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© 2013 SPiiPlus Training Class MC4U Trainer Setup 1
© 2013 Presentation Contents Introduction EtherCAT Configurator walkthrough System Configuration Wizard walkthrough System Information Viewer Complete setup of a single axis on an ACS drive 2
© 2013 Introduction This presentation is a step-by-step setup of the MC4Unt trainer unit. It is meant to give a flavor of what a real system setup is like. Setup in the presentation was done using SPiiPlus MMI Application Studio 2.10 software. The latest version can be found at acsmotioncontrol.com There are three main setup tasks for the trainer unit: 1.EtherCAT network configuration 2.System configuration 3.Axis setup and tuning The trainer unit has three axes. This presentation covers setup of one axis, the other two are up to you! 3
© 2013 MC4U Trainer Contents 4
© 2013 Establish Communication with Controller Connect an Ethernet cable between the PC and the MC4U (J6-ETH1) Open the MMI, and User Mode Driver (if not already running) Set Controller IP Address to and make sure your PC is on the same network, then click Connect When connection is established, the workspace window shows a green LED next to the connected controllers serial number 5
© 2013 Add Components to Workspace Right-click on the controller in the workspace window and select Add Component to add the following: o Setup Adjuster Wizard o Setup System Configuration Wizard o Setup EtherCAT Configurator o Utilities System Information Viewer o Utilities Communication Terminal o Application Development Program Manager 6
© 2013 EtherCAT Configurator Double click EtherCAT Configurator component in the workspace tree to open Select Scan System and the connected EtherCAT network will be displayed Click Generate Configuration to save to flash Wait for controller to reboot Close EtherCAT Configurator 7
© 2013 System Configuration Double click System Configuration Wizard in the workspace tree to open Select Change System Configuration radio button, click next Leave application details blank, click next Click Approve All at bottom of screen, click next When prompted to save configuration to controllers flash, select yes, and OK to reboot Click next to skip COC and Print Reports. Click Finish to close System Configuration Wizard 8
© 2013 System Information Viewer Double click System Information Viewer in the workspace tree to open Any relevant information about a system can be found using the System Information Viewer, as well as save/load system information 9
© 2013 System Information Viewer For instance, to view which IO are available: look under System Configuration Network Units Unit 0 Inputs/Outputs Assignment Looking at the pane to the right, there are 8 digital I/O, and 4 analog I/O 10
© 2013 Adjuster Wizard Double click Adjuster Wizard in the workspace tree to open Specify you are working with Axis 3 Select Setup New System or Controller option Click next to get to Initialization Leave user information blank, click next to get to Axis Structure 11
© 2013 Adjuster Wizard: Axis Structure Specify axis structure as Single Motor Specify motor-load topology as Rotary Motor and Rotary Load – Direct Drive Set feedback topology as Single, on motor Apply user units to motor Select Degrees as rotary units Press Next button 12
© 2013 Adjuster Wizard: Motor Press the + button to add a new motor Enter the following motor data: Click next 13 Motor Type3-phase DC Brushless/AC Servo Nominal Current4.4 Amps (peak of sine) Peak Current8.48 Amps (peak of sine) Maximum Velocity7000 RPM Number of Poles6 Back EMF Constant39 V/kRPM Phase ConnectionStar / Wye Phase Phase Resistance3.42 Ohm
© 2013 Adjuster Wizard: Drive 14 Press the + button to add a drive The ACS drive will automatically be recognized except supply input voltage and/or frequency Specify the input voltage as 110V Specify frequency as 60Hz Click next
© 2013 Adjuster Wizard: Motor Feedback Press the + button to add a new motor feedback Select the motor feedback type as Incremental Quadrature Encoder Specify the resolution as 2048 lines per revolution Set the external multiplier to 1 Click next 15
© 2013 Adjuster Wizard: Calculate Parameters Click Calculate Parameters A list of all calculated parameters different from current values is shown Click Apply Changes to update all parameters to the newly calculated values Click next 16
© 2013 Adjuster Wizard: Safety and Protection 17 !!! Important Safety Info !!! Skip to Current Limits by clicking on it in the task pane The adjuster sets current limits to prevent damage to the motor based on info entered in Components. It is important to verify it is correct Click next to get to Position Errors Position error parameters are set automatically too, but these may need to be relaxed temporarily for tuning purposes
© 2013 Adjuster Wizard: Verification Skip to Switches under the Verification heading by clicking on it in the task pane Verify upper and lower limit switch functionality and inverse logic if necessary Click next to get to Stop, Alarm and Brake Verify Hardware Emergency Stop functionality and inverse logic if necessary Click next 18 !!! Important Safety Info !!!
