Starting up Motors TM460

Transcription

1 t ep rin Starting up Motors no t fo rr TM460

2 Introduction Requirements Training modules: Software: Hardware: TM210 The Basics of Automation Studio TM400 The Basics of Drive Technology TM410 The Basics of ASiM AS or later / ACP10 software or later None 2 TM460 Starting up Motors

3 Introduction Table of contents 1. INTRODUCTION Objective 5 2. GENERAL Motor components Compatibility of motor components Installation PARAMETER SETTINGS Synchronous motor Induction motor Linear motor Encoder Temperature sensor Holding brake START-UP Holding brake Temperature sensor Encoder Motor CONTROLLER SETTING CHECKLIST FOR STARTUP EXERCISES SUMMARY APPENDIX Solutions 44 Starting up Motors TM460 3

4 Introduction 1. INTRODUCTION The high level of performance of a drive's controller is crucial for the quality, precision and dynamic capabilities during a process. A motor's characteristics must be known or be determined at the highest possible degree of accuracy in order to achieve the desired level of control performance. Fig. 1: B&R drive system After reviewing the basics, we will use a step-by-step approach to learn about the requirements a motor must meet in order to be run on a B&R servo drive, how motor parameters are determined and added to Automation Studio and will then take a step-by-step look at how a motor is put into operation. 4 TM460 Starting up Motors

5 Introduction 1.1 Objective You will learn the requirements for operating a motor on a B&R servo drive and will know which components ACOPOS is compatible with. You will learn how motor, encoder, temperature sensor and holding brake are configured in a parameter table and how the data is transferred to the ACOPOS. You will be able to perform the necessary steps to start up any motor, which is suitable for operation with ACOPOS. Fig. 2: Objectives Starting up Motors TM460 5

6 General 2. GENERAL 2.1 Motor components Several components are needed to safely operate the motor on a servo drive: Encoder: The encoder returns the current position of the shaft to the servo drive. Temperature sensor: The temperature sensor is used for monitoring the winding temperature. This monitor info can be used to protect the motor winding and other components from potential overheating. Motor holding break: The holding brake prevents the motor shaft from moving when the controller is switched off after standstill. However, this is not a safety criterion. Fig. 3: Servo motor structure (synchronous motor) 6 TM460 Starting up Motors

7 General 2.2 Compatibility of motor components When using B&R motors, you must make sure that the motor is compatible with the servo drive type: 8LS motors 8MS motors ACOPOS ACOPOSmulti Dielectric strength too low When using a motor from another manufacturer, make sure that all components are compatible for operation with ACOPOS. Note: All information and specifications for dimensioning with ACOPOS can be found in the respective manual or in the online help files under: Automation Hardware: Motion control Starting up Motors TM460 7

8 General Motor The following table contains an overview of potential motor designs and indicates which design can be used with a B&R servo drive: Operating principle Synchronous Induction Rotary Motion Linear The most important criterion for the motor is the dielectric strength of the insulation. Caution: The motor could suffer considerable damage or even be destroyed if the dielectric strength of the insulation and the motor's maximum rate of rise in voltage is smaller than the servo drive's maximum value. The required values can be found in the Manual: Technical Data or in the online help files under Automation Hardware: Motion control 8 TM460 Starting up Motors

9 General Encoder ACOPOS can be used with the following encoder interfaces: EnDat Resolver Incremental encoder Hiperface SSI Sin/Cos encoder (1Vss) Fig. 4: EnDat encoders EnDat and Resolver encoders are used in the B&R motors. Therefore, these interfaces are also recommended for motors from other manufacturers. When using any interface, make sure that the encoder interfaces match the data of the ACOPOS plug-in cards. Note: Induction motors can also be operated without encoder in the UF mode. Information is available in the online help files under: Automation Software: Automation Studio: NC Software: ACP10: NC Objects: NC Object "ncaxis": Closed Loop Controller. Starting up Motors TM460 9

10 General Temperature sensor Although not an absolute requirement, the selected motor should have a temperature sensor. ACOPOS also supports several types of sensors: Linear thermistor PTC switches Thermal switches The temperature sensors differ in their functionality: The PTC, as well as the thermal switches, have just two states. This means that the ACOPOS can only determine if the motor is too hot or not. The linear thermistor can be used to read the current temperature. This provides the benefit of enabling the servo drive to take action before the motor becomes too hot. Note: If a temperature sensor is not used, then monitoring is based on a calculated temperature model. 10 TM460 Starting up Motors

