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Motion Control with SIMATIC & SINAMICS Speed & Positioning axis

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Presentation on theme: "Motion Control with SIMATIC & SINAMICS Speed & Positioning axis"— Presentation transcript:

1 Motion Control with SIMATIC & SINAMICS Speed & Positioning axis
Technical slides │ August 2014 Motion Control with SIMATIC & SINAMICS Speed & Positioning axis

2 Motion Control with SIMATIC & SINAMICS … Motion Control Applications
Speed Pumps, fans, mixers Conveyors Auxiliary drives etc. Positioning Hoists, lifts Building technologies Feeders, palletizers etc. S7-1500 SINAMICS (EPos, DCC) Coordination (Gearing, camming) In future: S T Complexity Relative gearing Synchronized axes Rotary knife, Flying saw etc. Path Cartesian picker Delta picker Scara roboter etc.

3 Where can be Motion Control?
Motion Control with SIMATIC & SINAMICS … what and where is Motion Control? Decentral Central What is Motion Control? Interpolation Axis behaviour Axis coordination Position controller Where can be Motion Control? Within SINAMICS CPU gives commands to drive -> Motion control in the drive Within SIMATIC Motion control in the CPU -> Drive just operates as a converter The customer and the application determine the best applicable configuration

4 Motion Control - Central with SIMATIC S7-1200/S … powerful drive integration based on technology objects Technology Objects in every S7-1500 Technology objects for speed, positioning and gearing axis Technology objects take over the complete communication towards the frequency converter (PROFIdrive via PROFINET or PROFIBUS or analog connection) No special programming for communication necessary („Bit-set“, „Bit-reset“) System integrated diagnosis, generates automatic alarms displayed in the webserver of the PLC, in STEP 7, in the HMI and on the PLC display without any extra code Reset frequency converter alarms via HMI without any extra code Programming of MOTION functionalities via PLC-Open Blocks Technology Objects in every S7-1200 PTO axis (Puls-Train-Output) and with FW V4.1 also positioning axis via PROFIdrive Central Technology Objects Speed axis Positioning axis Gearing axis MOTION

5 Motion Control - Decentral with SINAMICS G/S … powerful drive connection based on function blocks
Positioning/gearing functionality in SINAMICS G/S Speed axis technology is a BASIC functionality within every SINAMICS. Integrated functionality for the absolute and relative positioning of linear- and rotary axis with motor encoder or machine encoder (EPos with SINAMICS G120/S120). Low PLC load, because the MOTION functionality is done by the drive. High number of axis feasible Harmonized standard function blocks take over the complete communication towards the frequency converter (PROFIdrive via PROFINET or PROFIBUS) Intuitive function block interfaces for a easy handling of all SINAMICS integrated MOTION functions. Comfortable and reliable because of integrated monitoring and compensation functions. Decentral Function Blocks SINA_SPEED SINA_POS SINA_PARA MOTION

6 Motion Control with SIMATIC & SINAMICS … where, with how many axis?
Decentral Motion Control with SINAMICS G/S (FB) Central Motion Control with SIMATIC S (TO) How many EPos axis can be controlled in maximum by S7-1500? How many TO axis can be calculated in maximum by S (FW1.5)? Depends on the number of connectable I/O Devices and the load memory size of each PLC. CPU 1511/1513: 6 axis CPU 1515/1516: 30 axis CPU 1517: 96 axis CPU 1518: 128 axis Which PLCs are suitable? Which drives are suitable? Every PLC including PROFINET–Controller or PROFIBUS-Master interface, especially SIMATIC PLCs. (S7-300, S7-400, S7-1200, S7-1500). Every drive with PROFIdrive or analog interface, especially SINAMICS G/S. The customer and the application determine the best applicable configuration

7 Motion Control with SIMATIC & SINAMICS … possible solutions for speed and positioning axis
Decentral Motion Control with SINAMICS G/S (FB) Central Motion Control with SIMATIC S (TO) FB SINA_SPEED PLCopen Blocks Motion instructions FB SINA_POS (EPos) Technology object (TO) Axis behaviour OB MC-Interpolator (OB92) Interpolator Axis behaviour Interpolation OB MC-Servo (OB91) Position controller Position controller Speed / Positioning axis Speed / Positioning axis The customer and the application determine the best applicable configuration

