SPiiPlus Training Class MC4U Trainer Setup

Presentation Contents Introduction EtherCAT Configurator walkthrough System Configuration Wizard walkthrough System Information Viewer Complete setup of a single axis on an ACS drive

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: EtherCAT network configuration System configuration Axis setup and tuning The trainer unit has three axes. This presentation covers setup of one axis, the other two are up to you!

1 4 3 MC4U Trainer Contents Controller Card SPiiPlus NT-LT-8; 8 axis EtherCAT network master Power Supply PSM3U-320V-8kW Drive DDM3U-4-320-3/6A; 4 axis PWM Drive Motors Axis 1: 3ph BLDC w/ incremental quad encoder Axis 3: 3ph BLDC w/ SINCOS encoder Axis 4: Open-loop stepper 1 4 3

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 10.0.0.100 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 controller’s serial number

Add Components to Workspace Right-click on the controller in the workspace window and select ‘Add Component’ to add the following: Setup  Adjuster Wizard Setup  System Configuration Wizard Setup  EtherCAT Configurator Utilities  System Information Viewer Utilities  Communication Terminal Application Development  Program Manager

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

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 controller’s flash, select yes, and OK to reboot Click next to skip COC and Print Reports. Click ‘Finish’ to close System Configuration Wizard

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

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

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’

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

Adjuster Wizard: Motor Press the ‘+’ button to add a new motor Enter the following motor data: Click next Motor Type 3-phase DC Brushless/AC Servo Nominal Current 4.4 Amps (peak of sine) Peak Current 8.48 Amps (peak of sine) Maximum Velocity 7000 RPM Number of Poles 6 Back EMF Constant 39 V/kRPM Phase Connection Star / Wye Phase Phase Resistance 3.42 Ohm

Adjuster Wizard: Drive 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

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

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

Adjuster Wizard: Safety and Protection 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 !!! Important Safety Info !!!

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 !!! Important Safety Info !!!

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: Current loop tuning Motor commutation Velocity loop tuning Position loop tuning

Adjuster Wizard: Axis Setup and Tuning ACS utilizes a cascaded control loop structure, ideal for motion control applications: Current loop Velocity loop Position loop The position loop generates a command to the velocity loop The velocity loop generates a command to the current loop

Adjuster Wizard: Axis Setup and Tuning Tuning rules of thumb: For current and velocity loops: Begin by setting proportional and integrator gains low (usually 10 is fine for both) Start by doubling proportional gain until response is noisy, then reduce by half Keep proportional gain fixed and begin doubling integrator gain until roughly 10-15% overshoot is observed For position loop: Start low (usually 10) and begin doubling until position error is minimized. Make sure position error while moving at constant velocity is not noisy.

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. 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% Typical values: 1000 – 10,000

Adjuster Wizard: Current Loop Tuning 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 = 15000 Too aggressive (excessive overshoot) SLIKP = 75, SLIKI = 12000 Well tuned

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)

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.

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’

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’

Adjuster Wizard: Position and Velocity Loops 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 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 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.

Adjuster Wizard: Position and Velocity Loops SLPKP = 1 Not responsive enough SLPKP = 500 Too aggressive (noisy) SLPKP = 100 Position error minimized

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.