1. Learning Control – Time based

2. 16 July, 20152 Overview Learning control feature provided by Servo processor optimizes path accuracy of repetitive cutting cycles typical applications - CAM grinding, Crankpin grinding,piston lathe, gear cutting, European Applications – at Junker, Kellenberger, Grob, IMT Rotary axis Crank-pin Grinder Learning Controller HRV Control Linear axis G05 Position Command CNC Position Error Servo Control Compensation Direct drive motor

3. 16 July, 20153 Learning Function What is “Learning Control” Function? Function for realizing HIGH-SPEED and HIGH-PRECISION cutting Learning Control = Learning Controller + Adaptive Preview Controller FANUC Learning Control Preview Repetitive Control Learning Controller Adaptive Preview Controller Learning Control Learning Controller

4. 16 July, 20154 Learning Control How does “Learning Control” work? Learning Control minimizes the path error The Learning Controller reads the path error within one specific period = “New Learning Data” The Learning Controller calculates compensation data based on the comparison of “Old Learning Data” and “New Learning Data” The compensation data is used to reduce the position error The “New Learning Data” is memorized for the next period Command + - Learning Controller Kp 1s1s Position Feedback Position Error Suspension Continuation Position Gain Motor G 0 (s) + +

5. 16 July, 20155 Adaptive Preview Control How does “Adaptive Preview Control” work? Learning Control decides the final path error Adaptive Preview Control increases the speed of “Learning”  Path error is reduced faster  Reduced machining time Adaptive Preview selects the best suitable feed-forward coefficients Command + - Learning Controller Kp 1s1s Position Feedback Position Error Position Gain Motor G 0 (s) + + + Adaptive Preview Controller + Preview Repetitive Control

6. 16 July, 20156 Learning Modes Suspension Mode Learning data renewed up to Suspension count BRCT P2513 counts down to 0 (lead cutting) Continuation Mode Learning data renewed up to the end of high speed cutting (piston lathe) Compensation Data Suspension Mode Data of first cycle after Power ON – like Suspension Mode Further cycles uses learning data of last previous cycle Learning data cleared after power OFF (cam grinding) Compensation Data Continuation Mode Data of first cycle after Power ON – like continuation Mode Further cycles uses learning data of last previous cycle Learning data cleared after power OFF (cam grinding)

7. 16 July, 20157 Learning Control – Targets Measurement Example - X-axis of Crank-shaft Grinding Machine Position Error Position One period Disturbance After 3 cycles  the error caused by disturbance disappeared.

8. 16 July, 20158 Part Program Part Program for Learning Control Time based Learning Control requires special part program format  ISO code format cannot be used with time based Learning Control Position command of each axis, which should use Learning Function must be prepared as “High-Speed Cutting Data” Incremental position every interpolation period in “Least Increment Unit” Interpolation period: 0.25ms, 0.5ms, 1ms, 2ms, 4ms  Example: Least increment unit: 0.0001mm or 0.0001deg, Interpolation period: 1ms TimeX-axisSpeedC-axisSpeed [sec][mm/min] [min-1] 0.000 0 0 0.001100 6001200 20 0.00220012001200 20 0.00330018001200 20 0.004 : : : : Speed (X) = 200 * 0.0001mm / 0.001s = 20mm/s = 1200mm/min Speed (C) = 1200 * 0.0001deg / 0.001s = 120deg/s = 20min-1

9. 16 July, 20159 Part Program High-speed cutting data must be prepared for the complete machining  X-axis data must include in-feed movement In case of many cutting cycles  amount of cutting data becomes very large Superimposed Control for High-speed Machining Only one cycle must be prepared in High-speed cutting data In-feed is realized by superimposed movement of a virtual axis. The virtual axis can be programmed in ISO-code. The complex oscillation operation can be done easily by superimposing NC program operation on high-speed cycle data.

10. 16 July, 201510 Part Program “High-Speed Cutting” can be achieved by 3 methods: Memory Operation Part program is prepared on PC (or Open CNC) Cutting data are transferred to P-Code area by Macro Executor Data Server Operation Part program is prepared on PC (or Open CNC) CNC runs in “High-Speed Binary Operation by Data Server” mode Cutting data are transferred from PC to CNC Data Server via Ethernet DNC Operation Part program is prepared on PC (or Open CNC) CNC runs in “DNC Operation” mode Cutting data are transferred via HSSB (High-Speed Serial Bus) There is a possibility that transmission rate cannot be kept by PC due to performance problems  could cause accuracy problems

11. 16 July, 201511 Part Program Program Format – High Speed Cycle Machining G05 P10xxx Lxxx P10001 to P10999 : Start number of the machining cycle to call L1 to L999 : Repeat count of the machining cycle B-63943EN-1/03 page 2228

12. 16 July, 201512 Learning control – 30i/31i-A C axis SYNCHRONOUS BUILT-IN SERVO MOTOR D i S 3000 LINEAR MOTOR L i S 6000B2 Z axis X axis D i S3000 Grinder  1250,350min -1 A axis “Direct Drive with Learning Control” - for high precision grinding machines X axis error X axis position fb X axis error 40  m within 0.6  m Standard control (5min -1 )Learning Control (10min -1 ) Enhanced Learning Control Longer learning period (  262 sec) Detecting irregular following error by Error watching function