11 General Holding brake Fig. 5: Holding brake cross-section A holding brake must have a rated voltage of 24 V in order to be controlled directly by the ACOPOS. The maximum current consumption must be lower than the maximum current provided by the ACOPOS. An additional switching circuit can be used if a holding brake with different characteristics must be operated. Starting up Motors TM460 11

12 General 2.3 Installation Delivery Wiring Check motor for any damage when removing from transport packaging. Protruding parts such as the motor or encoder connectors are at particular risk of damage. In very rare cases, transport safeguards may have been used on the motor to prevent the rotor from turning. These must be removed if present. If possible, the motor should not yet be connected to the machine mechanics. This is a precaution to prevent potential damage that could occur from unexpected movement during motor setup. The motor can now be connected to the ACOPOS using the motor cable and encoder cable. Cables prefabricated for use with ACOPOS are available for B&R motors. When using a motor from another manufacturer, the pin assignment for both cables must be taken from the ACOPOS User's Manual: Wiring and from the data sheets for the motor and encoder. Note: The shielding for the motor and encoder cables absolutely must be connected in order to prevent possible interference which could negatively affect control performance. Caution: Be sure to accurately follow all of the safety guidelines in the ACOPOS manual when wiring in order to prevent personal and material damage. Failure to follow the safety notices can result in death or injury! 12 TM460 Starting up Motors

13 Parameter Settings 3. PARAMETER SETTINGS All motor characteristics must be specified in order for the servo drive to operate and to protect the motor from damage. Note: Under certain circumstances, it may not be necessary to configure the motor parameters if the motor has an EnDat encoder because motor data can be saved on the EnDat. This data is automatically applied by the ACOPOS. This chapter looks at how to configure the motor in Automation Studio to achieve the best possible control performance. We will only cover motors from other manufacturers because all of the necessary data for B&R motors is already stored in a database (see TM 410). The best way to load the motor data to the servo drive is with a parameter table. This can be assigned to the respective axis right in the Deployment Table (in AS 3: NC Mapping Table). A parameter table can also be used for multiple axes. Select the "Motor" parameter group to add a motor from another manufacturer to a parameter table. Starting up Motors TM460 13

14 Parameter Settings In the subsequent dialog box you can choose between a synchronous and an induction motor and enter a new name for the motor. Fig. 7: Dialog box - Motor selection in AS 3 Fig. 6: Motor selection dialog box in AS 2.x Fig. 8: Dialog box - Defining a motor from another manufacturer in AS 3 14 TM460 Starting up Motors

15 Parameter Settings An "empty" motor template is added to the parameter table after completing the dialog box. This contains all of the parameters required for operation. Fig. 9: Parameter table for a synchronous motor The drive data can now be entered in the parameter table. Caution: Pay attention to the units used when entering the values. Starting up Motors TM460 15

16 Parameter Settings 3.1 Synchronous motor All of the motor data must be known when using a synchronous motor. Certain parameters can be measured or estimated in the event that the manufacturer's data sheet is not complete. Note: Information about individual parameters for the synchronous motor can be found in the online help files under: Automation Software: Automation Studio: NC Software: ACP10: ACOPOS drive functions: Synchronous motor Note: Any necessary data that is not contained in the data sheet must be requested from the manufacturer. The ACOPOS applies a replacement value for some parameters. This makes it possible to operate the motor, but there is no guarantee that these values are suitable for the motor. 16 TM460 Starting up Motors

17 Parameter Settings Example: Synchronous motor Create a new parameter table and configure the synchronous motor with the model number 110B D03JD-AA: Fig. 10: Synchronous motor data sheet Note: When using this data sheet for actual operation, the rated voltage must be requested from the manufacturer. Caution: The line cross section must be specified for the temperature model to function properly. This is not specified in this data sheet and must be requested from the manufacturer. The ACOPOS uses a default value if the parameter is set to 0, which only offers moderate protection. Starting up Motors TM460 17

