servo motor

MITSUBISHI

AC Servo Training Manual Mitsubishi Electric Asean Factory Automation Center

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CONTENTS

1. FUNDAMENTALS OF AC SERVO CONTROL - - - - - - - - - - - - 1-1

1.1 Definition of “servo” - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 1.2 Positioning and the performance of AC Servo - - - - - - - - - - - - - - - - 1-2 1.3 About MELSERVO - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6

1.3.1 The road map of MELSERVO - - - - - - - - - - - - - - - - - - - - 1-6 1.3.2 Positioning of a product - - - - - - - - - - - - - - - - - - - - - - - 1-7 1.3.3 General-purpose Servo amplifier specification comparison table - - - - 1-7 1.3.4 The model series and the feature of a servo motor - - - - - - - - - - 1-8 1.4 Structure of AC Servo - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-10 1.4.1 The principle of operation of Servo amplifier - - - - - - - - - - - - - - 1-10 1.4.2 The characteristic and principle of operation of AC servo motor - - - - 1-17

1.4.3 The function and principle of encoder operation - - - - - - - - - - - - - 1-20 2. Positioning control Using AC Servo - - - - - - - - - - - - - - - - - - 2-1 2.1 Positioning Method and Stopping Accuracy - - - - - - - - - - - - - - - - - - 2-1 2.1.1 Types of Positioning - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 2.1.2 Positioning control and stopping accuracy for speed control methods - - - 2-3 2.1.3 Types of position control - - - - - - - - - - - - - - - - - - - - - - - - - 2-5 2.2 Fundamentals of Positioning Control - - - - - - - - - - - - - - - - - - - - - 2-6 2.2.1 Position detection and number of pulses per motor revolution - - - - - - 2-6 2.2.2 Theory of servo positioning control - - - - - - - - - - - - - - - - - - 2-6 2.3 Positioning Accuracy - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-9 2.3.1 Feed distance per pulse - - - - - - - - - - - - - - - - - - - - - - - - - 2-9 2.3.2 Concept of overall accuracy for machine and electrical accuracy - - - - - 2-9 2.4 Motor Rotational Speed at the Maximum Machine Speed - - - - - - - - - - 2-11 2.5 Command Pulse - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-12 2.5.1 Electronic gear function - - - - - - - - - - - - - - - - - - - - - - - - - 2-12 2.5.2 Maximum pulse frequency - - - - - - - - - - - - - - - - - - - - - - - - 2-18 2.6 Speed Pattern and Setting time - - - - - - - - - - - - - - - - - - - - - - - - 2-19 2.6.1 Speed Pattern and performance of droop - - - - - - - - - - - - - - - - - - 2-19 2.6.2 Setting Time (ts) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-20 2.7 Relationship Between Moment of Load Inertia and Position Loop Gain(kp) - - 2-21 2.7.1 Moment of load inertia - - - - - - - - - - - - - - - - - - - - - - - - - 2-21 2.7.2 Real-time auto tuning - - - - - - - - - - - - - - - - - - - - - - - - - - 2-22

3. Positioning Controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 3.1 Classification of Positioning Controllers and Typical Miscellaneous Functions - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 3.1.1 The function of positioning controller - - - - - - - - - - - - - - - - - - 3-1 3.1.2 The function of Servo amplifier - - - - - - - - - - - - - - - - - - - - - - 3-1

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3.2 A classification and composition of positioning controller - - - - - - - - - 3-1 3.3 Setting data of positioning controller - - - - - - - - - - - - - - - - - - - 3-6 3.3.1 Basic parameter - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-6 3.3.2 The basic parameter for a starting point return - - - - - - - - - - - - 3-6

3.3.3 Positioning data - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-7 3.4 Position instruction interface - - - - - - - - - - - - - - - - - - - - - - - - 3-9 3.5 The foundations of the positioning control by positioning Controller - - - 3-11 3.5.1 The machine move direction and the servo motor rotation direction - - 3-11 3.5.2 The type of home position return - - - - - - - - - - - - - - - - - - 3-12 4. MELSERVO – J2S Performance and Functions - - - - - - - - - - - - 4-1 4.1 Basic Performance and Functions - - - - - - - - - - - - - - - - - - - - - - 4-1

4.2 Composition with peripheral equipment - - - - - - - - - - - - - - - - - - - - 4-2 4.3 Installation and Operation - - - - - - - - - - - - - - - - - - - - - - - - - 4-5 4.3.1 Operation flow from installation to operation start - - - - - - - - - - - - 4-5 4.3.2 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6 4.3.3 Wiring and sequence- - - - - - - - - - - - - - - - - - - - - - - - - - - 4-14 4.3.4 Standard connection diagram - - - - - - - - - - - - - - - - - - - - - - - 4-19

4.3.5 Power supply turned on - - - - - - - - - - - - - - - - - - - - - - - - - 4-31 4.3.6 Display and operation function - - - - - - - - - - - - - - - - - - - - - - 4-34

4.3.7 Parameter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-42 4.3.8 Parameter setting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-53

4.3.9 Checking the I/O signal - - - - - - - - - - - - - - - - - - - - - - - - - 4-54 4.3.10 Manual operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-57 4.3.11 Home position return - - - - - - - - - - - - - - - - - - - - - - - - - - 4-57 4.3.12 Automatic operation - - - - - - - - - - - - - - - - - - - - - - - - - - 4-57

4.3.13 Test operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-58 4.3.14 The operation procedure in each operation mode (conclusion) - - - - - 4-62

4.3.15 The function convenient for starting and diagnosis- - - - - - - - - - - 4-65

5. MELSERVO – H Performance and Functions - - - - - - - - - - - 5-1

5.1 I/O Terminal Function - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1 5.2 Parameter function - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3 5.3 Display and Diagnosis Functions - - - - - - - - - - - - - - - - - - - - - 5-12 5.3.1 MR-PRU01A Parameter unit- - - - - - - - - - - - - - - - - - - - - - 5-12 5.3.2 Monitor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-14 5.4 Setup and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-16 5.4.1 H/W Setting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-16 5.4.2 Power ON- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-16 5.4.3 Parameter setup- - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-16 5.4.4 Checking the I/O single- - - - - - - - - - - - - - - - - - - - - - - - 5-19

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6. Selection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 6.1 Provisional selection of motor capacity - - - - - - - - - - - - - - - - - 6-1 6.1.1 Moment of load inertia ( JL ) - - - - - - - - - - - - - - - - - - - 6-1 6.1.2 Load torque ( TL ) - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 6.1.3 Formulae to calculate moment of load inertia and load torque - - 6-2 6.2 Reduction Ratio - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-4 6.3 Operation Patterns and Required Motor Torque - - - - - - - - - - - - 6-5 6.3.1 Acceleration torque ( Ta ) - - - - - - - - - - - - - - - - - - - - - 6-5 6.3.2 Deceleration torque ( Td ) - - - - - - - - - - - - - - - - - - - - - 6-5 6.3.3 Driving pattern - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-6 6.3.4 Determining motor capacity- - - - - - - - - - - - - - - - - - - - - - 6-7 6.4 Example of Capacity Selection Procedure - - - - - - - - - - - - - - - 6-9 7. The measure against a noise, leak current, harmonics - - - - - - 7-1 7.1 The measure against a noise - - - - - - - - - - - - - - - - - - - - - - - 7-1 7.2 Leak current - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3 7.3 Harmonics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5 7.3.1 A basic wave and harmonics - - - - - - - - - - - - - - - - - - - 7-5 7.3.2 The characteristic of a rectification circuit and generating harmonics - - 7-6 7.3.3 The measure against harmonics - - - - - - - - - - - - - - - - - - - - 7-6

8. Maintenance and check - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 8.1 Maintenance and check - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 8.1.1 Notes at the time of maintenance and check - - - - - - - - - - - - - 8-1 8.1.2 Item of inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 8.1.3 Part exchange - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-5 8.1.4 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7 8.1.5 Remedies for warning - - - - - - - - - - - - - - - - - - - - - - - - 8-13 8.1.6 The cause investigation method at the time of position gap generating- - 8-14

APPENDICES APP.1. Symbols for the specifications - - - - - - - - - - - - - - - - - - - - App-1

App.2. Type of Drive System - - - - - - - - - - - - - - - - - - - - - - - - App-2 App.3. Example Application- - - - - - - - - - - - - - - - - - - - - - - - - App-6 APP.4. Positioning Controller performance comparison - - - - - - - - - - App-9

1. FUNDAMENTALS OF AC SERVO CONTROL 1.1 Fundamentals of AC servo control

Definition of “Servo” For the purpose of the Japanese Industrial Standards, a servomechanism is defined as a control system designed to track a target that changes unpredictably, with the position, bearing, orientation, etc., of a physical object as the control quantity. When the target value (position, speed, etc.) is input to the servomechanism from the command section, the servomechanism detects the current value, and continually executes control to reduce the difference between the current value and target value. The elements that comprise a servomechanism are called servo elements. And in the case of Mitsubishi’s “MELSERVO-J2S” AC servo, these elements are the drive amplifier (AC servo amplifier), the motor (AC servomotor), and the detector. The configuration of this servomechanism is shown in Fig. 1.1.

Fig. 1.1 Configuration of a Servomechanism

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1. FUNDAMENTALS OF AC SERVO CONTROL 1.2 General Characteristics of Servo

As implied in the foregoing section of a servomechanism, the basic function and performance requirement of a servomotor is to track a continually changing target quickly in response to speed/position control. To enable a servomotor to fulfill this requirement, it must be designed with greater consideration given to the moment of inertia of the rotor (also called GD2), and electrical responsibility, than is necessary for a general purpose motor. The reason for this is to ensure that the servomotor can respond to sudden changes in the voltage and current from the servo amplifier. The servo amplifier that drives the servomotor must also be capable of quickly and accurately transmitting the speed and position control commands to the servomotor. With these points in mind, the following gives a comparison between the typical characteristics obtained when using a servomotor in combination with a servo amplifier and the characteristics of a motor driven by a general purpose inverter (a widely used type of variable speed controller) (1) Comparison of characteristics of a servomotor and general purpose

inverter

The characteristics of a motor are commonly assessed by looking at its speed-torque characteristics. Fig 1.2 compares a servomotor and a general purpose motor used in combination with general purpose inverter on this basis. The superior qualities of the servomotor are clear from this figure. It has three main advantages: (a) The motor have a wide speed

control range (b) It maintains a constant output

torque from high speeds (the rated speed) to low speeds (the stalling speed).