© 2013 Adjuster Wizard: Axis Setup and Tuning The Axis Setup and Tuning process is covered in detail in the SPiiPlus Time Domain Tuning presentation, but in general involves: 1.Current loop tuning 2.Motor commutation 3.Velocity loop tuning 4.Position loop tuning 19
© 2013 Adjuster Wizard: Axis Setup and Tuning ACS utilizes a cascaded control loop structure, ideal for motion control applications: o Current loop o Velocity loop o Position loop The position loop generates a command to the velocity loop The velocity loop generates a command to the current loop 20
© 2013 Adjuster Wizard: Axis Setup and Tuning Tuning rules of thumb: For current and velocity loops: o Begin by setting proportional and integrator gains low (usually 10 is fine for both) o Start by doubling proportional gain until response is noisy, then reduce by half o Keep proportional gain fixed and begin doubling integrator gain until roughly 10-15% overshoot is observed For position loop: o Start low (usually 10) and begin doubling until position error is minimized. o Make sure position error while moving at constant velocity is not noisy. 21
© 2013 Adjuster Wizard: Current Loop Tuning Set both SLIKP and SLIKI = 10 (start out low) Default current level is 10% with 4ms pulse width. These values are fine, do not change. Click Scope Autoset and Run Double SLIKP until high frequency effects (noise) or overshoot are present, then reduce by half. o Typical values: 50 – 500 Changing SLIKI should not require returning the change SLIKP Double SLIKI until overshoot is excessive, then reduce by half. Overshoot should be roughly 10-15% o Typical values: 1000 – 10,000 22
© 2013 Adjuster Wizard: Current Loop Tuning 23 SLIKP = 25, SLIKI = 10 Not responsive enough SLIKP = 100, SLIKI = 10 Too aggressive (excessive overshoot) SLIKP = 75, SLIKI = 10 Okay SLIKP = 75, SLIKI = 1000 Not responsive enough SLIKP = 75, SLIKI = Too aggressive (excessive overshoot) SLIKP = 75, SLIKI = Well tuned
© 2013 Adjuster Wizard: Commutation Commutation is the process of keeping current vector perpendicular to motor magnetic field vector. Handled automatically in brush DC motors, and not necessary in steppers operating in micro-stepping mode. At controller startup the magnetic field orientation of a BLDC motor is not known and needs to be found. The adjuster has a facility for finding it and setting the commutation angle. Once found, the commutation angle is kept track of using motor feedback (encoder) 24
© 2013 Adjuster Wizard: Commutation Adjuster based commutation only needs to be done once during initial axis setup. Once axis is properly setup and tuned, ACSPL+ COMMUT command can be used instead. COMMUT command pings motor three times and finds commutation angle with very little physical motion. If motor is equipped with hall sensors, commutation angle is based on first hall state transition, and COMMUT command is not necessary. 25
© 2013 Adjuster Wizard: Commutation In the commutation dialog, click the default button to tailor the commutation process for this particular axis Click Start Commutation On top of finding the commutation angle, a number of magnetic pitches will be measured and checked against encoder feedback to verify settings On successful commutation, click next twice to skip to Position and Velocity Loops 26
© 2013 Adjuster Wizard: Position and Velocity Loops Select Velocity Loop Click Motion Manager Autoset, and Scope Autoset The only variables you need to be concerned with in velocity loop tuning are Proportional Gain (SLVKP), and Integrator Gain (SLVKI) Start SLVKP, SLVKI low and use a similar tuning approach as in current loop In Motion Manager, click Enable Motor and Start Motion 27
© 2013 SLVKP = 100, SLVKI = 10 Not responsive enough SLVKP = 2300, SLVKI = 10 Too aggressive (noisy) SLVKP = 400, SLVKI = 10 Okay SLVKP = 400, SLIKI = 200 Not responsive enough SLVKP = 400, SLVKI = 2000 Too aggressive (excessive overshoot) SLVKP = 400, SLVKI = 700 Just right Adjuster Wizard: Position and Velocity Loops 28
© 2013 Select Position Loop Click Motion Manager Autoset and Scope Autoset Enter the following settings in the Motion Manager: Click Enable Motor then Start Motion Adjuster Wizard: Position and Velocity Loops 29
© 2013 Adjuster Wizard: Position and Velocity Loops The only variable you need to be concerned with in position loop tuning is Proportional Gain (SLPKP) Start SLPKP low and double until position error is minimized while making sure it is not noisy at constant velocity. 30
© 2013 SLPKP = 1 Not responsive enough SLPKP = 500 Too aggressive (noisy) SLPKP = 100 Position error minimized Adjuster Wizard: Position and Velocity Loops 31
© 2013 Adjuster Wizard: Save to Flash Once all previous steps are complete the system is now setup and tuned. Save to flash so it will be available on controller startup. 32
© 2013 SPiiPlus Training Class Safety and Faults 1.
Copyright 2006 SPiiPlus Training Class Simple IB23810 Motor Setup.
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