8 Motion Control with SIMATIC & SINAMICS …which is the best applicable configuration?
Dezentral Zentral From the technical point of view and considering the following presentation inclusive recommendations, both solutions offer the same performance! The decision should be done based on the following core issues: From which technology does the customer come from? What kind of Motion Control does he already know? Which preference exists regarding S7 programming? Is the customer free in the selection of the PLC / SIMATIC CPU? What kind of application with which requirements does the customer have? Number of axis within the application? The customer and the application determine the best applicable configuration

9 Motion Control with SIMATIC & SINAMICS │ Speed & Positioning axis
Influences of the data transmission „isochronous“ versus „not isochronous“

10 hand over of information
Motion Control - Central with SIMATIC … influence of data transmission on positioning results Non isochronous communication via PROFINET RT or PROFIBUS DP SIMATIC SINAMICS hand over of information varies clock x clock y clock z x-Controller Interpolator x-Controller Data reception n-Controller I-Controller PROFINET/PROFIBUS RT (not isochronous) Interpolator Point of data reception OK M- Pre-Control control gets bumpy Data reception delayed amplifies effects with……… Using a not synchronized data transmission of actual position values to the SIMATIC TO causes equivalent problems. To avoid these problems it is recommended to deactivate the M-Pre-control or to choose well assigned task/clock ratios

11 hand over of information
Motion Control - Central with SIMATIC … influence of data transmission on positioning results Isochronous communication via PROFINET IRT or equidistant, isochronous PROFIBUS DP SIMATIC SINAMICS hand over of information always on clock clock x clock x clock x x-Controller Interpolator x-Controller Data reception n-Controller I-Controller PROFINET/PROFIBUS IRT (isochronous) Interpolator Point of data reception is guaranted M- Pre-Control The isochronous mode guarantees always a correct interpretable data exchange and offers thereby high quality (enhanced) Motion Control.

12 Motion Control - Central with SIMATIC … effects caused by non isochronous data transmission (PROFINET/PROFIBUS) Explanations General effects: Because of the missing isochronous data transmission there is no synchronization of the controller clocks between TO and drive. As a result of the asynchronism, data is sometimes received twice. This can lead to misinterpretations of values, which are not reflecting the reality. With wrong controller settings this can lead to unrequested effects in the motor control. (e.g. ripples in the torque, even torque strokes, etc.). Influence of the torque pre-control: Especially the activated torque pre-control will amplify the effects described above.  General recommendation, when using non isochronous communication: Deactivate the torque pre-control (M-Pre-Control) Or make sure that the clock cycle of the TO in the SIMATIC is calculated twice as fast as the SINAMICS clock cycle, when the torque pre-control should be absolutely needed. In that case the machine encoder has to be connected directly to the SIMATIC to avoid trouble in the transmission of the position actual value. (remember explanation of actual position transfer SINAMICS  SIMATIC)

13 Motion Control with SIMATIC & SINAMICS │ Speed & Positioning axis
Influence of different control modes on positioning performance and quality

14 Motion Control with SIMATIC & SINAMICS … principal function diagrams of control modes V/f, SLVC, VC and SC In the SINAMICS product portfolio not every control mode is available in every SINAMICS CU Control modes without motor encoder Control modes with motor encoder Open control loop Closed control loop There has always to be a motor encoder connected directly to the SINAMICS V/f-Control SLVC (Sensorless Vector Control) VC (Vector Control) SC (Servo Control) ⇒ Optimized on precision ⇒ Optimized on dynamic M n_set V f No feedback! Fixed relation V/f, according to the motor characteristics M Motor model n_set n_act M n_set n_act E

