SINAMICS POLYGON. Master-value-dependent characteristic functionality. Function Manual

Transcription

1 s SINAMICS POLYGON Master-value-dependent characteristic functionality Function Manual Edition 10/2015

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3 s Preface Fundamental safety instructions 1 SINAMICS POLYGON Master-value-dependent characteristic functionality Function Manual Applications, characteristics 2 Installation and activation 3 Function description and commissioning 4 Parameters 5 Function diagrams 6 Valid for OA application Firmware version POLYGON 1.1 for the drive SINAMICS S120/S150 from 4.5 SINAMICS Integrated from 4.5 Faults and alarms 7 Appendix Index A 10/2015 A5E

4 Legal information Warning notice system This manual contains information which you must heed to ensure your own personal safety and to avoid material damage. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to equipment damage have no safety alert symbol. Depending on the hazard level, warnings are indicated in a descending order as follows. If more than one level of danger is simultaneously applicable, the warning notice for the highest level is used. A warning notice with a safety alert symbol warning of injury to persons may also include a warning relating to property damage. Qualified personnel The product/system described in this documentation may only be operated by personnel qualified for the specific task in accordance with the relevant documentation for the specific task, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems. Proper use of Siemens products Trademarks Note the following: Disclaimer of liability DANGER indicates that death or serious injury will result if proper precautions are not taken. WARNING indicates that death or serious injury could result if proper precautions are not taken. CAUTION indicates that minor personal injury can result if proper precautions are not taken. NOTICE indicates that property damage can result if proper precautions are not taken. WARNING Siemens products are only permitted to be used for the applications listed in the catalog and in the associated technical documentation. If third-party products and components are deployed, then they must be recommended or approved by Siemens AG. These products can only function correctly and safely if they are transported, stored, set up, mounted, installed, commissioned, operated and maintained correctly. The permissible ambient conditions must be adhered to. Notices in the associated documentation must be observed. All names identified with are registered trademarks of Siemens AG. Any other names used in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner. We have verified that the contents of this document correspond to the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. The information given in this document is reviewed at regular intervals and any corrections that might be necessary are made in the subsequent editions. Siemens AG Division Digital Factory P.O. Box NUREMBERG GERMANY Document order number: A5E /2015 Subject to change Copyright Siemens AG All rights reserved

5 Preface Information about the SINAMICS documentation The SINAMICS documentation is organized in 2 parts: General documentation/catalogs Manufacturer/service documentation This documentation is part of the Technical Customer Documentation for SINAMICS. In the interests of clarity, this documentation does not contain all the detailed information for all product types and cannot take into account every possible aspect of installation, operation or maintenance. The contents of this documentation are not part of an earlier or existing agreement, a promise, or a legal agreement, nor do they change this. The Purchase Agreement contains the complete and exclusive obligations of Siemens, including the warranty provisions. These contractual warranty provisions are neither extended nor curbed as a result of the statements made in this documentation. Target group This documentation addresses commissioning engineers and service personnel who use SINAMICS. Objective This manual contains information about all parameters, function diagrams, faults, and warnings required to commission and service the system. This manual should be used in addition to the other manuals and tools provided for the product. Search tools The following guides are provided to help you locate information in this manual: 1. Table of contents for the complete manual (Page 7) 2. List of abbreviations (Page 64) 3. Index (Page 77) Technical Support Country-specific telephone numbers for technical support are provided in the Internet: Function Manual (FH15), 10/2015, A5E

6 Preface SINAMICS Information about SINAMICS can be found on the Internet at the following address: 6 Function Manual (FH15), 10/2015, A5E

7 Table of contents 1 Fundamental safety instructions General safety instructions Industrial security Applications, characteristics Installation and activation Installing an OA-application using STARTER General information Installing the OA Support Package in STARTER Download the technology package Activating the OA-application in the drive object Commissioning of the OA-application Uninstalling an OA-application using STARTER Installation of an OA application via SINUMERIK HMI General information Installing the OA application on the drive device Activating the OA application for the axis (drive object) Commissioning the OA application Uninstalling an OA application via SINUMERIK HMI Function description and commissioning How POLYGON works Commissioning Conditioning the master value Parameterizing the characteristic Examples of scaling the master value in POLYGON Example 1 rotary axis with incremental encoders without a gear unit Example 2 rotary axis with incremental encoders and a gear unit Example 3 referencing of the OA application POLYGON Example 4 referencing the OA application POLYGON using an absolute value encoder Examples for characteristics for POLYGON Example 5 sine with modulo Example 6 superimposition of multiple characteristics Example 7 - compensation of transfer function and dead times Function diagrams Sampling times and number of controllable drives Licensing SINAMICS Safety Integrated Function Manual (FH15), 10/2015, A5E

8 Table of contents 5 Parameters Overview of parameters List of parameters Function diagrams Faults and alarms A Appendix A.1 List of abbreviations A.2 Defining a characteristic (p31245, p31246[0 n]) with script A.2.1 Creating and running script A.2.2 Example of a script Index Function Manual (FH15), 10/2015, A5E

9 Fundamental safety instructions 1 Content 1.1 General safety instructions Industrial security 11 Function Manual (FH15), 10/2015, A5E

10 1 Fundamental safety instructions 1.1 General safety instructions 1.1 General safety instructions WARNING Risk of death if the safety instructions and remaining risks are not carefully observed If the safety instructions and residual risks are not carefully observed in the associated hardware documentation, accidents involving severe injuries or death can occur. Observe the safety instructions provided in the hardware documentation. When assessing the risk, take into account residual risks. WARNING Danger to life or malfunctions of the machine as a result of incorrect or changed parameter assignment Machines can malfunction as a result of incorrect or changed parameter assignment, which in turn can lead to injuries or death. Protect the parameterization (parameter assignments) against unauthorized access. Respond to possible malfunctions by applying suitable measures (e.g. EMERGENCY-STOP or EMERGENCY-OFF). 10 Function Manual (FH15), 10/2015, A5E