18 Parameter Settings 3.2 Induction motor There are many ways to determine the parameters for configuring the induction motor: Data sheet Data sheet Calculation using the data from the power rating plate Automatic parameter identification Note: Information about individual parameters for the induction motor can be found in the online help files under: Automation Software: Automation Studio: NC Software: ACP10: ACOPOS drive functions: Induction motor The data in the data sheet provides a simple method for configuration. Some values can also be estimated or calculated in the event that this data is not complete. Note: It is recommended to recalculate or recheck manufacturer specifications. 18 TM460 Starting up Motors

19 Parameter Settings Calculation using the data from the power rating plate When using an induction motor, all of the required motor characteristics can be calculated using the data from the power rating plate. Fig. 11: Calculation table for induction motors Caution: These specifications must be entered in accordance to the motor connection being used Y/ Note: This table is available in the online help files under: Automation Software: Automation Studio: NC Software: ACP10: ACOPOS drive functions: Induction motor: Parameter estimation from the power rating plate data Starting up Motors TM460 19

20 Parameter Settings Automatic parameter identification Automatic parameter identification is the easiest way to get the exact motor characteristics. To do this, different test signals are automatically applied to the motor output by the servo drive and their reactions are monitored. The identification quality is determined by matching a model with the measured values. Procedure: All of the necessary parameters from the power rating plate must be entered first Parameter PIDENT_MOTOR_TYPE PIDENT_CURR_RATED PIDENT_VOLTAGE_RATED PIDENT_SPEED_RATED PIDENT_COS_PHI PIDENT_FREQ_RATED Description 1...Induction motor Rated current Rated voltage Rated speed Active power factor Rated frequency The test procedure is now started by setting the parameter CMD_PIDENT (ParID 997) to ncswitch_on (258) Fig. 12: Signal form for identification 20 TM460 Starting up Motors

21 Parameter Settings The parameters PIDENT_STATE (ParID 996) = 0 and PIDENT_FIT (ParID 998) 0.0 indicate that the identification is complete. PIDENT_FIT indicates whether or not the procedure was successful: Note: PIDENT_FIT Evaluation: 80.1% 100% Good 60.1% 80% Satisfactory 60 % Unsatisfactory 0.0% Invalid After the identification has been completed successfully, all parameters can be read and saved in a parameter table. Repeating the procedure 2-3 times can improve identification. More detailed information and tips for using automatic parameter identification can be found in the online help files under: Automation Software: Automation Studio: NC Software: ACP10: ACOPOS drive functions: Parameter identification: Motor Note: The automatic parameter identification procedure is only allowed for induction motors! Starting up Motors TM460 21

22 Parameter Settings Example: Induction motor Use the power rating plate to create a parameter table for the induction motor AEG AMF V 1325 ZA 2: Rated frequency Rated speed Rated voltage Rated power Power factor Rated current 22 TM460 Starting up Motors

23 Parameter Settings 3.3 Linear motor In principle, ACOPOS can be used to operate a linear synchronous motor, although an intermediate step is required for configuring the parameters. All ACOPOS parameters are designed for rotary axes, which is why the linear motor data must first be converted. Note: Information about individual parameters for the synchronous motor can be found in the online help files under: Automation Software: Automation Studio: NC Software: ACP10: ACOPOS drive functions: Synchronous linear motor The following table are used for making the conversions: Fig. 13: Table for converting linear to rotary axes Note: This table is available in the online help files under: Automation Software: Automation Studio: NC Software: ACP10: ACOPOS drive functions: Synchronous linear motor: Parameter conversion from linear motor to synchronous motor Starting up Motors TM460 23

24 Parameter Settings Example: Linear motor Create a parameter table for the linear motor BLMX-502-B. Fig. 14: Linear motor data sheet 24 TM460 Starting up Motors

25 Parameter Settings 3.4 Encoder After all motor data has been entered in the parameter table, it is time to configure the next component, the encoder. This is done by inserting a parameter group which corresponds to the model number of the interface card. The number of the slot where the encoder card will be operated must also be specified. Fig. 15: Dialog box for inserting an encoder If the encoder card is capable of processing many different encoder interfaces, then the interface being used must be selected in the next window. Fig. 16: Dialog box for selecting the encoder type Starting up Motors TM460 25