(c) It has a high maximum torque. Note: Since the motor’s maximum

torque is high but its moment of inertia is low, it is capable of sudden acceleration and deceleration

When selecting a servomotor, the function and performance of the machine concerned must always be considered in the light of the points explained above.

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1. FUNDAMENTALS OF AC SERVO CONTROL

Some actual figures for servomotor characteristics are presented below to add some details to our explanation.

Table 1.1 Main Servomotor Characteristics Item Specification Descriptions

Speed control range 1 : 1000 to 5000 (1 : 10)

Can be used down to 1/1000th of the rated speed without any concern of reduced rotational stability or reduced torque

Output torque characteristics

No torque drop in low speed operation

A constant output torque is maintained throughout the speed control range, whether at the continuous output torque or maximum torque. In other words, the motor can be used safely over the entire speed range even with rated torque load.

Maximum torque Approx. 300% (150%)

An instantaneous maximum torque of approximately 300% of the rated torque can be obtained. This enables the motor to accelerate and decelerate suddenly, which means that it can be for high frequency positioning

Note: The figures in parentheses are typical specifications for a general purpose inverter.

(2) Application of AC servomotors The main characteristics of servomotors have been described. In addition, servomotors become capable of a function that is beyond other variable speed controllers when used in combination with servo amplifiers: the positioning function. The positioning function is described in detail in Chapter 2; here typical servomotor applications made possible by the characteristics described in section (1) on the previous page and the positioning function are explained. (a) Machines that require positioning

Using the AC servomechanism in combination with specialized positioning controller (see chapter 6) enables accurate positioning with good reproducibility. A general purpose Mitsubishi AC servomechanism is capable of a positioning resolution of 120000 to 4000 divisions per motor axis revolution, which is sufficient to achieve positioning in units of 1um with machine travel in the range 24 to 8 m/min. Example application: Machine tools, wood working machines, conveyors, packaging machines, inserter/mounters, feeder, cutters and specialized machinery.

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(b) Machines that requires a wide range of speed variation The AC servomotor has a speed control range of 1:1000, and features highly accurate speed control, with a coefficient of speed fluctuation of no greater than 0.03%. It also features constant output torque, a characteristics not featured by other variable speed motors. Because of these characteristics, it is used for control of production lines and other applications where highly accurate variable speed drive is required. Example Applications: Printing presses, paper processing machines, film manufacturing line, wire making machines, winding machines, feed mechanisms of specialized machines, conveyors, main shafts of winding/unwinding machines, and wood working machines.

(c) High frequency positioning Positioning is performed as explained in (a) on the previous page. The maximum torque of the AC servomotor is 300% of the rate torque and a motor, when it is unloaded, can follow the acceleration and deceleration from the stopped state to the rated speed in a mere several tens of milliseconds, which means it can drive positioning operations at frequencies of 100 times per minutes and higher. Another important characteristic of the AC servomotor is that it has no parts that make mechanical contact, in contrast to other positioning mechanism (clutch, brake, DC motors, etc.); this makes it maintenance-free and means that it is not greatly influenced by the ambient temperature. Example applications: Press feeder, bad-making machine, sheet cutting machine, loader/unloaders, filling machine, packaging machines, conveyors.

(d) Torque control Since recent digital servomotors feature torque control in addition to conventional functions such as speed control and position control, they can be used for applications that involve tension control, such as winding/unwinding machines.

1-4


(3) Other characteristics, Summary In addition to the speed control range already dealt with, there are other basic aspects of the performance of a motor- such as responsibility- that show its speed control characteristics. Fig 1.3 compares an AC servomotor and general purpose inverter on the basis of control performance and functions of an inverter and general purpose AC servo in actual use.

Responsibility The responsibility is a measure of the speed of follow-up in response to changes in commands and disturbance. It is a guide to the maximum severity of sudden load fluctuation that can be dealt with by following commands without causing any speed fluctuation. For example, a motor that has a responsibility of 600 rad/s will be able to tolerate a load fluctuation of approximately 100Hz with no appreciable influence on speed.

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1. FUNDAMENTALS OF AC SERVO CONTROL 1.3 About MELSERVO 1.3.1 The road map of MELSERVO

Demand item introduction is better to better of new technology and the industrial world that surely reflected technical innovation in the new product for general purpose AC servo in 1982. The environment that surrounds Servo now is shifting to the next generation. MR-J2-Super series raised the function and the performance of the MR-J2 conventional series and conventional compatibility for the performance of a machine in the maximum output sake to the correspondence to the further high speed and high precision, shortening of starting time, fullness of diagnosis and a maintenance, and these demands. The road map of MELSERVO is shown in the following table.

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1. FUNDAMENTALS OF AC SERVO CONTROL 1.3.2 Positioning of Product

Positioning of MELSERVO series is shown in a right table.

1.3.3 General-purpose Servo amplifier specification comparison table

Model

Item

MR-H-AN / KAN4 MR-H-BN / KBN4 MR-H-CN / KCN4

MR-HTN Series

MR-J2S-A

MR-J2S-B(*) Series

MR-CA MR-CA1

Series

MR-J2-03A5

MR-J2-03B5(*) MR-J2-03C5

Appearance

Feature

Highly performance The variation of a motor is abundant.

Those with setup software (MRZJW3-SETUP61 or subsequent ones)

Those with bus joint MR-H-BN

With a built-in 1 axis controller (MR-H-ACN)

Next-generation Servo Replacement of MR-J2 A servomotor is ABS-equipped standard.


Replacement from super-type

Minimize Motor distinction function Those with setup software (MRZJW3-SETUP61 or subsequent ones)

Mini small down size Servo

MR-J2 series DC24V correspondence


DIN rail attachment is possible.

32 axis multi-drops are possible.

Capacity 50W-55kW 50W-7kW 30W-400W 10W-30W

Gear. Brake With With With (however, it removes

with 30W slowdown machine)

With (on sale schedule)

Encoder signal Serial communication Serial communication Serial communication Serial communication A position per resolution 8192/16384 p/rev 131072 p/rev 4000 p/rev 8192 p/rev Detection system INC/ABS INC/ABS INC INC

Rated rotation speed

2000/3000 1000/2000/3000 3000 3000 Rotation speed

(r/min) Max Rotation speed

2000/2500/3000/4500 1200/1500/2500/3000/4500 4500 10W-20W, 5000

30W, 4500

Max torque 300% 300%

300%(400%, LESS 10W) 300%

Control mode Position/ speed / torque Position / speed / torque Position/speed (internal 2 speed) Position / speed / torque Frequency response 250Hz 550Hz 200Hz 250Hz Control theory Model adaptive control Model adaptive control Model adaptive control Model adaptive control Auto tuning Real time Real time Real time Real time Personal computer I/F Standard equipment Standard equipment Option Standard equipment

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Built-in card option Available Unavailable Unavailable Unavailable Speed control range 1:5000 1:5000 - 1:1000 The external power supply for I/F

Not required Not required Required DC24V Required DC24V

Regeneration brake resistance

Built-in Built-in An external option Unavailable

Dynamic brake Built-in Built-in Nothing Built-in Display (main part) 4-figure display 5-figure display 3-figure display 4-figure display

Other setting key Parameter unit Four-piece setting button Four-piece setting button Four-piece setting button Analog monitor 2CII (12 bit) 2CII (8 bit) Nothing Nothing Pulse part circumference output

A, B, Z Phase A, B, Z Phase Z phase A, B, Z phase

Test mode operation Available Available Available Available Motor-less operation Available Available Unavailable Available EN correspondence Acquisition (-UE) Acquisition Acquisition Acquisition UL-cUL standard correspondence

Acquisition (-UE) Acquisition Acquisition Acquisition

Correspondence motor

HC-MF series HA-FF series HC-SF series HC-RF series HC-UF series

HA-LHK series HA-LFK series

HC-KFS series HA-MFS series HC-SFS series HC-RFS series HC-UFS series

HC-PQ series HC-AQ series

<Note> this data is a thing as of June, 1999. * : one of the new sale schedule 1.3.4 Model Series and Feature of Servo Motor In AC Servo MELSERVO-C, J2S, and H-N series, it has had various motors in stock by machine

correspondence.

All the motors of MELSERVO-J2S series are the same sizes as a motor conventionally

in ABS and a 17-bit (130,000 pulses) encoder standard equipment.

Series name Capacity (W)

The encoder resolution pulse/rev

Correspondence of encoder

Rated rotation speed / maximum

rotation speed Adaptation

Servo amplifier type name

Protection form Usage

Mic

ro sm

all c

apac

ity

HC-AQ

10W-30W

8192

Only INC

3000/5000r/min 3000/4500r/min

MR-J2-5

IP55

• Small slider • Small actuator • Micro robot

Supe

r-lo

w in

ertia

smal

l cap

acity

HC-PQ 30W-400W 4000 Only INC 3000/4500r/min MR-C IP44 • inserter, molding,

bonding • Printed circuit board

hole-open machine • circuit tester • Label Printing

machine • Micro robot • robot tip part Etc.