11 1 Fundamental safety instructions 1.2 Industrial security 1.2 Industrial security Note Industrial security Siemens provides products and solutions with industrial security functions that support the secure operation of plants, solutions, machines, devices, and/or networks. They are important components in a holistic industrial security concept. With this in mind, Siemens products and solutions undergo continuous development. Siemens strongly recommends that you regularly check for product updates. To ensure that Siemens products and solutions are operated securely, suitable preventive measures (e.g. cell protection concept) and each component must be integrated into a stateof-the-art holistic industrial security concept. Any third-party products that may be in use must also be taken into account. You will find more information about industrial security at: To receive information about product updates on a regular basis, register for our product newsletter. You will find more information at: WARNING Danger due to unsafe operating states caused by software manipulation Software manipulation (e.g. by viruses, Trojan horses, malware, worms) can cause unsafe operating states to develop in your installation which can result in death, severe injuries and/or material damage. Update your software regularly. You can find information and newsletters on this subject at: Integrate the automation and drive components into a holistic, state-of-the-art industrial security concept for the plant or machine. You can find more detailed information at: Make sure that you include all installed products into the integrated industrial security concept. Function Manual (FH15), 10/2015, A5E

12 1 Fundamental safety instructions 1.2 Industrial security 12 Function Manual (FH15), 10/2015, A5E

13 Applications, characteristics 2 Applications For SINAMICS, the OA application "polygonal line" (POLYGON) is an expansion for the SERVO, VECTOR, and HLA drive objects. The polygonal line application makes it possible to create a master-value-dependent output signal based on a parameterized characteristic in the current controller sampling time (or an integer multiple of the current controller sampling time). The characteristics is defined by up to equidistantly distributed interpolation points between which linear interpolation is performed. The y-values of the interpolation points can be taken from an Excel sheet using a script. By interconnecting the output signals to different connector inputs, it is possible to create the different relationships via the characteristic functionality, e.g.: Position-position reference Position-speed reference Position-torque reference For example, for the following applications: Generation of special signal shapes together with the OA application SETPGEN, which generates the setpoint. Compensation for dead times and transfer function of speed setpoint oscillation. Encoder actual value as the master value for operating on a user-defined torque profile. Drive-integrated cam. Function Manual (FH15), 10/2015, A5E

14 2 Applications, characteristics Characteristics Application of the master value and calculation of the output signal in the current controller sampling time or in discrete integer multiples of the current controller sampling time. Specification of the master value as an integer via a connector input. By default, the encoder position actual value Gn_XIST1 (r0479[0]) is interconnected to this input. Conversion of the master value into a length or angle unit that is suitable for the application via a rational scaling factor (integer numerator / integer denominator). This scaling factor also considers the gear ratio of a gear unit, if there is one, (gear factor). Definition of a reference point possible by taking over a setting value. Periodic repetition of the master value on rotary axes by specifying a modulo length. Dynamic master value offset possible via a connector input. 3 Fixed values available for the static interconnection of the master value, setting value, or master value offset. Generation of the output signal via parameterizable characteristic with up to interpolation points, which are distributed equidistantly over the modulo length. The characteristic is defined by the number of interpolation points and their y-values. Interpolation is performed linearly between the interpolation points. Takeover of the y-values of the interpolation points from an Excel sheet possible using a script. Dynamic scaling of the output value via connector inputs: By specifying a factor (amplitude) By specifying an offset Provision of the scaled output signal via connector outputs for further interconnection as a percentage or integer. These connector outputs can, for example, be interconnected with connector inputs or analog outputs inside the controller. Additional information about POLYGON The OA application POLYGON is described in detail in Chapter "Function description and commissioning" (Page 29). 14 Function Manual (FH15), 10/2015, A5E

15 Installation and activation 3 Table of contents 3.1 Installing an OA-application using STARTER Uninstalling an OA-application using STARTER Installation of an OA application via SINUMERIK HMI Uninstalling an OA application via SINUMERIK HMI 28 Function Manual (FH15), 10/2015, A5E

16 3 Installation and activation 3.1 Installing an OA-application using STARTER 3.1 Installing an OA-application using STARTER Note The subsequent description in this chapter refers to the fictitious OA-application "ABC_OA". The procedure described in this chapter can be correspondingly applied to any real OA-application. This description to install and commission an OA-application is also applicable for engineering software with integrated STARTER (e. g. SIMOTION SCOUT). 16 Function Manual (FH15), 10/2015, A5E

17 3 Installation and activation 3.1 Installing an OA-application using STARTER General information Terms OA-application (OA, Open Architecture) Software component (technology package) which provides additional functions for the SINAMICS drive system. OA Support Package (OASP) By installing an OA Support Package (OASP), the STARTER commissioning tool is expanded by the corresponding OA-application. An OA Support Package is only required if the associated OA-application is used. Generally, it can be obtained through your local Siemens office. Devices This description is applicable for devices that require a memory card (e.g. S120, automation systems with SINAMICS Integrated). Requirements 1. The STARTER commissioning tool as of Version V4.2 must be installed. 2. The file for the OA Support Package "oasp_abc_oa_v1_2_oaif zip" must be located in a known directory. The file name for the OA Support Package comprises the following elements: oasp = OA Support Package abc_oa = name of the OA-application v1_2 = version of the OA-application oaif = OA-Interface version (OA-interface version) Version of the SINAMICS firmware from which this OA-application can be used ( = V4.4). Note The following description assumes that the commissioning of the control and drive has been completed. Function Manual (FH15), 10/2015, A5E

18 3 Installation and activation 3.1 Installing an OA-application using STARTER Installing the OA Support Package in STARTER In the following, the OA-application is installed in STARTER as a technology package. Requirements 1. The STARTER commissioning tool has been opened. 2. No project is open. Procedure Please proceed as follows: 1. Menu Tools > Select installation of libraries and technology packages. Fig. 3-1 Select and install OA Support Package (technology package) 2. Click the Add button. 3. Open file "oasp_abc_oa_v1_2_oaif zip". The technology package belonging to the OA-application ABC is added. 4. Click the Close button. 18 Function Manual (FH15), 10/2015, A5E