26 Parameter Settings After completing this dialog box, a parameter group is inserted in the table, which contains all the parameters required for operating the encoder. Fig. 17: Parameter group for an incremental encoder with DCM 26 TM460 Starting up Motors

27 Parameter Settings Example: Encoder Configure the respective plug-in card and encoder for each motor: Synchronous motor: EnDat encoder Induction motor: Incremental encoder with 512 inc/rev Linear motor: Sin/Cos encoder Material measure Graduated metal rule with AURODUR grid division Division period 20 µm Therm. expansion coefficient Depends on the mounting surface Accuracy class ± 5 µm Measurement length ML in mm 140 Reference marks One at the middle of the measurement length Limit switch L1/L2 with 2 different magnets Output signals: TTL (without cable driver) Max. movement speed 240 m/min Vibration 55 to 2,000 Hz 200 m/s² (EN ) Shock 11 ms 500 m/s² (EN ) Operating temperature 0 to 50 C Ground Scanning head: 20 g (not including cable) Scale: approx. 115g g/m measurement length Connection cable: 70 g/m Supply voltage 5 V ± 5%/< 200 ma (without load) Incremental signals TTL Signal period Integ. 5x interpolation: 4 µm Integ. 10x interpolation: 2 µm Electrical connection 3 m cable with DSUB plug (15-pin); Interface electronics integrated in the plug Max. cable length 20 m The reference length must be used as basis for calculation of the linear motor encoder's resolution. The resolution can also be found in the conversion table (Linear Rotary). Note: Information about individual parameters for the encoder can be found in the online help files under: Automation Software: Automation Studio: NC Software: ACP10: ACOPOS Parameter IDs: Encoder 1/2/3 Starting up Motors TM460 27

28 Parameter Settings 3.5 Temperature sensor The parameter IDs required for the temperature sensor are already contained in the motor structure's parameter table and can now be filled in. Fig. 18: Parameters for the temperature sensor The parameter IDs that must be specified depends on the type of sensor being used: Sensor type MOTOR_TEMPSENS_PAR Thermistor x x x x x x x x x x PTC switches x 0.0 x Thermal switches x X Disable x Required parameter 28 TM460 Starting up Motors

29 Parameter Settings The parameters for the PTC switch and thermal switch can be entered with the help of the data sheet. An Excel table must also be used for the linear thermistor: Fig. 19: Parameter calculation for a thermistor Note: Information about individual parameters for temperature sensors as well as the calculation table can be found in the online help files under: Automation Software: Automation Studio: NC Software: ACP10: ACOPOS drive functions: Motor temperature sensor Starting up Motors TM460 29

30 Parameter Settings Example: Temperature sensors Configure a KTY for the synchronous motor with the help of the Excel table: The induction motor does not have any temperature sensors. Configure a thermal switch (N.C.) for the linear motor, which is triggered at 120 C. 30 TM460 Starting up Motors

31 Parameter Settings 3.6 Holding brake Just like for the temperature sensor, parameters are also contained in the motor parameters for the holding brake. Fig. 20: Parameters for the holding brake If a holding brake is used, the ParIDs can now be written with values. If a holding brake is not present, then all of the parameters should be written with 0.0. Note: Information about individual parameters for the holding brake can be found in the online help files under: Automation Software: Automation Studio: NC Software: ACP10: ACOPOS drive functions: Motor holding brake control Note: Current and voltage are monitored on the servo holding brake connection. Therefore, all values must be set to 0 if a holding brake is not present in order to prevent error messages. Starting up Motors TM460 31

32 Parameter Settings Example: Holding brake Configure the holding brake 06.P1 for the synchronous motor. Fig. 21: Holding brake data sheet t1 Delay when switching on 32 TM460 Starting up Motors

33 Start-Up 4. START-UP Now that all of the motor components have been configured, we can now begin starting up the individual components. Note: Ideally, the motor shaft can move freely. This will make your startup considerably easier. 4.1 Holding brake The holding brake should first be operated manually (from the NC Test) to ensure functionality. The ParID CMD_BRAKE (ParID 86) can be used to execute the following commands: ncswitch_on (258) Engage brake ncswitch_off (259) Disengage brake After the switch-off command has been written, you should hear a "clicking" sound and should be able to move the shaft by hand. Note: In the event of a hanging load, the motor should be located on the lower stop position. Otherwise, the axis will fall when the brake is disengaged which can cause damage to the mechanics. Possible sources of errors: Holding brake circuit interrupted Circuit polarity reversed Starting up Motors TM460 33