15 Motion Control with SIMATIC & SINAMICS … Operation/Control modes without motor encoder
Operation mode V/f with SINAMICS G/S SensorLess VectorControl with SINAMICS G/S (SLVC) Characteristics No encoder necessary, very low configuration & commissioning effort High following error during movement Low positioning dynamic Position accuracy worse 1°(empirical value) No encoder necessary Good behavior during movement Medium positioning dynamic Position accuracy better 1°(empirical value) Following error in the final position is kept and not corrected Recommendation for central/decentral Motion Control (TO / EPos) Recommendations for central Motion Control (TO) Minimize the Kv of the position controller to achieve a smooth and steady behavior of the axis SINAMICS G: For a good & smooth axis behavior, deactivate the torque pre-control, because of the missing isochronous communication. Recommended OB MC-Servo (OB91) call: n*4 ms SINAMICS S: Only use isochronous communication Applications Simple positioning tasks with low requirements according dynamic and position accuracy (e.g. replacement for positioning on BERO, gate controls, etc.) NOT suitable for hanging / through pulling axis Positioning tasks with medium requirements according dynamic and position accuracy Applications that require a good behavior (following error, dynamic) during the positioning movement

16 Motion Control with SIMATIC & SINAMICS … Control modes with motor encoder
Vector Control with SINAMICS G120 (VC) Vector Control with SINAMICS S120 (VC) Characteristics Very good behavior during the positioning movement High positioning dynamic Very high position accuracy, depending on the encoder resolution (encoder resolution should be 10x higher, than the required position accuracy) Very high positioning dynamic Recommendations for central Motion Control (TO) For a good & smooth axis behavior, deactivate the torque pre-control because of the missing isochronous communication Recommended OB MC-Servo (OB91) call: n*4 ms Please only use isochronous communication Addapt the BICO-connection of the speed setpoint: Please move the speed setpoint received from the fieldbus from the RFG to the connector input “Speed setpoint 2 (p1160)” on the speed controller Applications Positioning tasks with high requirements according dynamic and position accuracy ( e.g.: simple crane applications, simple rack feeders/high bay warehouses, feeding facilities, palletizers, etc.) Suitable for hanging / through pulling axis Positioning tasks with high requirements according dynamic and position accuracy (e.g.: crane applications, rack feeders/high bay warehouses, feeding facilities, palletizers, etc.)

17 Servo Control with SINAMICS S (SC)
Motion Control with SIMATIC & SINAMICS … Control modes with motor encoder Servo Control with SINAMICS S (SC) Characteristics Excellent and well proven (SIMOTION, SINUMERIK) behavior during the positioning movement Highest positioning dynamic Highest position accuracy, depending on the encoder resolution (encoder resolution should be 10x higher, than the required position accuracy) Recommendations for central Motion Control (TO) Only to be used with isochronous communication (PROFINET IRT or isochronous PROFIBUS DP) Applications Positioning tasks with highest requirements according dynamic and position accuracy (e.g.: machine feeders, tool revolvers, rotary tables etc.)

18 Motion Control with SIMATIC & SINAMICS … further effects independent of the control mode and communication Explanations Influence of the Speed-Pre-Control: With the use of TO the Speed-Pre-Control is in standard set to 100%, independently from the chosen control mode in the drive. With the use of EPos the Speed-Pre-Control is in standard set to 0% and can be adjusted up to 100%, dependent on dynamic requirements. With activated Speed-Pre-Control, overshoots in the end position may occur. With regard to linear movements, it has to be checked that a overshoot in end position is possible and permissible. Furthermore it has to be checked, how a backward movement within the application is possible and permissible.  General recommendation: In the case that undesired overshoots in end position occur, the Speed-Pre-Control must be reduced or deactivated

19 Motion Control with SIMATIC & SINAMICS … possible movement cycles dependent on the SINAMICS control cycles Control cycles G120 SLVC S120 SLVC G120 VC S120 VC S110 SC S120 SC Current controller 0,5 ms 0,25 ms 0,0625 ms Speed controller (n) 2 ms 1 ms Position controller (x) 4 ms Interpolator (EPos) 8 ms Rise time (n) 60 ms 20 ms 30 ms 10 ms 5 ms Rise time (x) 160 ms 80 ms 40 ms Minimal movement cycle (x) 1000 ms 400 ms 200 ms 100 ms Rule of thumb: for the rise time: „controller cycle x 10 x safety factor“ (safety factor for SC/VC = 2 for SLVC = 4); For the movement cycle: „at least 5 x rise time (x)“ Legend: n speed SLVC SensorLess Vector Control VC Vector Control SC Servo Control x position