19 3 Installation and activation 3.1 Installing an OA-application using STARTER Download the technology package In the following, the OA-application ABC_OA is loaded into the device using STARTER. Requirements 1. A project matching the device is open. 2. The STARTER commissioning tool is in the ONLINE mode. Procedure Please proceed as follows: 1. Select the drive device in the project navigator. 2. In the shortcut menu (right mouse key), call the Select technology packages. The "Select technology packages" window opens. 3. For the technology package "ABC_OA", set the action "Load to target device" Fig. 3-2 Select technology packages 4. Click the Execute actions button. After successfully performing the action, the "OK" result field is displayed. 5. Then perform a power on (switch off/on) for the target device. Additional information on the "Select technology package" dialog For a technology package, the "Version (online)" column is only populated after executing "Load to target device". The version data between "Version (offline)" and "Version (online)" can differ. When downloading the technology package, the version in the target device is always overwritten. Function Manual (FH15), 10/2015, A5E

20 3 Installation and activation 3.1 Installing an OA-application using STARTER Activating the OA-application in the drive object In the following, the OA-application is assigned to a drive object. Requirements 1. A project matching the device is open. 2. The corresponding drive axes are created in the project. 3. The STARTER commissioning tool is in the OFFLINE mode. Procedure Please proceed as follows: 1. In the project navigator, select the drive object for which the OA-functionality is required (e.g. SERVO_03). 2. Select shortcut menu Properties (right mouse key). 3. Select the Technology packages tab. 4. Activate the checkbox for "ABC_OA" (set the check mark). Fig. 3-3 Object properties 5. Click the OK button. 20 Function Manual (FH15), 10/2015, A5E

21 3 Installation and activation 3.1 Installing an OA-application using STARTER 6. Checking the expert list of the drive object The additional parameters of the installed OA-application must now be visible in the expert list of the corresponding drive object. Fig. 3-4 Expert list 7. Download the project To activate the OA-application for the drive object, a project download is required (establish the ONLINE mode, download the project) Commissioning of the OA-application By setting the corresponding additional parameters, the OA-application ABC_OA can be commissioned using the STARTER commissioning tool via the expert list. Parameters p30000 p30003 are available for ABC_OA. Commissioning POLYGON For the OA application POLYGON, parameters starting at p31230 are available, see "List of parameters" (Page 53). Commissioning is described in detail in Chapter "Function description and commissioning" (Page 29). Function Manual (FH15), 10/2015, A5E

22 3 Installation and activation 3.2 Uninstalling an OA-application using STARTER 3.2 Uninstalling an OA-application using STARTER Uninstalling an OA-application using STARTER is performed in the inverse sequence to that of installation. 1. Deactivate the OA-application in the drive object, see "Activating the OA-application in the drive object" (Page 20) 2. Delete the technology package belonging to the OA-application in the drive unit, see "Download the technology package" (Page 19). Deactivate the technology package in the OFFLINE mode. For the technology package in the ONLINE mode, select the "Delete" action and click the Execute actions button. 3. Uninstall the OA-application in STARTER, see "Installing the OA Support Package in STARTER" (Page 18). 22 Function Manual (FH15), 10/2015, A5E

23 3 Installation and activation 3.3 Installation of an OA application via SINUMERIK HMI 3.3 Installation of an OA application via SINUMERIK HMI Note The subsequent description in this chapter refers to the fictitious OA application "ABC_OA". The procedure described in this chapter can be correspondingly applied to any real OA application General information Terms OA application (OA, Open Architecture) Software component (technology package) which provides additional functions for the SINAMICS drive system. Portable service system for NCU Emergency Boot System (EBS) on a USB memory. If service is required, you can initiate that the NCU powers up from the service system, in order to execute various service tasks (e.g. data backup or update). Note The portable service system for NCU, as well as the procedure to generate it on a USB memory, is described in detail in the following reference: References: /IM7/ SINUMERIK operating system NCU commissioning manual Chapter "Diagnostics and service" Devices This description applies to SINUMERIK devices with SINAMICS Integrated (e.g. SINUMERIK 840D sl). Function Manual (FH15), 10/2015, A5E

24 3 Installation and activation 3.3 Installation of an OA application via SINUMERIK HMI Preconditions 1. The HMI appropriate for the associated SINUMERIK version must have been installed (e.g. HMI-Operate, used here, or HMI-Advanced). 2. A USB memory, which is installed on the portable service system for the NCU, is available. 3. The file for the OA application ABC_OA "abc_oa_v1_2_oaif tgz" is copied to the FAT partition of the USB memory with the portable service system. The file name for the OA application ABC_OA comprises the following elements: abc_oa = name of the OA application v1_2 = version of the OA application oaif = OA interface version Version of the SINAMICS firmware from which this OA application can be used ( = V4.4). Note The following description assumes that the commissioning of the control and drive has been completed Installing the OA application on the drive device In the following, the OA application is installed on a drive object. Procedure 1. Connect the USB memory with portable service system to USB interface X125 or X135 of the SINUMERIK NCU. 2. Restart the SINUMERIK NCU: Switch off the device and then switch on again. or Press the "Reset" button. SINUMERIK NCU starts with the service system. 3. In the service system, execute the following actions one after the other: In the main menu, select menu item "Update NCU Software and Data". Then select menu item "Update system software from USB memory stick". Select file "abc_oa_v1_2_oaif tgz" and acknowledge with "OK". File "abc_oa.cfs" is extracted from file "abc_oa_v1_2_oaif tgz", and is saved in the directory "/card/oem/sinamics/oa". 4. Restart SINUMERIK NCU as described under Step 2. The ABC_OA OA application is installed in the "/card/oem/sinamics/oa" directory when the system boots. The appropriate data is made available in the "abc_oa" subdirectory. 24 Function Manual (FH15), 10/2015, A5E