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HC-MFS 50W-750W 131072 ABS, INC 3000/4500r/min MR-J2S IP55

(IP65)

HC-MF 50W-750W 8192 ABS/INC 3000/4500r/min MR-H-N IP44

HC-KFS 50W-400W 131072 ABS,INC

3000/4500r/min MR-J2S IP55

(IP65)

HC-KF 50W-400W 8192 ABS,INC

3000/4500r/min MR-H-N IP44

Low

iner

tia sm

all c

apac

ity

HA-FF

50W-600W

8192

ABS,INC

3000/4000r/min

MR-H-N

IP44 (IP65)

• LCD, wafer conveyance equipment

• Food machine • Press machine • small loader • Small robot • small X-Y table

Etc.

HC-SFS 0.5kW -7.0kW 131072 ABS,INC

MR-J2S IP65 (IP67)

Mid

dle

iner

tia m

iddl

e ca

paci

ty

HC-SF 0.5kW -7.0kW 16384 ABS,INC

1000/1500r/min 1000/1200r/min 2000/3000r/min 2000/2500r/min 2000/2000r/min 3000/3000r/min

MR-H-N IP65 (IP67)

• Conveyance machine

• exclusive machine • robot • loader • wiring, tension

equipment • X-Y table • examination

machine Etc.

HC-RFS 1.0kW -5kW 131072

ABS/INC 3000/4500r/min MR-J2S

IP65 (IP67)

low

iner

tia m

iddl

e C

i

HC-RF 1.0kW

-5kW 16384 ABS,INC

3000/4500r/min MR-H-N IP65

(IP67)

• chip box • loader • Quantity frequency

conveyance machineetc.

Low

iner

tia la

rge

capa

city

HA-

LHK 11kW -22kW

16384

ABS/INC corresponden

ce is possible.

2000/2000r/min MR-H-N IP44

• Ejection molding machine

• Semiconductor fabrication machinesand equipment

• A lifter, an automatic warehouse system

• Large-sized conveyance machine

• Press Feeder • press transfer Etc.

HC-UFS

0.1kW -5kW

131072

ABS/INC

MR-J2S

IP65

Flat

type

HC-UF

0.1kW -5kW

16384

ABS,INC

2000/3000r/min2000/2500r/min3000/4500r/min

MR-H-N

IP65

• Robot • Conveyance

machine • Food machine • Wiring and tension

equipment Etc.

Larg

e ca

paci

ty

HA-LFK 30kW

-55kW

16384 ABS/INC

2000/2000r/min MR-H-N4 IP44

• Ejection molding machine

• Semiconductor fabrication machinesand equipment

• Large-sized conveyance machineEtc.

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1. FUNDAMENTALS OF AC SERVO CONTROL 1.4 Mechanism of the AC servo 1.4.1 Servo amplifier block diagram and principle of operation

The basic function and principle of operation of a servo amplifier are described here by reference to the block diagram presented below.

Fig 1.3 Block Diagram of AC Servomotor

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(1) Main Circuit

The basic function of the main circuit is to rectify and smooth a commercial power supply (3-phase,

200 to 230 VAC, 50/60Hz) by means of a converter (diode bridge, capacitor), and supply a 3-phase

current of any voltage and frequency that is subjected to sine wave PWM control by the inverter

(power transistor module)- to the motor to control its speed and torque.

(a) Converter, smoothing capacitor The commercial power supply is rectified by a diode bridge and then has its ripple reduced by a smoothing capacitor to generate a low-ripple DC power supply.

(b) Inverter The inverter generates, from the DC power supply created by the converter and smoothing capacitor, a current matched to the frequency and load torque at the motor’s rotational speed.

Fig 1.5 Configuration of the inverter section Fig 1.6 Inverter output current

1-11


As shown in Fig. 1.7, the direction of rotation and the rotational speed (frequency) of the motor are determined by the direction of the current and the width of turn on time in each direction, which depend on the ON/ OFF switching of the transistors in the inverter section. This type of the control, in which the size of the current is controlled by the width of turn on time, is called PWM control (pulse width control).

Fig. 1.7 Current Control Using the PWM Method (c) Regenerative brake

1) Regenerative brake circuit The regenerative brake operates when the actual rotational speed of the motor is higher than the speed reference- e.g. during deceleration, during descent on a vertical axis, or when a braking force is applied to an unwinding shaft – to achieve a braking effect by absorbing (consuming) the rotational energy of the motor and load in the servo amplifier. This kind of operation is called ‘ regenerative ’, and servo amplifiers normally incorporate a regenerative circuit. This regenerative circuit acts as a load on the motor, and its rate of energy consumption determines the regenerative braking force. The amount of rotational energy consumed varies according to the operating condition. When a large amount of energy has to be consumed, a circuit capable of consuming this energy is provided outside the servo amplifier.

2) Types of regenerative brake circuit Where a small braking capacity is required (the amount of rotational

energy to be consumed is small ), braking is achieved by using the energy to temporarily charge the smoothing capacitor mentioned previously. This is called the condenser regenerative method and can be used for applications up to about 0.4kW.

In case where a medium braking capacity is required, a method in which current is passed through resistors and the energy consumed as heat is adopted; this is called the resistor regenerative methods. The problems associated with this method include the need to use large resistors if the amount of energy to be consumed is large, and adverse effects on surrounding parts due to heat radiating from the resistors.

In case where a large braking capacity is required, a method in which energy is returned to the power supply has recently been adopted in order to avoid the deficiencies of the resistor regenerative method. This is called the power supply regenerative method and it can be use when the amount of energy involved exceeds 11kW.

1-12


(d) Dynamic brake When it stops with the output of inverter parts, such as the time of power cut off and alarm generating, ( base interception ), a motor serves as a free run, and time long to a stop may be required, the long overrun may become large, and it may serve as fault of colliding with a stroke end. A dynamic brake functions to stop the motor quickly in the event of a base circuit cut-off by short circuiting the servomotor terminals through an appropriate resistor and consuming the rotational energy as heat. a dynamic brake is usually installed separately from the motor and amplifier, but it is incorporated into some models of servo amplifier. Since a dynamic brake has no holding power when a mechanical brake if the motor drive motion on a vertical axis.

1-13


Due to the delay in the control circuit, the motor will rotate with delay on input of the command pulse to the position control section. The pulses that accumulate during this delay are held at the deviation counter; these pulses are called droop pulse. The droop pulses are output to the speed control section as speed commands. (2) Control Circuit

While carrying out operation processing of the amount of control (a position, speed, current) at high speed and with high precision from an instruction value (target value) and the present value using a microcomputer and realizing Servo control with high accuracy by high response, the monitor of the contents of control and protection of a unit are performed. The outline of the contents of control is explained below.

(a) Position Control

In a pulse sequence, control of the rotation speed and the direction of a motor and highly precise positioning are performed.

1-14


(b) Speed Control The output of a position control part deviation counter is proportional to instruction speed, and this serves as speed instructions. A speed instruction part outputs the deviation of speed instructions and motor speed as current instructions. In addition, when operating in speed control mode, analog voltage (0-±10V) is inputted from the exterior as speed instructions.

(c) Current Control and 3-phase generating circuits

A current control part controls the current of a motor so that the inverter of the main circuit is controlled and a motor moves as position instructions or a speed instruction. In order to achieve this control, the phases of the 3-phase alternating current are set to coincide with the magnetic field of the motor(determined by the positions of the rotor’s permanent magnets) and a current that corresponds to the speed deviation is output

1-15

1. FUNDAMENTALS OF AC SERVO CONTROL When supplying current to a synchronous motor, the position of the magnetic fields (magnetic pole positions) must be aligned with the phases. To achieve this alignment, the motor’s detector detects the magnetic pole positions and continually feeds back this information to the servo amplifier. On the basis of this signal, the servo amplifier generates the reference 3-phase current in the 3- phase generating circuit. The current control section multiplies the reference 3-phase current by speed deviation to generate 3 –phase current commands and controls the PWM circuit. Note: Induction type servomotors do not have independent magnetic fields. Accordingly, magnetic pole position detection is not necessary when they are used. A PWM system is a system which several times of switching pulses is generated in 1 cycle, and the pulse width is changed, and changes output voltage. The thing of the number of switching pulses generated in 1 second is called career frequency. In the case of a PWM system, the motor vibration and the motor noise of a frequency ingredient proportional to this career frequency occur. Fig 1.9 Principle of PWM Control (MR-J2S)

1-16

1. FUNDAMENTALS OF AC SERVO CONTROL 1.4.2 Characteristics and principle of operation of the AC servomotor

(1) Characteristic The output torque of the servomotor is proportional to the current supplied to it. See Section (3). Since the servo amplifier continually detects the motor speed and executes control to change the amount of current supplied in accordance with the speed deviation, the servomotor is able to produce a constant torque from low speeds to high speeds. The torque characteristics of a servomotor operated in combination with a servo amplifier are shown in the figure to the right.

(2) Principle of operation All motors, whether large or small operate according to the same principle: when a current is passed through a conductor in a magnetic field, a force – whose direction can be determined by using Fleming’s left-hand rule- is imparted to the conducted (see the figure to the right). The SM type (synchronous) AC servomotor has permanent magnets as its rotor and windings through which the current is made to flow as its stator; the current passed through the stator windings is controlled in order to achieve the required rotor motion (rotational speed and direction, output torque).