13. 16 July, 201513 System Requirements - Servo Special servo card ( 8 axes/90D3, 16 axes/90E3) – A02B-0303-H088 (A20B-3300-0450) On additional Servo card – Learning is not supported Servo software – 90D3 ➜ 2 axes per DSP for HRV2/3 ➜ 1 axes per DSP for HRV4 Servo software – 90E3 ➜ 4 axes per DSP for HRV2 ➜ 3 axes per DSP for HRV3 ➜ no HRV4 Servo Software – 90E7 ➜ 4 learning axes in HRV4 TMS10/041E Remark: No. of axes depending on velocity sampling time A-63639E-108/04 page 10

14. 16 July, 201514 System Requirements - CNC CPU card - High-speed 128MB DRAM type D3 (High-speed) A02B-0303-H010 Necessary Software option Learning Control A02B-xxxx-J705 or Preview Repetitive control A02B-xxxx-J706 High Speed cycle cutting A02B-xxxx-J832 or High-speed binary operation A02B-xxxx-J516 Setting unit IS-C A02B-xxxx-J805 or Setting unit IS-D A02B-xxxx-S694 or Setting unit IS-E A02B-xxxx-S805 Additional Software option – A-63639E-108/04 page 68

15. 16 July, 201515 Learning control – Application Examples C1-axis D i S85/400 C2-axis D i S85/400 X-axis L i S3300C1/2 Grinder Crank-pin 15µm p- p 1.5µm p- p 5µm/div 50µm/div Standard control Synchronous error Precision of work Learning Control Standard Control Learning Control Structure

16. 16 July, 201516 FSSB Setting Learning axes can be assigned:1,3,5,7 axes (2 per DSP) - 90D3 1,5,9,13.. axes (1 per DSP) - 90E3 1,5,9,13.. axes (1 per DSP) - 90E7 (3,4,7,11.. are not available as controlled axes) Remaining axes on DSP can be configured as standard axes High speed cutting axes needs to be 1 st and subsequent axes – no mixture with standard axes Manuel FSSB setting 2 recommended – in case of using HRV3 or HRV4 required Type of HRV applied to learning axes requires same type of HRV for standard axes (same HRV control type per Servo board) Additional axes board can be used for standard axes in combination with Learning control board L24 required CNC Software A-63639E-108 page 67

17. 16 July, 201517 FSSB Setting FSSB – Hardware Connection 1 FSSB channel 2 FSSB channels – semi closed learning axis

18. 16 July, 201518 FSSB Setting 2 FSSB channels – full closed learning axis

19. 16 July, 201519 Servo parameter setting Servo Parameter High servo control rigidity – Requirement for efficient Learning control Position gain P1825 = 6000 PI controlP2003#3=1 current controlP2004=xx1x0001 – setting depends on HRV type and Velocity sampling time Learning control P2019#6=1 or Adaptive preview control P2019#5=1 Vel. Proportional gain P2044 2* standard value – Tune by Servo Guide Navigator

20. 16 July, 201520 Servo parameter setting HRV Parameter Learning HRV3 Servo HRV3 controlP2013#0=1 Current loop gain magnificationP2334=150 Velocity gain magnificationP2335= 100-400 Regular high speed HRV controlP2271#0=1 – HRV enabled in G1 (different to standard software) Learning HRV4 Servo HRV4 controlP2014#0=1 Current gain IP2040 - 1.5 times of HRV2 standard value Current gain PP2041 - 1.5 times of HRV2 standard value Current loop gain magnificationP2334=200 Velocity gain magnificationP2335= 100-400 Regular high speed HRV controlP2271#0=1 P2003#0 and P2004 depends on HRV type and velocity sampling rate

21. 16 July, 201521 Learning Parameter Frequency band of the low pass filter P2512=200 0 to 700 stepping up every 50 (When Velocity 0.5msec) 0 to 350 stepping up every 25 (When Velocity 1msec) Maximum order of GxP2526=10 0 to 20 Minimum order of GxP2527=0 0 to GODMX Coefficient 1P2528=64 Coefficient 2P2528=-32 A-63639E-108 page 28 …

22. 16 July, 201522 Learning Parameter Adaptive Preview Parameter enable Adaptive Preview Control - INVSYS P2019#5 using Adaption – ADAPT P2442#1 transmit Feed forward data automatically to P2544-2549 – TRASMT P2442#2 Adaptive control uses Position error – ADRERSL P2442#5 Adaption coefficient ADPCE – P2543 Feed forward coefficient – FORW1-6 P2544-2549 determined by adaptive mode Adaption Method: Set P2019#5=1 and P2442#1=1 Clear P2544-2549 Start with P2543=100 Run learning cycle with G05 several times Increase P2543 by steps of 50 – observe POSF or ERR with Servo Guide After reaching accuracy target – P2442#1=0 Transmit Feed forward data to P2544-2549 - P2442#2=1 Termination of adaptive process – P2442#2,1=0

23. 16 July, 201523 Learning Buffer Buffer Size: Servo card A02B-0303-H088 SW: 90D3 - 282624 sampling data 90E3 - 270336 sampling data Calculation of maximum sampling period: No. of Profile PRFALL= 4 Buffer Size BUFSIZE = 282624 Learning period MAX_PRIOD= 8000ms No. of Learning Steps STEPNO= 5 2 sampling periods are possible Exponent of sampling rate N – check DNG253 (P2115=0, P2151=6225)

24. 16 July, 201524 Learning Data Transmission Overview After completion of learning process – storage of learning data Learning data transmitted from Servo processor to FROM can be accessed also by Memory card or by PC FOCAS2 is available – check of data transfer Lump deal method P2511=0 – saving all learning data partial deal method P2511= Profile No. – specific saving of learning data Learning data needs to be applied with corresponding program data A-63639E -108 page 41

25. 16 July, 201525 Learning Data Transmission FROM Servo – Learning data CNC – Buffer Save and Restore of Learning data