25 3 Installation and activation 3.3 Installation of an OA application via SINUMERIK HMI Activating the OA application for the axis (drive object) In the following, the ABC_OA OA application is assigned to the desired axes and the appropriate drive objects. Configuration example A 3-axis SINUMERIK system comprises the following drive objects, for instance: Control Unit (DO_1) Infeed (DO_2) X axis (DO_3, AX1) Y axis (DO_4, AX2) Z axis (DO_5, AX3) Procedure To activate the OA application on the desired axes, proceed as follows: 1. Deactivate the pulse enable for SINAMICS (e.g. via the EP terminal) 2. Control Unit: Set the configuration for the OA application p0009 = Perform the following tasks for the first axis or drive object on which this OA application should be activated (e.g. DO_3, AX1): p4956[0] = 0 1 For SINUMERIK, this is displayed as follows in the drive machine data: Fig. 3-5 OA application activated in the drive machine data Function Manual (FH15), 10/2015, A5E

26 3 Installation and activation 3.3 Installation of an OA application via SINUMERIK HMI Note The number of OA applications is displayed in r4950. r4955[0 8] contains the designation for OA application 1 r4955[9 17] contains the designation for OA application 2, etc. For r4950 = 1, the following applies: There is only one OA application. In this case, p4956[0] is used to activate an OA application. For r4950 > 1, the following applies: Several OA applications are available. The associated index for activating the OA application ABC_OA depends on the designation. If "ABC_OA" is in r4955[0 8], the following applies p4956[0] If r4955[9 17] contains "ABC_OA", p4956[1] applies, etc. 4. For additional axes on which this OA application is to be activated (e.g. DO_4, AX2), repeat step Control Unit: Exit the configuration for the OA application p0009 = 50 0 Note If extension modules (e.g. NX assembly units) are present, the following is true for axes calculated on these modules: Commissioning mode (p0009 = 50) must be set for these modules before the OA application for these axes can be activated. 6. Backing up the parameters 7. Reactivate the pulse enable for SINAMICS 8. Check the parameter list for AX1 The additional parameters of the installed OA application must now be visible in the parameter list for the axis AX1 (DO_3). 26 Function Manual (FH15), 10/2015, A5E

27 3 Installation and activation 3.3 Installation of an OA application via SINUMERIK HMI Fig. 3-6 Expert list Commissioning the OA application By setting the corresponding additional parameters, the OA application ABC_OA can be commissioned via HMI Operate. Parameters p30000 p30003 are available for ABC_OA. Commissioning POLYGON For the OA application POLYGON, parameters starting at p31230 are available, see "List of parameters" (Page 53). Commissioning is described in detail in Chapter "Function description and commissioning" (Page 29). Function Manual (FH15), 10/2015, A5E

28 3 Installation and activation 3.4 Uninstalling an OA application via SINUMERIK HMI 3.4 Uninstalling an OA application via SINUMERIK HMI Procedure To uninstall an OA application via SINUMERIK HMI, proceed as follows: 1. Deactivate the OA application in the drive object, see "Activating the OA application for the axis (drive object)" (Page 25). 2. Stop the system: Connect via Secure Shell (SSH). Run the following command: sc stop all. 3. Delete the subdirectory and files on the memory card: Select the system data. Select directory "/oem/sinamics/oa" under the system CF card. Select "abc_oa" and delete. Select "abc_oa.cfs" and delete. Note Pay attention to the sequence when deleting: First the subdirectory and then the file. 4. Carry out a POWER ON (switch off/switch on). 28 Function Manual (FH15), 10/2015, A5E

29 Function description and commissioning 4 Table of contents 4.1 How POLYGON works Examples of scaling the master value in POLYGON Examples for characteristics for POLYGON Function diagrams Sampling times and number of controllable drives Licensing SINAMICS Safety Integrated 50 This chapter describes the method of operation and commissioning of the OA application POLYGON. It complements the following chapters: "Applications, characteristics" (Page 13) "Installation and activation" (Page 15) Function Manual (FH15), 10/2015, A5E

30 4 Function description and commissioning 4.1 How POLYGON works 4.1 How POLYGON works The OA application POLYGON allows you to generate an output signal depending on a master value via a characteristic. The characteristic is defined via interpolation points. The master value is typically an encoder position actual value Gn_XIST1 (r0479[0]). In this case, the position actual value depends on the number of encoder pulses p0408 and the fine resolution p0418. With parameters p31235 and p31236, the encoder position actual value Gn_XIST1 is converted to a length or angle unit suitable for the application, e.g. millidegrees ( / 1000) for rotary movements. If a gear unit is interposed between the motor or encoder and the load, the gear ratio is also considered in these parameters. A certain position actual value can be specified at a reference point by applying a setting value. A periodic signal is generated by defining a modulo length p Via the master value offset, a specific phase offset can be set during run time, for example, to consider the transfer function of the mechanical structure. The characteristic if defined by up to equidistant interpolation points (p31245, POLYGON characteristic number of interpolation points). The y-values are stored in p31246[0 n] (POLYGON characteristic y-value). Interpolation is performed linearly between the interpolation points. The y-values of the interpolation points can be taken from an Excel sheet using a script. Any signal shape can be stored. The output amplitude can be freely scaled. Superimposition of multiple characteristics is possible. In this way, additional signals can be superimposed on a useful signal. These additional signals can be generated, for example: With the OA application POLYGON as master-value-dependent additional signals, i.e. depending e.g. on the momentary angle of rotation. With the OA application SETPGEN as time-dependent additional signals that are independent of a master value. The resulting signal can, for example, be interconnected as a torque, speed, or position actual value Commissioning The following description of the functionality also describes the normal sequence for commissioning the POLYGON. The "Examples of scaling the master value in POLYGON" (Page 36) and the "Examples for characteristics for POLYGON" (Page 40) are also used as a commissioning guide. The installed OA application POLYGON is also transferred with the "Load to file system" function. This can be used for a series commissioning. 30 Function Manual (FH15), 10/2015, A5E