Fig 1.12 Torque characteristics of a servomotor (MELSERVO-J Series)

Principle by which motor Torque is generated

Principle of Operation of SMType AC Servomotor

1-17


The amplifier transistors are switched ON and OFF so as to supply current to each motor winding when it is perpendicular to the magnetic flux from the rotor magnet. The applied voltage is switched at a frequency of several kilohertz, and the current is smoothed by the reactance of the windings and take the form of a sine wave. The intervals during which the winding voltage is plus and minus are known from the magnetic pole position detection signal which emitted by the detector connected directly to the motor shaft Since this system ensures that the magnetic flux and current flow are always perpendicular to each other, the problem of getting out of step that affects normal synchronous motors does not occur. The generated torque T, determined by the following formula:

T = K1 • Φ • Ia ……….(1-1) Is proportional to the winding current, Ia, while the rotational speed, determined by the following formula: V - Ia • Z Is proportio Meaning of T: to V: a

………(1-2)

(3) Principle ofThe principsame for ansynchronoufrom the crothe rotor domagnet whicurrent, Ia,equation (1this type ofthe rotor withe current grooves duand the mawinding cur

N =
K2 • Φ
nal to the applied voltage, V.

symbols: rque; la: current; N: rotational speed; K1K2: constants pplied voltage; Φ: magnetic flux; Z: winding resistance

the IM (induction motor) type of AC servomotor le of torque generation is the induction motor as it is for a

s motor. However, as can be seen ss sectional diagram to the right, es not incorporate a permanent

ch means that separate supply of and magnetic flux, Φ, (see -1) and (1-2)) is impossible. In motor, current is passed through ndings and torque is generated by

caused to flow in the rotor’s e to electromagnetic inductance gnetic flux created by the stator rent.

Fig. 1.14 Cross section of IM type AC servomotor

1-18


Both torque current and magnetic flux current flow in the stator windings. The relationship between the two is expressed by the following formula: I1 = Ia + Ib ………..(1-3) I1: Stator winding current Ia: Torque current Ib: Magnetic flux current Note: The equation above represents a vector sum, no an arithmetic sum. The two currents in an IM type AC servomotor must be controlled separately; this form of control is called vector control. Vector control gives an IM type AC servomotor the same torque characteristics as an SM type AC servomotor.

(4) Types of servomotor and their characteristics There are two main type of servomotor – AC servomotor and DC servomotors- but the category of AC servomotor is further divided into the SM type (synchronous motors) and the IM type (inductance motors). Table 1.2 indicates the configuration and characteristics of each type of servomotor. Table 1.2

Characteristics Type Configuration Advantages Disadvantages

SM type AC servomotors

• Maintenance-free • Excellent resistance to adverse

environmental conditions • Large torque is possible • Dynamic braking possible

when power is cut • Light and compact • High power rate

• The servo amplifier is somewhat more complex than that of a DC motor

• A 1:1 correspondence between the motor and servo amplifier is required

• The magnet can become demagnetized.

IM type AC servomotor

• Maintenance-free • Excellent resistance to adverse

environmental conditions • High speed/Large torque is

possible • Large capacity combined with

high efficiency • Sturdiness construction

• The servo amplifier is somewhat more complex than that of a DC motor.

• Braking is not possible when the power is cut off.

• Characteristics change with temperature.

• A 1:1 correspondence between the motor and servo amplifier is required

DC servomotor

• Simple construction of the servo amplifier

• Dynamic braking possible when the power is cut

• Low cost (for low capacity models)

• High power rate

• Maintenance and periodic inspections are required to ensure proper commutator circumference.

• Debris is created as the brushes wear; not suitable for clean locations.

• Cannot be used at high speed with a large torque due to the commutator brushes.

• The magnet can become demagnetized.

1-19


The servomotors growing base on DC motors that is liable to control. However, with the development of electronic devices, and the microprocessor in particular, it became possible to execute complex control faster and more cheaply, and the market shifted to maintenance-free, easily manufactured AC motors; currently, SM type AC servomotors are used in place of DC motors for most applications requiring more than 0.4KW. IM type AC motors are sturdy constructed and can combine large size with high speed. Since their efficiency improves as their capacity increases, they are mainly used for applications requiring 7.5KW or more. Due to improvements in their suitability for high-accuracy applications, their use is increasing in large-scale production lines; an area formerly dominated by DC motors and vector control inverters. DC servomotors have the advantage that small capacity models can be produced cheaply, and because of this they continue to be used mainly for applications requiring less than about 80W. Fig. 1.15 shows the recent development in the use of servomotors.

0. 01 0. 1 1 11

Capacity

(kW)

IM type AC servomotor 55 22

SM type AC servomotor

DC servomotor

1980

1985

1990

1995

2000

Figure 1.15 Recent development in the use of servomotors

1.4.3 Principle of operation of encoder As explained previously, in servo control the actual value (motor speed, position) is feedback for comparison with the command value and control is executed to reduce the deviation between the two. (1) Construction of encoders

The construction of the most commonly used type of detectors is shown below.

1-20


(2) Function of encoders and the signal types The three major functions of encoders mounted on servomotors are:

1) Detection of the motor position 2) Detection of the motor speed 3) Detection of the magnetic pole position of the motor (does

not apply to IM type AC servomotors and DC servomotors) A 2-phase pulse output incrementally as the motor rotates is used for functions 1) and 2).

For position and speed detection Several thousand pulses per revolution (number differs according to the motor) Used for home position return etc. 1 pulse per revolution For detecting position magnetic pole

1.4.2.1.1.1 pulse per revolution 2 (not used with IM type AC servomotors

or DC servomotors)

Fig 1.17 Encoder Signals

(3) Interface for encoder signals The two types of interface shown below can be used for encoder output signals. Recently, the differential driver output system, which has the advantage of reliable signal transmission, has become the more commonly used.

Waveforms tend to be dulled during transmission over long distances. Badly affected by noise. High frequency transmission is possible. Resistive against noise.

1-21


(4) Absolute position encoders Fitting absolute position encoders to motors is becoming an increasingly common practice. The reasons for this include the need to improve time-efficiency (an absolute position detection system makes it unnecessary to perform a home position return operation after the power has been cut off). Since an absolute position detection system must be able to determine the rotational position when the power is switched ON, the encoder has to output another signal in addition to the increment signals. (A,B) introduced in (2) above. This signal is the absolute position signal, and in case of the encoder shown to the right it would comprise 7 bits. A block diagram for an absolute position system is shown below. Note: In addition to increment signals (phase A and B), absolute position detectors feature absolute position detection within single motor revolutions and a counter that counts the number of motor revolutions and a counter that count the number of motor revolutions from the home position. Since this information is stored in memory, once the position has been fixed by performing a home position return operation the servo amplifier and controller always know the motor position even if the power is switched OFF. This means that is only necessary to perform a home position return operation after switching the power ON once; position and speed control can be continued without repeatedly performing home position return operations.

Fig 1.20 Block Diagram of Absolute Position System.

1-22

2. POSITIONING CONTROL USING AC SERVO

2.1 Positioning Method and Stopping Accuracy 2.1.1 Types of positioning

There are two types of method for stopping the moving part at a fixed position within a required accuracy: mechanical methods and electrical methods. Examples of mechanical methods include use of a stopper (inverter stopper control and AC servo torque limit are used up until the point the moving parts makes contact with the stopper). And forced positioning by trapping the moving part (using a cylinder-actuated mechanism, for example), but when these methods are used the moving parts can only be stopped at particular positions. In contrast, the electrical method makes use of a position sensor that make it easy to stop at any required position. Electrical positioning can also be divided into a variety of types depending on the methods used for position detection and control, but there are two major methods- the speed control method and the position control method. (1) Speed control methods

The motor is not equipped with the position output device but there is a device for positioning purposes (such as limit switch) installed in the machine.

(2) Position control methods There is no device for position detection in the machine, but the detector fitted to the servomotor is capable of precise position control.

These two types of method are compared in Table 2.1. Table 2.1 Comparisons of Positioning Methods

Method type

Method Description Schematic Diagram

A limit switch is located at a point past which the moving part traverses; when the moving part actuates this switch, the switch outputs a signal that stops the motor. Generally, two switches are used; the signal from the first causes the motor to reduce to low speed and the signal from the second switches the motor OFF and causes application of a brake that stops the moving part. Since this method does not require the use of a positioning controller and involves only simple control, the necessary equipment can be installed cheaply.

Spee

d C

ontro

l

Lim

it sw

itch

met

hod

Guide to stopping accuracy …approx. + 0.5 to 5.0mm (Note)

B

INV

IMIMIMIM

Limit switch For stopping

Limit switch to Reduce the speed

Ball screw

Travel distance

Low speed

High speed IM: Induction Motor B: Brake INV: Inverter

Moving part

2-1


Method type

Method Description Schematic Diagram

A pulse generator (pulse encoder) that detects the position of a revolving shaft is fitted to the shaft of the motor that drives the moving parts, and the number of pulses output by the encoder is counted by a high speed counter. The number of pulses is proportional to the distance moved, and when the counter reaches the set count value it output a stop signal to stop the moving part. When this method is used the system can be configured without using devices such as limit switches and the stopping position such as limit switches and the stopping position can be changed easily. (High-speed counter units such as the Melsec-A series AD61 can be used in such system)

Spee

d co

ntro

l

Puls

e co

unt m

etho

d

Guide to stopping accuracy …approx. + 0.5 to 5.0mm (Note)

An AC servomotor whose rotation is proportional to the number of pulses input is used. High speed positioning over distances proportional to the number of pulses corresponding to the travel distance to the servo amplifier of the Ac servomotor. (Units such as the Melsec-A series 3 axis positioning unit AD75 can be used in such systems.)

Command pulse input

Ball screw

INV

IMIMIMIM

Travel distance

Mediumspeed

Lows

peed

High speed

AD61 High speed counter

PLGMoving part

PC

IM: Induction Motor PLG: Pulse Generator INV: Inverter PC: Programmable controller

Position control

Pulse count method

Guide to stopping accuracy …approx. + 0.001 to 0.05mm

Command pulse input

AD75 Positioning control unit

Ball screw

Servo Amplifier

SM

Travel distance

PLGMoving part

PC

IM: Induction Motor PLG: Pulse Generator PC: Programmable controller

Note: The stopping accuracy indicated are based on a low speed of between 10 mm/sec and 100 mm/sec.