34 Start-Up 4.2 Temperature sensor The startup process for temperature sensors depends on the type of sensor being used: Sensor type Linear thermistor PTC switches Thermal switches Testing sequence Monitor the temperature in the NC Test at room temperature (without pre-heating or load). The case of over-temperature due to internal or external rise in temperature must be tested. Must be tested for broken connection. Must be tested for short-circuit. The case of over-temperature due to internal or external rise in temperature must be tested. Must be tested for broken connection. Must be tested for short-circuit. The case of over-temperature at nominal response temperature due to internal or external rise in temperature must be tested. Over-temperature can be easily tested using switches. 34 TM460 Starting up Motors

35 Start-Up 4.3 Encoder Unlike temperature sensors, there is no difference between encoder interfaces when starting up the encoder. The encoder (or shaft) must first be rotated manually while checking the LEDs on the plug-in card. The LEDs should light up corresponding to the direction of rotation. Fig. 22: AC123 plug-in card The next step is to manually rotate the shaft to a certain degree (preferably 360 ) and to monitor how the actual position behaves (direction, resolution). If open circuit recognition is supported by the encoder, this can be tested by removing the plug from the plug-in card. The following conditions may cause the encoder to react in a manner other than expected: Incorrect wiring Shielding not connected Faulty plug-in module or encoder Incorrect configuration Clockwise Counter-clockwise Starting up Motors TM460 35

36 Start-Up 4.4 Motor The motor can now be started up. The following sequence is different for synchronous and induction motors. One more important step is needed for synchronous motors without which motor control would not be possible, phasing. Phasing is used in synchronous motors to determine on which encoder position the field direction rotates. The difference between this position and the current rotor position produces what is known as the "commutation offset" ρ 0. Furthermore, phasing can be used to check the wiring as well as the motor and encoder's direction of rotation. Fig. 23: Commutation offset Phasing is only used on induction motors to test the wiring and the direction of rotation. Unlike synchronous motors, phasing is not required for operating the motor. Various specifications determine how the phasing is implemented. Caution: Make sure that the mode is selected according to the motor and mechanics. Failure to do so can cause serious damage. 36 TM460 Starting up Motors

37 Start-Up This decision tree and the corresponding table can provide some assistance here: Fig. 24: Phasing: Decision tree Method Induction motors Motor structure Incremental encoders Holding brake (engaged) Saturatio n Ironless motors Stepper Dither Movement during phasing Oscillating (shaking) Min. 1 pole Measured values Commutation offset Number of pole pairs Direction of rotation Inspection Motor phase failure pair length Oscillating (shaking) Direct 0 Fig. 25: Phasing: Selection table Starting up Motors TM460 37

38 Start-Up Phasing is activated by setting the parameter PHASING_MODE (ParID 276) to the following values... Saturation mode 0 Stepper mode 1 Dither mode 2 Direct mode 3...and writing the parameter CMD_PHASING (ParID 334) with ncstart (260). Modes 0 2 are used to determine the commutation offset, whereby direct mode is used to set the commutation offset to the value of the parameter MOTOR_COMMUT_OFFSET (ParID 63). Caution: The phasing procedure should be repeated and checked 2-3 times to prevent measurement errors. After a satisfactory result has been achieved, the value can be stored as motor parameter in the parameter table when using an absolute value encoder. When using an incremental encoder, phasing must be repeated each time the ACOPOS is restarted or after each encoder error. Note: Phasing is not necessary when using B&R motors because the commutation offset is either 0 (resolver) or is stored in the EnDat memory. Note: More detailed information about the individual modes can be found in the relevant technical literature. 38 TM460 Starting up Motors

39 Controller Setting 5. CONTROLLER SETTING Control performance can still be improved after the motor is running by properly setting the controller. Note: Detailed information on the topic of the Control concept and settings can be found in TM450 Starting up Motors TM460 39