31 4 Function description and commissioning 4.1 How POLYGON works Preconditions The following requirements must be met when commissioning the OA application POLYGON: When installed using STARTER: The OA application has been installed as a technology package in the STARTER, see "Installing the OA Support Package in STARTER" (Page 18). It is loaded into the Control Unit, see "Download the technology package" (Page 19). It is assigned to the SERVO, VECTOR, or HLA drive object, see "Activating the OA-application in the drive object" (Page 20). For installation using SINUMERIK HMI: The OA application has been installed on the drive device, see "Installing the OA application on the drive device" (Page 24) It is activated for the axis (drive object), see "Activating the OA application for the axis (drive object)" (Page 25). Licensing is required, see "Licensing" (Page 49). Configuration The configuration of the POLYGON is shown in the following function diagrams: "7331 POLYGON structure" (Page 60). The settings required for the configuration are as follows: 1. Setting the sampling time for POLYGON The sampling time is set as a multiple of the current controller sampling time (p0115[0]). The permissible sampling times are listed in detail in the description of p31230, see "List of parameters" (Page 53). 2. Interconnection and conditioning of the master value Interconnecting the signal source of the master value (CI: p31234) Scaling the master value: p31235, p31236 Interconnecting the setting value and its application (CI: p31238, BI: p31239) Defining the modulo length: p31244 Interconnecting the master value offset (CI: p31240) See also Section "Conditioning the master value" (Page 32) 3. Parameterizing the characteristic Defining the number of interpolation points (p31245) Defining y-values of the interpolation points (p31246[0 n]) Interconnecting the amplitude and offset (CI: p31247, CI: p31248) Enabling (BI: p31231) See also Section "Parameterizing the characteristic" (Page 34) Function Manual (FH15), 10/2015, A5E

32 4 Function description and commissioning 4.1 How POLYGON works Conditioning the master value Interconnecting the signal source for the master value The connector input p31234 is interconnected to the signal source provided by the master value. The master value source must provide the master value as an integer (data type Integer32). Typical BICO connections include: Master value of a real axis CI: p31234 = r0479[0] (diagnosis encoder position actual value Gn_XIST1, encoder 1) Note After startup, after data set switchover, or after park encoder, the following applies: The new value may only be available after several 100 ms at connecter inputs that are interconnected with connector output r0479[0]. Virtual master value based on OA application SETPGEN CI: p31234 = r31222 (SETPGEN output total integer) Virtual master value based on the function module EPOS (r = 1) CI: p31234 = r2665 (EPOS position setpoint) Scaling the master value The purpose of scaling is to represent the master value in a length or angle unit that is suitable for the application. For rotary movements, the position actual value is best represented in angle units. Because of the higher resolution, it is advisable to choose millidegrees ( / 1000) as the unit. The scaling factors p31235 and p31236 will then contain the following values: p31235 (POLYGON master value scaling numerator): The numeric value for 1 revolution is assigned to this parameter in the chosen angle unit. With millidegrees as the unit, millidegrees corresponding to one revolution, i.e. p31235 = p31236 (master value scaling denominator): In the case of rotary encoders, the numeric value for 1 revolution is assigned to this parameter in encoder increments. This value depends on the resolution of the encoder used, which is specified in the following parameters: p0408[0] (rotary encoder pulse number) p0418[0] (fine resolution Gx_XIST1 (in bits)) The number of encoder increments per revolution is p0408[0] 2 p0418[0], i.e. p31236 = p0408[0] 2 p0418[0]. With a virtual master value based on the OA application SETPGEN, p31236 must be chosen in accordance with the parameterization of SETPGEN. With a virtual value based on the function module EPOS, the value of r2524 (LU/revolution) can be assigned to parameter p Function Manual (FH15), 10/2015, A5E

33 4 Function description and commissioning 4.1 How POLYGON works Note Internally, the scaled master value is represented in data type FloatingPoint to minimize rounding differences. Referencing using the setting value The setting value and its application provides a way of defining a reference point. The setting value is defined in the length or angle units chosen by the user; the corresponding numeric value is, for example, stored in the fixed value p31241[0 2]. The connector input p31238 (POLYGON master value setting value) is interconnected with the signal source of the setting value (factory setting p31241[0]). The setting value is applied with a 0/1 signal at the binector input p The setting value will be used for future changes to the scaled master value once it has been applied (master value after setting value = scaled master value + setting value scaled master value on application of the setting value). Modulo calculation Modulo calculation permits periodic repetition of the master value for rotary axes. The modulo length depends on the periodic lengths of the master value and the output signal. It is defined in the length or angle unit chosen by the user. The corresponding numeric value is entered in p31244 (POLYGON modulo length). By default, p31244 = , that is the modulo length corresponds to one revolution in the unit millidegrees. If the period lengths of the master value and the output signal are different, p31244 must be modified accordingly. For example, the torque characteristic of a cylinder in a 4-stroke internal combustion engine only repeats after 2 revolutions. In this case, the modulo length must be set to 2 revolutions, that is, p31244 = The effective master value after modulo generation is displayed at the connector output r31242[0] (POLYGON master value active, master value before position offset). Master value offset The master value offset via the connector input p31240 (POLYGON master value offset) permits dynamic phase offset of the master value on rotary axes. The master value offset is defined in the length or angle unit chosen by the user. For static setting of the master value offset, one of the fixed values p31241[0 2] can be used. The effective master value after master value offset is displayed at the connector output r31242[1] (POLYGON master value active, master value after position offset). Function Manual (FH15), 10/2015, A5E