2-2


2.1.2 Positioning control and stopping accuracy for speed control methods (1) Limit switch method

When the part whose motion is driven by the motor is to be stopped automatically, its position is normally detected by a device such as a limit switch and the motor is stopped by the signal from the limit switch (generally, a brake is applied at the same time). The graph in figure 2.1 plots the speed of the moving part (vertical axis, mm/sec) against time (Horizontal axis, seconds); the shaded portion of the graph is therefore the distance move in millimeters.

V

C

Heavy load

Light load

[mm/sec] Speed V

S [mm]

V B C

A Time E D [sec] E D2 D1 Fig 2.1 Operation (Speed) pattern Fig 2.2 Dispersion of overrun distance

The overrun distance after the limit switch has been actuated corresponds to the area of CDE, and the stopping accuracy is the dispersion of this area of CDE. The factors that affect the stopping accuracy (the factors that cause variation in the area of CDE) by referring to Fig.2.2. They are changes in the stopping time, ED, (caused by fluctuation in load torque or brake torque), fluctuation in the speed of the moving part at point C, dispersion in the sensor operation position at point C, and dispersion in the time delay between sensor operation and the point at which the motor actually starts decelerating. It is of course necessary to keep the dispersion of these characteristics as low as possible, but the most effective strategy is to reduce the speed (V). Therefore, if the stopping accuracy when the moving part is stopped while it is traveling at the normal speed is unsatisfactory, the most common solution is to install a limit switch (see Table 2.1) that will reduce its speed to the low speed before it is stopped. This approach is widely used because it is convenient and improves accuracy, but its disadvantage is the longer time required for positioning; a longer time must be allows because if the period of constant low speed travel (duration of “creep speed”) is not made long enough, the speed of the moving part as it passes the “stop” limit switch will not be stable due to factors such as load fluctuation. Another disadvantage is that an increase in the number of stop positions makes more sensors necessary.

2-3


(3) Pulse count method

An improved version of the limit switch method is the pulse count method. This method allows selection of stop positions without restriction and allows any number of deceleration points to be established; this makes time reductions possible for travel over short distances. The stopping accuracy is no better or worse than that of the limit switch method, but since the present position of the moving part is continually monitored it is easy to compensate if the stop position is over shot. However, the stopping accuracy is affected by the same factors as listed for the limit switch method and no improvement can be expected. The method of positioning using of a servomotor is not subject to the disadvantages described for the other methods above. As in the pulse count method, the position of the moving part is continually detected, and it is stopped within the required accuracy by respected speed control as it approaches the target position, slowing it from high speed to a stop without any period of travel at the creep speed. This method can be called a “position control method”, in contrast to the “speed control methods” described above.

2-4


2.1.3 Types of position control A servomechanism performs positioning control by continually detecting the position and feeding back position information. The types of detection method are shown in Table 2.2. (Note that the open loop method is not a servo control method but is shown for the purpose of comparison with the closed loop method.)

Fig 2.2 Types of Position Control Method Type of loop System configuration Characteristics

Open loop

• There is no feedback so this is not servomechanism

• In the event of an overload the motor get out of step and stops.

• Only small capacity systems can be configured.

Table Stepping motor Positioning controller

Mot

or sh

aft

dete

ctio

n

Sem

i-clo

sed

loop

Det

ectio

n at

feed

sc

rew

end

Closed loop

Positioning controller



Because importanMELSERVO ACwith the detector

Servo am-plifier

Reduction gear

• Simple configuration • Fastest response of all system types • Reliable control system • Reduction gear backlash has to be

compensated

Table

Servo-motor

Speed

encoder

o

Servo am-plifier

• Rather complex configuration (involves a separately installed detector).

• The system is reliable to instability caused by the reduction gears and feed screw

Reduction gear

Servo-motor

Position detector

Speed

encoder Table

Servo am-plifier

• Reduction gear backlash doesn’t have to be compensated

• Requires an expensive position

detector. • The system is liable to instability

caused by the reduction gears and the feed screw, and it is not possible to increase the speed of response.

• Reduction gear backlash doesn’t have to be compensated

Reduction gear

Servo-motor

Position detector

Speed

Reduction gear

encoder

Linear scale

Table

ce is placed on stability of the control system and ease of use, servomechanisms are configured as semi-closed loop system n the motor shaft.

2-5


2.2 Fundamentals of Positioning Control Using AC Servo

The following is an explanation of positioning control when using the pulse command.

2.2.1 Position detection and number of pulse per motor revolution As explained in Section 2.1.3, MELSERVO series AC servomechanisms are configured as semi-closed loop in which the motor rotational position (machine position) is detected by an encoder (detector) that is connected directly to the motor shaft. The encoder generates a pulse signal in accordance with the rotation angle of the motor and this pulse signal is input to the servo amplifier and used for position control.(for more details on encoders, refer to section 1.3.4) This feedback pulse becomes the standard that operates for a unit (resolution) of movement of the machine connected with the motor, and it can perform highly precise positioning control, so that there are many pulses per motor rotation. In the case of the servomotor of a model HC-KFS, they are 131072 pulses (it is expressed as 131072/rev). (Refer to section1.3.4 ).

2.2.2 Theory of servo positioning control Position controller (AD75 series) Servo Amplifier

Position

CMX CDV

Deviation counter SM

PLG Com

man

d

∆λc ∆λ0

Speed command

Speed lifi

Feedback pulse (131072 p/rev) Encoder

In the case of HC-KFS series

Table

Electronic gear

movements per pulse Ap <= 65535 AI <= 65535 Am1, 10, 100, 1000

PLG

The number of pulses Ap Movements AI X mag-

nification Am

Setting unit 1/10µm 1/105inch 1/105degree 1Pulse

+ -

X4

Ball

Fig. 2.3 Composition of position Servo

Positioning by the servomotor is controlling a motor so that servo amplifier’s takes in the command pulse and the feedback pulse according to motor number of rotations at a deviation counter and the difference serves as zero, when the command pulse is inputted from positioning controller.

2-6


For this reason, servomotor can carry out strict positioning by the command pulse. A motion of the motor axis per command pulse to servo amplifier (machine) is to the foundations of the positioning control by servo.

(a) The feed distance is proportional to the total number of command pulse;

(b) The speed of a machine is proportional to the speed of the pulse train (pulse frequency).

(c) As long as it carries out the completion of positioning in the range of last ±1 pulse and there are no position commands henceforth, it is holding the position in the state of a servo lock.

(1) Deviation counter and amount of motor rotations While the counter is counting up the command pulses received from the position controller, the counter value is simultaneously decremented as the feedback pulses are returned. When the deviation counter pulses were large, the speed command is also large, and the motor rotates at high speed. On approaching the target stopping position the no. of command pulses decreases; when it reaches zero the output from the deviation counter drops and the motor speed consequently drops too. When the deviation counter reaches zero, the speed command value also becomes zero and the motor stops. In other words, the output from the deviation counter is automatically controlled so that the no. of feedback pulses(i. e. the amount of motor rotation) is made to equal to the no. of command pulse. For example, for rotating motor HC-KFS of MELSERVO-J2S series of feedback pulse 131072 p/rev 1/2, it is from positioning controller. It is necessary to carry out a 65536 pulse input.

(2) Motor rotational speed By control of a deviation counter, the rotation speed of a motor is proportional to the speed of pulse train from the rotation angle of a motor being proportional to the quantity of the pulse train. For example, if an instruction pulse is carried out in 1 minute in 393.216X3000 rotation X 131072 pulse =393.216X106 pulses and 1 second in order to operate the motor of HC-KFS series by 3000 r/min, it is necessary to input 393.216X106 / 60= 6553.6X103 pulses (for it to be expressed as 6553.6kpps) from positioning instruction equipment. Usually, it inputs using the electronic gear function by the side of instruction equipment and servo amplifier.

2-7


(3) The completion of positioning, and servo lock

If the output (droop pulse) of a deviation counter becomes zero (i.e., if the number of command pulses and the number of feedback pulses are in agreement), it will become the completion of positioning. Then, there is work which is going to make the rotation correction of the motor in the direction in which the feedback pulse from the encoder inputs into the deviation counter if a servo motor is turned by a certain external force, the speed command from a deviation counter come out, it always collects, and a pulse becomes zero, and it is always going to limit to the regular position. This function is called the “servo lock”.

2-8


2.3 Positioning Accuracy

2.3.1 Feed distance per pulse The feed distance per pulse is the minimum unit which a machine motion. The feed distance per one pulse as shown in Fig. 2.4 (1), in case a ball screw and a slowdown machine do not have the machine system becomes like the formula (2-1). When machine system is except a ball screw, and when a slowdown machine sticks, in order to calculate the feed distance per one pulse, it thinks on the basis of feed distance (deltas) of the machine per motor 1 rotation. If the feed distance per motor 1 rotation of Fig. 2.4 is substituted for ∆S of a formula (2-1), the feed distance (deltal0) can be calculated per pulse.

∆ S ∆ S ∆λo = = (mm/pulse) -----------(2-1)

P f 0 131072 Where Pf0 is the No. of feedback pulses per motor revolution. However, the Pf0 values for different motor model are indicated below. HC-PQ Motor 4000 [pulse/rev] HC-MF motor 8192 [pulse/rev]. HC-SF motor 16384 [pulse/rev]. Fig. 2.4 as following shows examples of mechanical systems and the corresponding calculation formula.

2.3.2 Concept of overall accuracy for machines and electrical accuracy The overall accuracy of a machine, ∆ε, is the mechanical accuracy plus the electrical accuracy. The mechanical accuracy is set y the machine’s manufacturer. The electrical accuracy depends on the feed distance per pulse - ∆lο (mm/pulse)- for the machine’s shaft. In a Mitsubishi MELSERVO series system, travel is finally stopped to within an accuracy of +1 output electrical gear pulse (or +∆lο when calculated in terms of the machine axial motion), and the servo lock is imposed at this point. While the servo lock is effective, the position is held provided that no command pulses are input. Therefore, in order to ensure that the electrical accuracy ∆lο does not affect the overall accuracy of the machine ∆ε, the system is generally set so that the following condition is satisfied: ∆lο < (1/5 to 1/10) x ∆ε−−−−−−−−−−−−−−−(2-2) REMARK Overall machine accuracy, ∆ε,and feed distance per pulse, ∆lο The feed distance per pulse, ∆ε, can be determined by taking the overall accuracy of the machine, ∆lο into consideration.