20 Influence of the encoder configurations
Motion Control with SIMATIC & SINAMICS │ Speed & Positioning axis Influence of the encoder configurations

21 Motion Control with SIMATIC & SINAMICS … influence of encoder configuration on positioning results
Controller cascade for positioning task inclusive possible encoder configurations SIMATIC with SINAMICS Motor Machine Machine E Gear box M V/f or SLVC n-Control i-Control x-Control 1 encoder E Machine Gear box n-Control i-Control x-Control M Machine Gear box n-Control i-Control x-Control M E 2 encoder

22 Motion Control - Central with SIMATIC S and SINAMICS G/S … Technology Object with 1-encoder system Machine encoder at Technology Module Machine encoder as PROFIdrive encoder Machine encoder connected to the drive Motor encoder connected to the drive G110M, G120C V/f, SLVC G120 CU240B/E-2 G120 CU250S-2 VC G120D CU240D-2 S110 SC S120 VC, SC V/f SLVC VC SC Open Control Loop SensorLess Vector Control Vector Control Servo Control Legend: Isochronous communication Technically feasible / recommended NON isochronous communication Technically NOT feasible / recommended Operation/Control mode: Telegram TLG S TM SINAMICS G/S S7-1500 SINAMICS G/S S7-1500 SINAMICS G/S S7-1500 SINAMICS G/S TLG 1/2 TLG 1/2 TLG 3 TLG 3 *) *) S120 with SC uses TLG5 incl. Dynamic Servo Control (DSC)

23 Motion Control - Central with SIMATIC S and SINAMICS G/S … Technology Object with 2-encoder system Motor encoder + Machine encoder at Technology Module Motor encoder + Machine encoder as PROFIdrive encoder Motor encoder + Machine encoder connected to the drive G110M, G120C G120 CU240B/E-2 G120 CU250S-2 VC G120D CU240D-2 S110 SC S120 VC, SC V/f SLVC VC SC Open Control Loop SensorLess Vector Control Vector Control Servo Control Legend: Isochronous communication Technically feasible / recommended NON isochronous communication Technically NOT feasible / recommended Operation/Control mode: Telegram TLG SINAMICS G/S S7-1500 SINAMICS G/S S7-1500 SINAMICS G/S S TM TLG 2 TLG 2 TLG 3 *) *) S120 with SC uses TLG5 incl. Dynamic Servo Control (DSC)

24 Motion Control - Decentral with S7-300/400 & S7-1200/1500 and SINAMICS G/S … Basic positioner (EPos) with 1- & 2- encoder system EPos with Machine encoder connected to the drive EPos with Motor encoder connected to the drive EPos with Motor encoder + Machine encoder connected to the drive G110M, G120C G120 CU240B/D/E-2 G120 CU250S-2 V/f, SLVC VC G120D CU250D-2 S110 SC S120 VC, SC V/f SLVC VC SC Open Control Loop SensorLess Vector Control Vector Control Servo Control Legend: Isochronous communication Technically feasible / recommended NON isochronous communication Technically NOT feasible / recommended Operation/Control mode: Telegram TLG S7-300/400 S S7-1500 SINAMICS G/S S7-300/400 S S7-1500 SINAMICS G/S SINAMICS G/S S7-300/400 S S7-1500 TLG 111 TLG 111 TLG 111

25 Motion Control with SIMATIC & SINAMICS │ Speed & Positioning axis
SIMATIC S7-1500: Influence of the integrated Motion Control functions (TO) on the PLC

26 Cyclic user program (OB1)
Motion Control - Central with SIMATIC S … Cyclic program - Program execution Actualization of the input process image Writing of the output process image Cyclic user program (OB1) Cycle time tcyc The PLC executes the OB1 program cyclic. The programm execution can be interrupted by Interrupt-OBs (e.g. cyclic interrupt, Time-of-day interrupt, Hardware interrupt, isochronous mode interrupt, …). The cycle time varies, dependent on the occurrence of the different Interrupt-OBs.