34 4 Function description and commissioning 4.1 How POLYGON works Parameterizing the characteristic Define interpolation points The characteristic is defined via interpolation points. Number of interpolation points: The number of interpolation points is defined in p31245 (POLYGON characteristic number of interpolation points). The interpolation points are equidistantly distributed over the modulo length. For the following effective master values, the interpolation points are therefore at: modulo length i p31245, where i : number of the interpolation point, i [ 0, ( p ) ] y-values of the interpolation points The y-values of the interpolation points are defined in p31246[0 n] (POLYGON characteristic y-value). Interpolation is performed linearly between the interpolation points. Note The number 1.0 corresponds to 100 %. This means that, for example, for interconnection as a torque setpoint, a torque of p2003 (reference torque) is specified. The upper limit of the dynamic index is determined by p31245 (POLYGON characteristic number of interpolation points): n = p Importing interpolation points from an Excel sheet With a large number of interpolation points, manual entry in parameter p31245[1 n] is difficult and error-prone. The values are often calculated or measured values that are already available in a table. The scripting functionality of the commissioning tool (e.g. STARTER) allows you to edit such tables if they are in the format of the Excel spreadsheet program. Appendix "Defining a characteristic (p31245, p31246[0 n]) with script" (Page 73) contains a script by way of example that takes over values from a column of an Excel sheet and writes them into the specified parameters. Defining the amplitude and offset The characteristic can be dynamically scaled via the connector inputs p31247 (POLYGON amplitude) and p31248 (POLYGON offset). If these connector inputs are not interconnected, their factory settings will apply (1 for p31247 or 0 for p31248). 34 Function Manual (FH15), 10/2015, A5E

35 4 Function description and commissioning 4.1 How POLYGON works Interconnecting outputs The scaled output signal is available for further interconnection at the following connector outputs: in r31249 (POLYGON output) as the percentage value. This connector output can be interconnected as follows, for example: With connector inputs inside the closed-loop control, e.g.: Supplementary setpoint (CI: p1075[c]) Supplementary torque (CI: p1511[c]) Speed controller P gain adaptation signal (CI: p1455[c]) Speed controller P gain scaling (CI: p1466[c] With connector inputs of other OA applications, e.g. SETPGEN signal shape amplitude (CI: p31212[0 2]) SETPGEN signal shape offset (CI: p31214[0 2]) With connector inputs of the OA application POLYGON on another drive object, e.g. POLYGON amplitude (CI: p31247) POLYGON offset (CI: p31248) With analog outputs, e.g.: TM31 analog outputs, signal source (CI: p4071[0 1]) in r31251 (POLYGON output integer) as an integer in format Integer32. To improve the resolution, the signal can first be scaled with p31250 (POLYGON output integer scaling). To enable the outputs, the binector input p31231 (POLYGON enable) must be interconnected with a 1 signal Function Manual (FH15), 10/2015, A5E

36 4 Function description and commissioning 4.2 Examples of scaling the master value in POLYGON 4.2 Examples of scaling the master value in POLYGON For real axes, the encoder position actual value Gn_XIST1 (r0479[0]) is usually used as the master value. For this purpose, the connector input p31234 (POLYGON master value raw value) is interconnected to r0479[0]. The purpose of scaling is to represent the master value in a length or angle unit that is suitable for the application Example 1 rotary axis with incremental encoders without a gear unit For rotary movements, the position actual value is best represented in angle units. Because of the higher resolution, it is advisable to choose millidegrees ( / 1000) as the unit. The scaling factors p31235 and p31236 will then contain the following values: p31235 (POLYGON master value scaling numerator): 1 Revolution corresponds to millidegrees p31236 (master value scaling denominator): The numeric value for 1 revolution is assigned to this parameter in the chosen angle unit. This value depends on the resolution of the encoder used: p0408[0] (rotary encoder pulse number) p0418[0] (fine resolution Gx_XIST1 (in bits)) 1 Revolution corresponds to p0408[0] 2 p0418[0]. The scaling factors for a sin/cos encoder with 512 pulses/revolution and a fine resolution of 11 bits are shown in the following table: Table 4-1 Scaling of the master value for a rotary axis with incremental encoders without a gear unit Parameter Parameter name Value Comment p0408[0] Rotary encoder pulse number 512 p0418[0] Fine resolution Gx_XIST1 (in bits) 11 Corresponds to fine resolution 2048 p31234 POLYGON master value raw value r0479[0] Interconnection with encoder position actual value G1_XIST1 p31235 POLYGON master value scaling numerator revolution corresponds to millidegrees p31236 POLYGON master value scaling denominator revolution corresponds to p0408[0] 2 p0418[0] = =2 20. p31244 POLYGON modulo length revolution p31244 (POLYGON modulo length) permits periodic repetition of the master value for rotary axes. By default p31244 = , that is, the modulo length corresponds to one revolution. If the period lengths of the master value and the output signal are different, p31244 must be modified accordingly. 36 Function Manual (FH15), 10/2015, A5E

37 4 Function description and commissioning 4.2 Examples of scaling the master value in POLYGON Example 2 rotary axis with incremental encoders and a gear unit If a gear unit is installed between the motor and load, the gear ratio is considered in the scaling parameters p31235 and p p31235 (POLYGON master value scaling numerator): The number of revolutions of the load is considered as a factor. p31236 (master value scaling denominator): The number of revolutions of the motor is considered as a factor. The following table shows the scaling factors: Motor encoder is a sin/cos encoder with 512 pulses/revolution and a fine resolution of 11 bits, corresponding to "Example 1 rotary axis with incremental encoders without a gear unit" (Page 36). A gear unit with the following gear factor is additionally installed between the motor and the load: 7 revolutions of the motor cause 3 revolutions of the load. Table 4-2 Scaling of the master value for a rotary axis with incremental encoders with a gear unit Parameter Parameter name Value Comment p0408[0] Rotary encoder pulse number 512 p0418[0] Fine resolution Gx_XIST1 (in bits) 11 p2504[dds] LR motor/load motor revolutions 7 7 revolutions of the motor p2505[dds] LR motor/load load revolutions 3 3 revolutions of the load p31234 POLYGON master value raw value r0479[0] Interconnection with encoder position actual value G1_XIST1 p31235 POLYGON master value scaling numerator load revolutions correspond to millidegrees. p31236 POLYGON master value scaling denominator revolutions of the motor correspond to p31244 POLYGON modulo length revolution of the load Example 3 referencing of the OA application POLYGON In parameters p31238 (POLYGON master value setting value), p31239 (POLYGON master value apply setting value) and p31241[0 2] (POLYGON fixed value), a reference point can be defined for the OA application POLYGON. Referencing must be performed when the axis is stopped. General procedure: The setting value is defined in the length or angle units chosen by the user; the corresponding numeric value is, for example, stored in the fixed value p31241[0 2]. The connector input p31238 (POLYGON master value setting value) is interconnected with the signal source of the setting value (factory setting p31241[0]). The setting value is applied with a 0/1 signal at the binector input p Function Manual (FH15), 10/2015, A5E