2-9


(1) Ball screw(direct connection) (2) Ball screw( connected via gears) (3) Rack and pinion

Feed distance per motor revolution

∆S= PB

Z1 1 ∆S = PB • = PB •

Z2 n

1 ∆S = PL•Z• n

Z: No. of pinion teeth

(4) Roll feed (5) Chain drive(direct connection) (6) Driver by chain and timing belt

Feed distance per motor revolution

1 ∆S= π• D •

n

1 ∆S = PC• Z•

n

Z: No. of sprocket teeth

Z1 1 ∆S = PT• Z • =Pr •Z • Z2 n

Z : No. of pulley teeth

Driv

e sy

stem

V

PL Z

PLGM I /n

PLG M

V

PB PLG M

V

Z1

Z2

PB

PLGM

PT

VZ

Z2

Z1

V

Z

PC

PLGI /n M

V

D

PLG

M

I /n

Drive system

Fig 2.4 Feed Distance per Motor Revolution for Various Mechanical Systems

2-10


2.4 Motor rotation speed at the maximum machine speed As shown in Fig 2.5, if the mechanical system is driven by a ball screw through gears, the motor’s rotational speed N (rpm) for a particular machine speed, V (mm/min), can be determined using formula (2-3) below Motor’s rotational speed =Machine speed x 1 ----------(2-3) Ball screw lead Reduction ratio If the ball screw lead is expressed as PB (mm) and the reduction ratio as 1/n, formula (2-3) can be expressed thus: N = V . n [rpm] - - - - - (2-4) PB If maximum machine speed, Vo is fixed, a high positioning accuracy can be obtained and the power of the motor can be used effectively by making the motor rotational speed that corresponds to Vo as close as possible to the rate rotational speed Nr (rpm) without exceeding it.

Table

Servo Motor

Servo Amplifier

V

Command pulse train

Pa

Encoder

Ball screw

Z2

Z1

Ball screw load Pa [mm] Feed distance per command pulse ∆lο [mm/pulse] Reduction ratio 1/n (=Z1/Z2)

Fig 2.5 Relationship between machine speed and motor speed

2-11


2.5 Command Pulses

In a positioning servomechanism, a number of feedback pulses equal to the number of pulses input from the positioning controller is returned during motion, and, when running steadily, the motor operates at a speed at which the command pulses and feedback pulses balance each other out. It must be confirmed that there is a consistent relationship between the smallest command unit for positioning and the feed distance pr pulse (see section 2.3.1) , and that the pulse frequency at the motor’s maximum rotational speed is acceptable for both the position controller and the servo amplifier.

2.5.1 Electronic gear function

The electronic gear function of MELSERVO-J2S series AC servomechanisms makes it unnecessary to select a detector that matched to the mechanical system, and allows flexible positioning. The following is a description of the electronic gear function.

PC1

∆l1 Fc1= Fc.


Command pulse

magnification


PLG×4

Command pulse

Pc fC ∆lC (PC0)

CMX CDV

CMX/CDV

=1/50 to 20

Feed screw lead, PB

V

Servomotor

*1000 P/R *Position feedback pulses Pro = 1310752P/R

Pfo

A

Electronic gear

Fig 2.6 Electronic Gear Function Fig 2.6 is a block diagram for the electronic gear function. A guide to this function and the associated relational equations is presented below. For MELSERVO-H series systems, the value of PF0 is either 8192 or 16384 p/rev, depending on the motor used, but the relational equations are the same as those for the MELSERVO-J2S series. Meaning of symbols in Fig 2.6 PC : Number of command pulse [unit = phases] PC1 : Number of deviation counter input pulses [unit = phases] Pf : Number of feedback pulses [unit = pulses] Pf0 : Number of feedback pulses per motor revolution [unit = p/rev] PC0 : Number of command pulses per motor revolution [unit = p/rev] fC : Command pulse frequency [unit = pps] fC1 : Deviation counter input command frequency [unit = pps] ∆lο : Machine travel per feedback pulse [unit = mm/pulse] ∆lc : Machine travel per command pulse [unit = mm/pulse] CMX : Command pulse magnification numerator CDV : Command pulse magnification denominator

2-12


(1) Relation between electronic gear setting and command pulse

(a) The number of deviation counter input is obtained by multiplying the number of command pulses by the electronic gear ratio. PC1 = PC . CMX - - - - - - (2-5)

CDV Where,

PC : Number of command pulse [unit = pulse] PC1 : Number of deviation counter input pulses [unit = pulse] CMX : Command pulse magnification numerator CDV : Command pulse magnification denominator

The relationship between PC and PC1 when the electronic gear ratio (CMX/CDV) is 8 shown in Fig 2.7.

Fig 2.7 Input/Output Relationship at the Electronic Gear Setting section

when the gear ratio is 8

(b) The same relationship for pulse frequency:

fC1 = fC . CMX - - - - - - - (2-6) CDV

fC : Command pulse frequency [unit = pps] fC1 : Deviation counter input pulse frequency [unit = pps]

PC

PC1 = Pf

t

(c) Since the electronic gear is configured outside the position control loop, a resolution (∆lο) of 0.09 degrees on the motor shaft is always maintained regardless of the value set for the command pulse magnification.

(d) If the value set for the electronic gear ratio is “1” or less, a single input command pulse will not be output to the deviation counter. A pulse will only be output when the number of the input command pulses multiplied by the magnification factor reaches a value of “1”.

t

PC Fig 2.8 Gear ratio is ½

PC1 = Pf

2-13


(e) The setting ranges for the electronic gear ratio, the numerator, and the denominator are indicated below.

1 CMX < < 500 - - - -- -- - - - - (2-7)

50 CDV (2) Relationship between the electronic gear ratio setting and the

mechanical system. (a) The motor shift rotation angle that represents one unit of machine

travel is the angle corresponding to one feedback pulse.

P B - - - - - - - - - (2-8) ∆l0 = Pf0

(3) Since one command pulse input to the deviation counter causes a motor rotation corresponding to one position feedback pulse, it is possible to set the motor rotational angle per command pulse, which is equal to machine travel, to any required values by multiplying the command pulse by the electronic gear ratio; this makes it possible to set units with no fraction (1 µm, 10 µm, etc.)

By analogy with formula (2-5), the relationship between the number of command pulses per motor revolution, PCO, and the number of feedback pulses per motor revolution, PCO, as follows:

CMX P oc CDV

• = Pf0 -- - - - - - (2-5)

Formula (2-8) can be re-expressed as follows to obtain the travel per command pulse:

PB ∆l = - - - - - - (2-8) o PC0

Combining these two relationship:

PB PB CMX CMX ∆l0 = = ∆l = = - - - - - - - (2-9) 0 • PC0 Pf0 CDV CDV

Therefore, by setting the electronic gear ration as follows:

CMX ∆l Pc f0⎯⎯⎯ = ⎯⎯ = ∆l • ⎯⎯ - - - - - - - (2-11) cCDV ∆l0 PB

The travel per command pulse, ∆lc, can be set to any value, regardless of any consideration arising from the mechanical system (Pf0, PB).

2-14


(4) The motor speed is determined by the pulse train frequency (fC1) input to the deviation counter after the command pulse has been multiplied by the electronic gear ration (a frequency of 200 kpps is equivalent to a speed of 300 rpm). Consequently, even if the number of pulses output from the positioning controller (the command pulse frequency) is low, the motor can be driven at high speed by making f C1 highly.

Since the deviation counter input pulse frequency (fC1) is in balance with the feedback pulse frequency (fF) when the motor is running at a constant speed, the relationship between the motor speed and electronic gear under this condition can be expressed by formula (2-11)

CMX N fC1 = fC• f0 CDV 60

= P • - - - - - - - (2-11)

Where, fC : Command pulse frequency [unit = pps] fC1 : Deviation counter input pulse frequency [unit = pps] N : Motor rotational speed [ unit = rpm]

It follows that the electronic gear ratio when the motor is run at a rotational speed of N with a command pulse frequency of fc can be obtained using this formula:

CMX f 1 N C1 = = •Pf0• - - - - - - ( 2 – 12)

CDV f C f C 60

REMARK

Functions of the electronic gear (1) Allows the positioning accuracy ∆l0 and the setting resolution ∆lc to be set

independently of each other, making it possible to set units without fractions of ∆lc. (2) The deviation counter input pulse frequency when the motor is run at the rated

rotational speed is fixed (see equation (2-11)), but it is possible to run the motor at lower command pulse frequencies.

2-15


Example 2.1

Question (1) Calculate the amount L0 of machine movements per feedback 1 pulse. Question (2) How much for the Servo amplifier side electronic gear ratio K in per

command pulse at the time of making the AD75 side electronic gear into 1/1 and amount L0= 0.1of m[micro-m/pulse]?

Question (3) In K for which it asked with the question (2), a motor is 3000 [r/min]. What is the command pulse frequency (fc) at the time.

Question (4) What is the Servo amplifier side electronic gear ratio K at the time of command pulse frequency 200kpps?

PB=8mm Speed=24m/Pf0=131072p/

MR-J2S servo Amplifier AD75 position controller

Fc Positioning data

CMX CDV


PLGX4

A

HC-KFS Servomotor

Sending screw lead PB=8[mm/rev]

Pro

Electronic gearCMX ≤65535 CDV ≤65535 CMX/CDV 1/50 ∼500

Servomotor HC-KFS, 3000r/min 131072p/rev

Pulse No.(Ap) Amount of movements X

magnification Am

Unit 1/10µm 1/105inch 1/105degree 1Pulse

The movements per one pulse. Ap ≤65535 Al ≤65535 Am = 1 10 100 1000

The maximum pulse command frequency AD75P Open collector 200kpps Differential system 400kpps Note: The open collector system, itchanges by wiring length. Ifexceeded, it will become positiongap and alarm.

