring: Comprehensive classification of the performance of an axis at a glance. As

Here: Natural frequency of the X-axis ≈ 30 Hz.

Th. Reichel, A&D MC E55 Controller.doc Page 5 of 22

Maximum allowed jerk in dependence of the natural frequency:

speed feedforward control : Max. Jerk [m/s³] at X_Delta = ...µ

Reference: Dr. Tröndle, A&D MC E55, Siemens AG

Max. reachable Kv-factor in dependence of the natural frequency:

Min. natural frequency / Hz

Th. Reichel, A&D MC E55 Controller.doc Page 6 of 22

Frequency response of the closed speed control loop:

Frequ_Resp_0 (green): 1407 SPEEDCTRL_GAIN_1 2

Frequ_Resp_1 (blue): 1407 SPEEDCTRL_GAIN_1 5.5

Frequ_Resp_1 (green): 1407 SPEEDCTRL_GAIN_1 5.5

Frequ_Resp_2 (blue): 1407 SPEEDCTRL_GAIN_1 5.5

Th. Reichel, A&D MC E55 Controller.doc Page 7 of 22

Frequ_Resp_2 (green): 1407 SPEEDCTRL_GAIN_1 5.5

Frequ_Resp_3_Ref_Mod (blue): 1407 SPEEDCTRL_GAIN_1 5.500000

Frequ_Resp_2 (green): 1407 SPEEDCTRL_GAIN_1 5.5

Frequ_Resp_5 (blue): 1407 SPEEDCTRL_GAIN_1 5.500000

Th. Reichel, A&D MC E55 Controller.doc Page 8 of 22

Longer integrator time of the speed controller:

Frequ_Resp_6 (green): 1407 SPEEDCTRL_GAIN_1 5.500000

Frequ_Resp_2 (blue): 1407 SPEEDCTRL_GAIN_1 5.5

Th. Reichel, A&D MC E55 Controller.doc Page 9 of 22

Frequ_Resp_2_250 (green): Closed speed controller loop up to 250 Hz

Mechanic (blue): Mechanical frequency response

Frequ_Resp_3_Ref_250 (green): 1407 SPEEDCTRL_GAIN_1 5.500000

Mechanic (blue): Mechanical frequency response

Th. Reichel, A&D MC E55 Controller.doc Page 10 of 22

Frequ_Resp_2_250 (green): 1407 SPEEDCTRL_GAIN_1 5.5

Frequ_Resp_4_SF (blue): 1407 SPEEDCTRL_GAIN_1 5.500000