27 Motion Control - Zentral mit SIMATIC S7-1500 … Motion program - Motion execution level
Cyclic program sequence x Cyclic program sequence x+1 Cyclic program sequence x+2 t Motion Control in the S creates an own execution level (MC OBs) OB Servo (OB91) & OB Interpolator (OB92) are Interrupt-OBs, executing technology objects. They are executed in the configurable interrupt cycle ttask (= position controller cycle) Motion commands (PLCopen Blocks) can be programmed anywhere (e.g. OB1, FB xy) ttask ttask ttask OB Servo OB IPO OB Servo OB IPO OB Servo OB IPO OB Servo OB IPO Cyclic program (x) Cyclic Program (x+1) t tOB91/92

28 Motion Control - Central with SIMATIC S7-1500 … Runtime Motion program
Runtime of OB Servo and OB Interpolator in regard to the number of axis? These values apply for positioning axis only. Speed axis require only two-thirds (⅔) of these values. S7-1511 S7-1513 The table shows the runtimes at high axis activity (=> permanent new commands to the axis). At low axis activity the shown values has to be reduced on to two-thirds (⅔)!

29 Motion Control - Central with SIMATIC S7-1500 … Runtime Motion program
Runtime of OB Servo and OB Interpolator in regard to the number of axis? These values apply for positioning axis only. Speed axis require only two-thirds (⅔) of these values. S7-1515 S7-1516 S7-1518 The table shows the runtimes at high axis activity (=> permanent new commands to the axis). At low axis activity the shown values has to be reduced on to two-thirds (⅔)! … (up to 30 axis) … (up to 30 axis) … (up to 128 axis)

30 Motion Control with SIMATIC & SINAMICS │ Speed & Positioning axis
SIMATIC S7-1500: Influence of Standard-FBs (FB284 – FB287) on the PLC load

31 Motion Control - Decentral with SINAMICS G/S … new function blocks within TIA Portal for SIMATIC S7-300/400 & S7-1200/1500 Standard function blocks for SINAMICS (FB) FB impact on the SIMATIC S7-1200/1500 load SINA_SPEED FB285 SINA_POS FB284 Function block (FB) Load memory Work/ Code work Instance datablock SINA_SPEED 14890 Byte 1170 Byte 236 Byte SINA_POS 87640 Byte 7070 Byte 436 Byte SINA_PARA Byte 14940 Byte 860 Byte SINA_PARA_S 85370 Byte 7590 Byte 324 Byte SINA_PARA FB286 SINA_PARA_S FB287 Rule of thumb for the PLC memory utilization per FB: PLC memory utilization per FB = Load memory + Work memory + n * Instance datablock memory n = number of axis respectively number of FB calls The cycle time load thru the use of FB is negligible! High number of axis possible, because of minimal impact on the PLC load

32 Motion Control with SIMATIC & SINAMICS │ Speed & Positioning axis
Summary

33 Motion Control with SIMATIC & SINAMICS … Highlights: Motion Control - Central and Decentral
Low PLC load and very high numbers of axis feasible Extensive drive diagnostics and messages Harmonized Standard-FBs with intuitive interface Additional drive integrated functions feasible (monitoring and compensation functions) Axis behavior and dynamics instantaneously NOT changeable Central Highest usability and engineering efficiency without special drive technology knowledge Extensive drive & technology diagnostics and messages Axis behavior and dynamics instantaneously changeable Motion programming with PLC-Open Standard Higher PLC load

34 Motion Control with SIMATIC & SINAMICS … Recommendations for speed axis / drives
Decentral Recommendation for Central Motion Control: Commissioning and testing of speed axis without specific drive knowledge Speed / Positioning and Coordinated axis with technological dependency among each other, are operated on the same PLC Clear program structure based on PLC Open Standard Number of axis in the application is supported by the used PLC Recommendation for Decentral Motion Control: No Motion Control load for the SIMATIC PLC is requested, especially for high numbers of axis Speed axis is a integrated basic function in every SINAMICS drive and completely independent from any PLC Advanced drive functions are requested (e.g. automatic restart, kinetic buffering, etc.) Central The customer and the application determine the best applicable configuration