The maximum command frequency =200kpps

CMX= ? CDV= ?

Ap= ?

Al= ? Am= ?

Question(1) Formula (2-8)

PB 8 ∆λ = = ≈ 0.061 X 10-3 (mm/pulse) o Pfo 131072 ∗ When it considers as 300mm of positioning, it will become 300/0.061x10-3 =

4918032.787 pulses will come out.

Question(2) Formula (2-10)

CMX P 131072 1024 fo K = ⎯⎯⎯ = ∆ λ c • ⎯ = 0.1X 10-3 X ⎯⎯⎯ = ⎯⎯ CDV PB 8 625 ∆λ c at the time of putting in the above-mentioned electronic gear PB CMX 8 1024 ∆λ = ⎯⎯ X ⎯⎯⎯ = ⎯⎯⎯X ⎯⎯ = 0.0001 (mm/pulse) c Pfo CDV 131072 625

2-16


∗ When it considers as 300mm of positioning, it becomes 300/0.0001= 3 million pulses come out. ∗ There is the necessity of checking whether maximum command frequency 200kpps of AD75 positioning command equipment being exceeded by the electronic gear ratio for which it asked above.

Question (3) Formula (2-11) N 3000

= P f X ⎯ =131072 X ⎯⎯⎯ = 6553600 ( PPS) F c 1 o 60 60

Formula (2-6)

CDV 625 F = ⎯⎯ • f c 1 CMX 1024

c = ⎯⎯ X 6553600 = 4000000 = 4000 (kpps)

∗ Command pulse frequency can exceed maximum command pulse frequency 200kpps of AD75, and cannot control it. (It asks for the Servo amplifier side electronic gear at the time of maximum command pulse frequency 200kpps of AD75.)

Question (4) Formula (2-6)

CDV CMX f 6553600 4096 c1 F = • f ⇒ = = = c c 1 CMX CDV f c 200X103 125

The positioning accuracy ∆λo at the time of putting in the above-mentioned electronic gear is checked.

P CMX 8 4096 B ∆λ = ⎯⎯ X ⎯⎯ = ⎯⎯⎯X ⎯⎯ = 0.002 (mm/pulse) c P f o CDV 131072 125

The conclusion of the example 2.1 The case of 300mm of positioning is considered.

F Position

Data

CMX=4096CDV=125

Deviation

t

PLG X4

A

HC-KFS Servomotor V

PB=8

The amount of positioning move-ments is 300(mm)

P f o

The number of pulsesafter a Servo amplifierelectronic gear ratio(the No. of motor

AD75 Position controller

Ap=4000 Al=800XAm=

MR-J2s Amplifier

Positioning The maximum command frequency =200kpps

Command pulse150000[pulse] Pf0=131072p/rev

2-17


2.5.2 The maximum input pulse frequency The Servo amplifier maximum input frequency becomes settled following condition.

MR-J2S series selects the value of an electronic gear by the formula (2-11) and (2-12) so that the servomotor can be used to rated rotation speed on the maximum input pulse frequency (open collector --200kpps, differential receiver --500kpps).

Furthermore, the maximum input pulse frequency of the whole including position controller turns into the above-mentioned Servo amplifier and the maximum frequency with which are satisfied of both controller. (The maximum output pulse frequency of positioning controller is reference in Appx. 4)

Exercise 2.2 (1) How many kpps is the maximum input pulse frequency of the open collector

input of MR- J2S (3000 r/min) series? (2) When you use the rated rotation speed of MR-J2S below on the maximum

input pulse frequency, what is the range of the electronic gear K of MR-J2S? (3) How many kpps is the maximum input pulse frequency as MR-J2S and

the AD75 whole in the open collector input?

(1) They are 200kpps. (2) It is the range of the value K of an electronic gear from formula (2-11), and (2-12).

3000 3000 f 6553.6 X103 32768 c1 f c 1 = P X ⎯⎯ =131072 X ⎯⎯ = 6553.6X10 f 0

60 60 f 3pps 500 >k ≥ ⎯ = ⎯⎯⎯⎯⎯ = ⎯⎯

c 200 X10 3 1000 (3) The max. frequency that is satisfied for both MR-J2S and AD75, is 200kpps.

Exercise 2.3 (1) How many kpps is the maximum input pulse frequency of the differential

driver input of MR-J2S (3000 r/min) series? (2) When you use the rated rotation speed of MR-J2S below on the maximum

input pulse frequency, what is the range of the electronic gear K of MR-J2S? (3) How many kpps is the maximum input pulse frequency as MR-J2S and

AD75 whole in the differential driver input?

(1) They are 500kpps. (2) It is the range of value K of an electronic gear from formula (2-11), and (2-12).

3000 3000 f 6553.6X103 32768 c1 f c 1 = P X⎯⎯ =131072 X ⎯⎯ = 6553.6X10 f o 60 60 f

3pps 500 >k ≥ ⎯ = ⎯⎯⎯⎯ = ⎯⎯⎯ c 500X10 3 2500

2-18


(3) The frequency with which are satisfied of both MR-J2S and AD75 is 400kpps.

2.6 A speed pattern and stop setting time

2.6.1 Speed pattern and performance of droop

The “droop pulses” are the pulses that accumulate in the deviation counter of the servo amplifier as a result of the display between the No. of command pulses and No. of feedback pulses received at the deviation counter. The performance of the deviation counter pulses is shown in Fig2.9.

(1) Performance between t0 and t2

The feedback pulses from the encoder are displayed in relation to the command pulses due to the acceleration lag of the servomotor, and the droop pulses “ε” are generated.

f K• f

t 0 t 1 t 2 t 4 t 5 t[sec]t 3 D

C E B

A Tpsd ts

Feedback Pulses

(actual form of

movement)

Command pulses

(1) (2)

[pps]

Pulses frequency

c1 c ε= ⎯ = ⎯⎯⎯ (pulse) ------(2-13) PG1 PG1

Fig. 2.9 Speed Pattern and Droop Pulses

PG1: Position loop gain.


The command pulses are synchronized with the servomotor’s rotational speed and the motor runs with a position lag equivalent to the droop pulses obtained in formula (2-13).


The system attempts to make up the position lag equivalent to droop pulses obtained in formula (2-13). If there are still droop pulses remaining at point t4 ( the point at which input of command pulses finishes), the motor continues to revolve even though no command pulses are being input.


The motor continues to rotate to clear all the remaining droop pulses. The interval between t4 and t5 is the “setting time” required to stop within accuracy 1 pulse.

(5) Motor operation

Both the rotational speed of the servomotor and the droop pulses change as exponential functions over time.

Finally, when the droop pulses have reached 1 pulse accuracy limit, the servo lock is applied.

As a result, the No. of command pulses (area ABCD) +1 is equal to the actual feed distance (area

AECF); And, the quantity of pulses that accumulate during acceleration, (1)(area ABEA) is equal to

the reduction in the No. of deviation counter pulses during deceleration, (2) (area CFDC).

2-19


Exercise 2.4 Referring to the left figure, it can set on the following conditions as PG 1= 36 [sec-1] – collect and ask for Pulse epsilon

Fc1=K•fc =180k,18k,0.9k,72 [pps] Also calculate the feed length from the droop pulses(assuming that ∆λo=0.01 [mm/pulse] in each case.) (Electronic gear ratio k= 1/16)

t[sec]

[pps]

t 0 t 1 t 2 t 4 t 5 t 3

Pulse

freq

uenc

y

Respectively, it is as follows refer to this formula ε=k•fc /PG1 (pulse). k•fc = 180kpps (1318r/min)

180000 ε = ⎯⎯⎯⎯ = 5000(pulse), Feed length equivalent 5000X 0.01=50(mm)

36 k•fc =18kpps (132r/min)

18000 ε = ⎯⎯⎯ =500 (pulse), Feed length equivalent 500 X 0.01=5(mm)

36 k•fc = 0.9kpps (6.6r/min)

900 ε = ⎯⎯ =25 (pulse), Feed length equivalent 25 X 0.01 = 0.25(mm)

36 k•fc = 72pps (0.53r/min)

72 ε = ⎯⎯ = 2 (pulse), Feed length equivalent 2X 0.01=0.02(mm)

36

2.6.2 Setting time (ts) Since it finishes issuing commands, and time until position is completed and expressed a baton time is decided in this setting time with part mounting machines, such as an inserter and molding, stop setting time is a factor with very important time shortening.

Setting time Command Pulses

Droop pulses

Operation pattern comparison of J2-Super and J2 stop establishment time Conditions: Servomotor: HC-MFS13 Servo Amplifier: MR-J2S – 10A

Load inertia ratio: 3 times

J2S J2 Stop Setting time 0.9 ms 5 ms

2-20


(1) The view of stop setting time Stop setting time can calculate an outline value by the model side position control

gain 1 (PG1) of model adaptive control. However, since the value of the position control gain 1 receives influence in the situation of a machine, the value of a load inertia moment, etc. greatly, when sending and stop setting of a high response of high frequency operation are required, it needs to take correspondence also including the machine system into consideration. Stop setting time until it becomes about ten or less pulses serves as the following formula experientially.

Ts

Command

t

Pr5 (INP) is set as 10.

0 pulse 10 Pulse

ts ≅ 3 (sec) PG1

If it collects in the accuracy that the machine is demanding and a pulse enters, even if a servomotor moves, it will consider that it stopped and the completion signal of positioning will be outputted.

Stop setting time affects the cycle time at the time of high frequency positioning.