38 4 Function description and commissioning 4.2 Examples of scaling the master value in POLYGON Example 4 referencing the OA application POLYGON using an absolute value encoder If absolute encoders are used, the function module "Basic positioner, EPOS," can be used to reference the OA application POLYGON. Note If the function module "Basic positioner, EPOS" or "Position control, LR" is used, please note: The following settings must be made analogously: 1. For configuration of the drive: The settings for position control (screen form "Mechanics" in the STARTER commissioning tool). 2. In the OA application POLYGON: The settings for master value scaling (p31235, p31236) and modulo length (p31244). For example, the following figure shows the screen form "Mechanics" for a drive with modulo length LU (length units). The modulo length corresponds to 1 revolution of the load. Fig. 4-1 Screen form "Mechanics" for configuration of the position control 38 Function Manual (FH15), 10/2015, A5E

39 4 Function description and commissioning 4.2 Examples of scaling the master value in POLYGON Analogous parameterization of the OA application POLYGON is shown in the following table: Table 4-3 Scaling of the master value in an analogous way to the "Mechanics" screen form Parameter Parameter name Value Comment p0408[0] Rotary encoder pulse number 512 p0418[0] Fine resolution Gx_XIST1 (in bits) 11 Corresponds to fine resolution 2048 p31234 POLYGON master value raw value r0479[0] Interconnection with encoder position actual value G1_XIST1 p31235 POLYGON master value scaling numerator revolution corresponds to millidegrees Identical with p2506[dds] (LR length unit LU per load revolution) p31236 POLYGON master value scaling denominator revolution corresponds to p0408[0] 2 p0418[0] = = 2 20 p31244 POLYGON modulo length revolutions of the load Identical with p2576 (EPOS modulo correction modulo range) For referencing, the position actual value of the position control (r2521[0]) should be used as the setting value for POLYGON. This value must be applied in a 0/1 signal at the digital input 6. This results in the following parameterization: Table 4-4 Parameterization for application of the setting value Parameter Parameter name Value Comment p31238 POLYGON master value setting value r2521[0] Interconnection with LR position actual value p31239 POLYGON master value apply setting value CU_S: r Interconnection with digital input DI 6 Function Manual (FH15), 10/2015, A5E

40 4 Function description and commissioning 4.3 Examples for characteristics for POLYGON 4.3 Examples for characteristics for POLYGON Example 5 sine with modulo 360 This example shows how a sinusoidal signal with 12 interpolation points (p31245 = 12) is generated via a modulo length of 360 (p31244 = ). The interpolation points of the characteristic are equidistantly distributed over the modulo length. The y-values of the interpolation points are set in p31246[0 11]. Interpolation is performed linearly between the interpolation points. Scaling of the master value is performed analogously to the examples in Section "Examples of scaling the master value in POLYGON" (Page 36). Table 4-5 Parameterization of the characteristics with 12 interpolation points Parameter Parameter name Value Comment p31244 POLYGON modulo length p31245 p31246[0] p31246[1] POLYGON characteristic number of interpolation points POLYGON characteristic y-values (0 degrees) POLYGON characteristic y-values (30 degrees) sin (0 ) = sin (30 ) = 1 2 p31246[2] POLYGON characteristic y-values (60 degrees) sin (60 ) = 3 2 p31246[3] POLYGON characteristic y-values (90 degrees) sin (90 ) = 1 p31246[4] POLYGON characteristic y-values (120 degrees) sin (120 ) = 3 2 p31246[5] p31246[6] p31246[7] p31246[8] p31246[9] p31246[10] p31246[11] POLYGON characteristic y-values (150 degrees) POLYGON characteristic y-values (180 degrees) POLYGON characteristic y-values (210 degrees) POLYGON characteristic y-values (240 degrees) POLYGON characteristic y-values (270 degrees) POLYGON characteristic y-values (300 degrees) POLYGON characteristic y-values (330 degrees) sin (150 ) = sin (180 ) = sin (210 ) = sin (240 ) = sin (270 ) = sin (300 ) = sin (330 ) = Function Manual (FH15), 10/2015, A5E

41 4 Function description and commissioning 4.3 Examples for characteristics for POLYGON The following are shown: r31242[1]: POLYGON master value active, master value after position offset (orange) r31249: POLYGON output (black) The zero lines of the signals shown are not identical. Fig. 4-2 Example of a sinusoidal function with 12 interpolation points per 360 Note The number 1.0 corresponds to 100 %. This means that, for interconnection as a torque setpoint, a torque of p2003 is specified. The following table shows parameterization of the characteristic with 1200 interpolation points by way of example. The y-values can be calculated in an Excel sheet, for example, and written into parameter p31246[0 n] using a script. Appendix "Defining a characteristic (p31245, p31246[0 n]) with script" (Page 73) provides an example of a script that takes over values from a column of an Excel sheet and writes them into the specified parameters. Table 4-6 Parameterization of the characteristic with 1200 interpolation points Parameter Parameter name Value Comment p31244 POLYGON modulo length p31245 POLYGON characteristic number of interpolation points 1200 Taken over from the Excel sheet using a script. p31246[0 1199] POLYGON characteristic y-values Calculated in an Excel sheet and taken over using a script. Function Manual (FH15), 10/2015, A5E