35 Motion Control with SIMATIC & SINAMICS … Recommendations for positioning axis / drives
Decentral Recommendation for Central Motion Control: The better usability thru the drive & automation technology integration within the TIA Portal is fully exploited => Engineering Efficiency Cost sensitive positioning applications with low to medium requirements regarding positioning accuracy & dynamic, in conjunction with SINAMICS G Number of axis in the application is supported by the used PLC Recommendation for Decentral Motion Control: No Motion Control load for the SIMATIC PLC is requested, especially for high numbers of axis Additional decentral drive intelligence is requested, e.g. Free Function Blocks (FFB), Drive Control Chart (DCC) etc. Central The customer and the application determine the best applicable configuration

36 Motion Control with SIMATIC & SINAMICS … Recommendations for positioning axis / drives
Positioning accuracy > 1° Positioning accuracy < 1° Positioning dynamic low (Movement cycle > 1s) Positioning dynamic medium (Movement cycle < 1s) Positioning dynamic high (Movement cycle < 100ms) G110M, G120C G120 CU240B/E-2 G120 CU250S-2 G120D CU240D-2 S110 S120 Central (TO) Decentral (EPos) G110M, G120C G120 CU240B/D/E-2 G120 CU250S-2 G120D CU250D-2 S110 S120 Isochronous communication Technically feasible / recommended NON isochronous communication Technically NOT feasible / recommended Restricted recommended, because of range limitations or overdimension Legend:

37 Motion Control - Central with SIMATIC & SINAMICS … Technology Objects offer new possibilities for positioning applications SIMATIC S & SINAMICS G120 SIMATIC S & SINAMICS S120*) Basic communication interface PROFIdrive / PROFINET Integrated SAFETY functions, controlled via PROFIsafe Automatic generated drive alarm messages are available via the diagnostic channel on the HMI, Web-Server, PLC-Display and TIA Portal, without any extra line of code Efficient MOTION applications based on technology objects incl. automatically generated technology messages and message acknowledgement on the HMI, without any extra line of code Positioning applications with low / medium requirements on positioning dynamic Positioning applications with high requirements on positioning dynamic Optimized control structure thru Startdrive Commisioning-Wizard Isochronous mode incl. optimized control structure: Pulse frequency cycle / current control cycle aligned to field bus cycle (IRT) Clock cycle reduction between master application cycle (OB91) and field bus cycle (1 up to 14) Integrated engineering based on TIA-Portal Highest positioning performance thru Dynamic Servo Control (DSC) Integrated data management, all data (incl. converter parameters) are kept in one TIA Portal project. Engineering Efficiency Positioning performance The customer and the application determine the best applicable configuration *) SINAMICS S120 connection to SIMATIC S via GSD/GSDML-File Tool: STARTER GSDML File Script

38 Motion Control with SIMATIC & SINAMICS … learn more!
Documentation Application examples Further Documentation: SIMATIC S7 S Programmable controller SIMATIC S S Motion Control V13 Update 3 SINAMICS G120 Function Manual Basic Positioner SINAMICS G120D frequency converter with control units CU250D-2 SINAMICS S120 Function Manual Drive Functions Overview: Application overview or SINAMICS G: Speed Control of a G120 (Startdrive) with S (TO) via PROFINET or PROFIBUS with Safety Integrated (via Terminal) and HMI Positioning a G120 (Startdrive) with S (TO) via PROFINET or PROFIBUS with Safety Integrated (via Terminal) and HMI Speed Control of a G120 (StartDrive) with S (TIA Portal) via PROFINET/PROFIBUS DP with Safety Integrated (via Terminal) and HMI Speed control of a G120C using S with PROFINET/PROFIBUS and Safety Integrated (via terminal) Speed control of a G120 using S7-300/400 (TIA-Portal) with PROFINET/PROFIBUS and Safety Integrated (not via PROFIsafe) and HMI SINAMICS S: Positioning with S120 inclusive acyclic communication

39 Thank you for your attention!
Mr. Heinz Kerpen I DT MC GMC D5 Frauenauracher Strasse Erlangen Telefon: +49 (9131) Supported by: APC Erlangen, SUP FA Nürnberg Mr. Klaus Fröhlich I DT MC RMC GMC-BD4 Frauenauracher Strasse Erlangen Telefon: +49 (9131) Mr. Christian Rabus I IA AS S SUP FA Gleiwitzer Strasse Nürnberg Telefon: +49 (911) siemens.com/answers


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