40 Checklist for Startup 6. CHECKLIST FOR STARTUP Component compatibility Motor STEPS COMMENTS OK Motor type/movement Dielectric strength of the insulation Rate of rise in voltage Encoder Encoder interface Temperature sensor Sensor type Holding brake Rated voltage Max. current Installation Motor cable properly connected Motor cable shielded Encoder cable properly connected Encoder cable shielded Drive system grounded Parameter settings Motor Synchronous / induction Encoder Plug-in card Interface type Temperature sensor Type / name Holding brake 40 TM460 Starting up Motors

41 Checklist for Startup Start-up Holding brake "Clicking" sound when switching Shaft able to be rotated by hand Temperature sensor Encoder Motor Measure room temperature Cable break Direction of rotation LED s Encoder resolution Phasing mode Phasing Controller settings TM450 Starting up Motors TM460 41

42 Exercises 7. EXERCISES Example: Induction motor 2 Configure the following motor and its components: Induction motor is run in delta connection: Fig. 26: Induction motor parameter chip Temperature sensor: KTY Fig. 27: KTY83-1xx value table Encoder: Incremental encoder with 1024 inc/rev 42 TM460 Starting up Motors

43 Summary 8. SUMMARY Understanding how the motor parameters are used means that you can configure any motor for operation with an ACOPOS servo drive. The quality of the motor parameters and encoder signal is crucial for the control performance of the axis. Fig. 28: B&R drive system Commissioning and starting up the motor should be done step by step, performing tests at each step along the way. This is the only quick and effective path to success. Starting up Motors TM460 43

44 Appendix 9. APPENDIX 9.1 Solutions Synchronous motor (Ch. 3.1) Fig. 29: Synchronous motor parameter table Induction motor (Ch. 3.2) Fig. 30: Induction motor parameter table 44 TM460 Starting up Motors

45 Appendix Linear motor (Ch. 3.3) Fig. 31: Linear motor parameter table Encoder (Ch. 3.4) Fig. 32: Incremental encoder Fig. 33: Sin/Cos encoder Temperature sensor (Ch. 3.5) Fig. 34: Thermistor solution Starting up Motors TM460 45

46 Appendix Fig. 35: PTC switch solution Holding brake (Ch. 3.6) Fig. 36: Brake solution Induction motor 2 (Ch. 7) Fig. 37: Solution to induction motor 2 in delta connection 46 TM460 Starting up Motors

47 Appendix Overview of training modules TM210 The Basics of Automation Studio TM211 Automation Studio Online Communication TM213 Automation Runtime TM220 The Service Technician on the Job TM223 Automation Studio Diagnostics TM230 Structured Software Generation TM240 Ladder Diagram (LAD) TM241 Function Block Diagram (FBD) TM246 Structured Text (ST) TM250 Memory Management and Data Storage TM261 Closed Loop Control with LOOPCONR TM400 The Basics of Motion Control TM410 The Basics of ASiM TM440 ASiM Basic Functions TM441 ASiM Multi-Axis Functions TM445 ACOPOS ACP10 Software TM446 ACOPOS Smart Process Technology TM450 ACOPOS Control Concept and Adjustment TM460 Starting up Motors TM480 Hydraulic Drive Control not TM500 The Basics of Integrated Safety Technology TM510 ASiST SafeDESIGNER TM540 ASiST SafeMC TM600 The Basics of Visualization TM610 The Basics of ASiV TM630 Visualization Programming Guide TM640 ASiV Alarm System, Trend and Diagnostic TM670 ASiV Advanced TM700 Automation Net PVI TM710 PVI Communication TM711 PVI DLL Programming TM712 PVIServices TM730 PVI OPC TM800 APROL System Concept TM810 APROL Setup, Configuration and Recovery TM811 APROL Runtime System TM812 APROL Operator Management TM813 APROL XML Queries and Audit Trail TM830 APROL Project Engineering TM840 APROL Parameter Management and Recipes TM850 APROL Controller Configuration and INA TM860 APROL Library Engineering TM865 APROL Library Guide Book TM870 APROL Python Programming TM890 The Basics of LINUX for reprint Starting up Motors TM460 47

48 Appendix Back cover (number of pages divisible by 4) Contact (Headquarters) Weblink Internationality Copyright Model number TM460TRE.00-ENG by B&R. All rights reserved. All registered trademarks are the property of their respective owners. We reserve the right to make technical changes. 48 TM460 Starting up Motors