42 4 Function description and commissioning 4.3 Examples for characteristics for POLYGON The following are shown: r31242[1]: POLYGON master value active, master value after position offset (orange) r31249: POLYGON output (black) The zero lines of the signals shown are not identical. Fig. 4-3 Example of a sinusoidal function with 1200 interpolation points per Example 6 superimposition of multiple characteristics The OA application POLYGON can be parameterized on multiple drive objects. This makes it possible to define individual frequencies separately. Generation and superimposition of 2 master-value-dependent signals are shown below. On drive object SERVO_02, the measured torque characteristic of a 4-cylinder 4-stroke internal combustion engine is stored. Number of measurement points: The modulo length corresponds to 2 revolutions ( = 720 ). A sinusoidal oscillation is parameterized on drive object SERVO_03. The aim is to generate 12 sine oscillations within the modulo length of the torque characteristic. The modulo length of the sine oscillation is therefore 1/12 of the modulo length of the torque characteristic ( = 60 ). The following tables show the parameterization of the torque characteristic and the sine oscillation. Scaling of the master values is performed identically on both drive objects and analogously to the examples in Section "Examples of scaling the master value in POLYGON" (Page 36). In particular, p31234 (POLYGON master value raw value) is interconnected to the same signal source (same drive object). 42 Function Manual (FH15), 10/2015, A5E

43 4 Function description and commissioning 4.3 Examples for characteristics for POLYGON Table 4-7 Parameterization of the torque characteristic with 1264 interpolation points to drive object SERVO_2 Parameter Parameter name Value Comment p31244 POLYGON modulo length revolutions p31245 POLYGON characteristic number of interpolation points 1264 Taken over from the Excel sheet using a script. p31246[0 1263] POLYGON characteristic y-values Measured values taken over from the Excel sheet using a script. p31247 POLYGON amplitude 1 Default setting Table 4-8 Parameterization of the sine function with 1200 interpolation points on drive object SERVO_3 Parameter Parameter name Value Comment p31244 POLYGON modulo length sine oscillations within 2 revolutions p31245 POLYGON characteristic number of interpolation points 1200 Taken over from the Excel sheet using a script. p31246[0 1199] POLYGON characteristic y-values Calculated in an Excel sheet and taken over using a script. p31247 POLYGON amplitude r2900 Interconnected to fixed value1[%] r2900[dds] Fixed value Corresponds to 27.0 % The variation over time of the following signals with a frequency of rotation of 20 Hz (cycle duration for 2 revolutions = 100 ms) is shown below: r31242[1]: POLYGON master value active, master value after position offset (orange) SERVO_02: r31249: POLYGON output (black) (torque characteristic) SERVO_03: r31249: POLYGON output (green) (sine oscillation) Fig. 4-4 Torque characteristic and sine oscillation To superimpose the sine oscillation of the torque characteristic, drive object SERVO_2 must be parameterized additionally (as shown in the following table): Function Manual (FH15), 10/2015, A5E

44 4 Function description and commissioning 4.3 Examples for characteristics for POLYGON Table 4-9 Additional parameterization to drive object SERVO_2 for superimposition Parameter Parameter name Value Comment p31248 POLYGON offset SERVO_3: r31249 The following figure shows the sum signal at a frequency of rotation of 20 Hz (cycle duration for 2 revolutions = 100 ms). The following signals are displayed: r31242[1]: POLYGON master value active, master value after position offset (orange) SERVO_02: r31249: POLYGON output (red) (torque characteristic with superimposed sine oscillations) Fig. 4-5 Torque characteristic with superimposed sine oscillation Note If the superimposing signal is not dependent on the master value (e.g. simulation of a constant resonant frequency), the OA application SETPGEN can also be used to generate it. The offset of POLYGON (p31248) is interconnected with the output signal of SETPGEN (r31215[0 2], r31220). 44 Function Manual (FH15), 10/2015, A5E

45 4 Function description and commissioning 4.3 Examples for characteristics for POLYGON Example 7 - compensation of transfer function and dead times In the case of known setpoint signals that have a sinusoidal curve, amplitude and phase deviations in the leading behavior can be compensated for. The following figure shows the leading frequency response of a moderately set speed controller in the form of a Bode diagram: Fig. 4-6 Measured frequency response of a speed controller In this Bode diagram, for example, at 100 Hz (corresponds to 10 ms cycle duration of one sine oscillation), we can see a phase offset between the input and output signal of and an amplitude reduction of -3.4 db. The following figure explicitly shows the phase offset and the amplitude reduction for a superimposed speed setpoint oscillation of 100 Hz ( = cycle duration 10 ms). The variation over time of the following signals is shown: r31242[0]: POLYGON master value active, master value before position offset (green) r0062: Speed setpoint after the filter (black) r0061[0]: Speed actual value, unsmoothed, encoder 1(red) Fig. 4-7 Phase offset and amplitude reduction between the setpoint and actual value signals With the OA application POLYGON, it is possible to generate an additional oscillation with the relevant frequency and a suitable phase offset and amplitude for the existing speed setpoint oscillation, depending on the position actual value. If this additional oscillation is superimposed on the existing oscillation, the amplitude reduction and the phase offset are reduced. Function Manual (FH15), 10/2015, A5E

46 4 Function description and commissioning 4.3 Examples for characteristics for POLYGON The following figure shows this principle for the oscillation with 100 Hz by way of example. If the resulting setpoint corresponding to the leading frequency response is subject to a phase offset of 97.9 and an amplitude increase of 150 % (corresponds to 3.4 db), the resulting actual value has the correct phase angle and amplitude: Fig. 4-8 Actual value after phase offset and amplitude increase of the setpoint This is shown in the following figure. It shows: the original setpoint profile the actual value profile after adaptation of the phase angle and amplitude of the setpoint profile. Fig. 4-9 Actual value profile after adaptation of the setpoint profile and original setpoint profile Note If the signals are interconnected as a torque setpoint, the transfer function has a substantially higher cut-off frequency because the current controller sampling time is active. However, in this case, too, the effects mentioned are measurable and can be compensated for via this functionality. To arrive at a correct compensation profile for changeable frequencies, the master value offset (CI: p31240) and the amplitude (CI: p31247) must be dynamically defined from outside. An analog procedure can be used for compensation of dead times. 46 Function Manual (FH15), 10/2015, A5E