2.7 Relationship between the machine system and response setup

2.7.1 Response setup

By the conventional control system, the position loop gain and speed loop gain of Servo need to be adjusted according to each machine condition. Especially, to the inertia moment ratio of load, or machine rigidity, the relation with each loop of a servo system needed to be known enough, and adjustment sometimes took time plentifully. In MELSERVO-H, J2S, and C series, since model adaptive control and real-time auto tuning are performed, an ideal model part and a real loop part are automatically adjusted to the optimal gain only by setting an auto tuning response setup as the value corresponding to the rigidity of a machine. About an auto tuning response setup, it can set up with a parameter. Since MR-J2S were summarized into the table below, please make it reference.

2-21


Table 2.3 MR-J2S basic parameter Pr.2

Setting value

Auto tuning response

The standard of a machine

1 ~ 3 Low response What has low machine rigidity? A belt, a chain drive, the large machine of a backlash, etc.

4 ~ 6

Low-middle

response

The rigid level of an average general-purpose machine. A belt, a chain, a rack & pinion drive, etc. The setting value at the time of shipment.

7 ~ 9 Middle response A little high level of machine rigidity. When you want to improve a response by the ball screw, the rigid high timing belt, etc.

A ~ C Middle-high response

The use that machine rigidity is high and positions in high frequency.

D ~ F High response The use, which wants for machine rigidity to be used very high, and the position to super-high frequency.

Note) machine starts hunting, or a setting value is made small when gear sound is loud.

In raising a performance, it enlarges a setting value, such as shortening stop setting time.

2.7.2 Real-time auto tuning

If an auto tuning response setting value is set as a parameter and a servo motor is moved, the load inertia moment at that time will be tuned up automatically, and the gain (a position, speed) of each control loop will be set as the optimal value to the set-up response setting value. At this time, since vibration will occur or it will become unstable if the auto tuning response setting value over a machine system is not suitable, please improve an auto tuning setting value again. The inertia moment result of the tuned-up load can be checked by a state display monitor's load inertia moment ratio. The recommendation load inertia moment ratio has restrictions of a response, regeneration energy, a dynamic brake, etc. Usually, a load inertia moment ratio recommends 30 or fewer times as a standard to a servo motor. (Each catalog is consulted for details.)

2-22


Although it can set up by real-time auto tuning by most machines, when there is the necessity of adjusting to a limit, the manual carries out gain adjustment.

<Reference> The method of adjustment of a manual gain When a load inertia moment is excessive and the tuning with it is not obtained with a rise-and-fall axis, and when a machine cannot respond by auto tuning response setup, the manual performs each gain adjustment for the very large imbalanced load. For details, please refer to the section 6.3.3.

2-23


2-24

Memo

3. POSITIONING CONTROLLER

3.1 Servo function and positioning controller

Positioning control by AC Servo is performed by the positioning controller and the Servo amplifier that generate the command pulse sequence sharing a function as follows respectively.

3.1.1 The function of positioning controller (1) The output of the command pulse equivalent to the amount of sending of a machine; (2) Determination of machine speed (command pulse frequency); (3) Determination of an operation pattern (at the time of accelerator or decelerator constant); (4) A theoretical machine position is memorized.

3.1.2 The function of Servo Amplifier (1) A pulse sequence is followed from positioning controller, and it is positioning

control to the command position; (2) Servo lock function; (3) The output function of the positioning completion signal.

3.2 A classification and composition of positioning instruction equipment

Positioning unit

Setting

data

Writing and read-out of data

Parameter data positioning data Zero return data

Peripheral equipment

Input X CMX CDV


PLGX4

Reverse pulse Electronic Gear

A

Feedback pulse

Speed command D/A

converter

Forward pulse

Sequence program

Output Y

Servomotor Servo Amplifier Sequencer

Figure 3.1 Composition of a positioning system

a) The deviation counter integrates the pulse sequence taken out from the positioning unit,

this pulse collects, and D/A conversion is carried out, and quantity becomes direct-current analog voltage, and becomes speed command;

b) The motor rotates by speed command, simultaneously, from PLG, a deviation counter is returned and covered with a feedback pulse, and a pulse is subtracted;

c) If the pulse sequence, which has come out of the positioning unit, becomes slowdown command, a deviation counter will collect, a pulse will be lost and a motor will stop.

3 - 1


Servomotors are being used in an increasingly wide variety of applications and there is a growing trend to combine them with controllers for supply as systems; these developments account for the extremely large number of positioning systems for use with servomotors that are currently being developed and put on the market. Therefore, the selection of the most suitable positioning controller for a particular application is as important a factor as the selection of the servomotor in determining the level of system efficiency, and the performance to cost ratio, that can be achieved. The following is a discussion of the classification and function of positioning controllers on the basis of the concept outlined above.

(1) Position system A servo position system including positioning controller and Servo amplifier is as follows.

Stand-alone type - - - - - - - - - - (1 axis controller with built-in amplifier)

System

FX2N – 1PG FX – 1GM

FX – 10 GM

FX 2N – 10GM FX – 20GM E – 20GM A1SD75P - P3 A1SD75M

+ Servo Amplifier

Servomotor

+

MR – J2 C MR - HACN

+

FX series

Motiocontro

Multi-axis controller system

Note. About model selection, it refers to Appx. 4.

Sequencer familiartype

(2) The number of controUsually, it says whether simultaneously controllableinto a simultaneous controlmore numbers of control ax

1 axis - - - -Controlled axes No.

2 axes - - - -3 axes - - - -4 axes - - - -8 axes - - - -32axes - - -

(3) Simultaneous control

A series
+ Servo Amplifier s Q serie A1SD778M
AD75P - S3 AD75M AD778M

A171SH/ A172SH A173UH / A273UH

+ Servo Amplifier

Servomotor

Servomotor

n ller

lled axes how many sets of a servomotor or servo amplifier are by one set of positioning controller. Moreover, it is divided system or an independent control system when it has two or es. - A1SD75P1-S3, A1SD75M1, FX-10GM, MR – J2 C, MR – H CAN; - A1SD75P2-S3, A1SD75M2, FX-20GM, - A1SD75P3-S3, A1SD75M3 - A171SH - A172SH, A1SD778M, AD778; - - A1173UH, A273UH;

and independent control

3 - 2


(a) Simultaneous control In positioning controller with the number of control more than one axis, the function that enable control of multiple axes simultaneously is called the simultaneous control function. That is, control of multiple axes is made from the single program, and operation modes (automatic, manual operation, home position return, etc.), and starting and a stop are performed simultaneously. It is recently becoming common for controllers with this function to feature an interpolation control capability.

(b) Independent control The functions that have the capability to control more than one axis, the function that enables control of the individual axes independently is called the independent control function. That is, control of each axis is made from each program, and operation modes (automatic, manual operation, home position return, etc.), and starting and a stop control are executed independently for each axis.

(4) Interpolation control The interpolation function controls the motion of the multiple axes involved in the control in relation to each other. The interpolation function includes liner interpolation and circular interpolation.

(a) Liner interpolation The multiple axes are controlled so that the start point and end point(target position) are connected by the shortest path. In this case, since the generated path is a straight line, the control mode is called liner interpolation. Usually, two-axis liner interpolation and three-axis liner interpolation are available.

X-axis Z-axis

End point

Start point

Y-axis End point

Start point X-axis

Y -axis

(b) Two-axis linear interpolation (b) Three-axis linear interpolation

Fig. 3.2 Axis Motion in Linear Interpolation Control

3 - 3


Applicable 2-axis linear - - - - FX- 20GM, AD75P2-S3, AD75M2, etc; 3-axis liner - - -AD778M, A273UH, etc. ( 2-axis is also possible)

(c) Circular interpolation

The multiple axes are controlled so that the start point and end point(target position) are connected by an arc. Since an infinite number of arcs can be defined if only start and end points are specified, the radius of the arc, center of the arc and/ or direction of the arc are specified in a program in addition to the two points so that a specific are can be defined.

CW

CCW

Start point Locus of the center of the arcs

End point

Fig. 3.3 Axis Motion in Circular Interpolation Control

Applicable models ----- A273UH, AD75-P2/P3-S3, AD75M2/M3, AD778,FX20GM, Etc. (5) Absolutely position detection

An absolutely position detector is installed in a servomotor so that the machine position is retained in the positioning command device when the power off. This allows automatic operation to be restarted from the present position without carrying out a home position return after turn on the power.

The absolute positioning control system consists of a motor equipped with the absolute position transducer, a compatible Servo amplifier, and a positioning controller.

3 - 4



Servo amplifier Encoder

A273UH

Built-in type Servo amplifier MR-J2B series

MR - J2 B series MR - H BN series

A171SH

A172SH

A173UH

AD75M

A1SD75M

MR-J2B series

MR - J2 B series

MR - H BN series

HC-MF HC-MFS

HA-FF

HC-KFS

HC-SF

HC-SFS

HC-RF

HC-RFS

HC-UF

HC-UFS

HC-MF

Note 1. Each positioning controller can combine which Servo amplifier.

(6) The type of positioning program

The program types for each of the device types are summarized below.

Sequence program ------ A1SD75, AD75, A1SD778M, AD778; The command only for positioning----FX- 1GM, FX10GM,

Positioning program

Motion program ----A273UH, A171SH, A172SH, A173UH (NC language and an exclusive language) Point of contact (BCD, binary)--- MR-HACN, MR- J2C.

3 - 5


3.3 Setting data of positioning controller

The setting data of AD75P positioning controller is explained.

3.3.1 Basic parameter

Basic Parameter

Group No. Unit

Setting Range Initial

Type Item mm inch degree pulse Value Setting unit 0:mm 1:inch 2:degree 3:pulse 3

Number of pulses per revolution (Ap)

1 ~ 65535 pulse 20000

Travel value per revolution(Al)

0.1 ~ 6553.5 µm 0.00001 ~

0.65535inch 0.00001 ~

0.65535degree 1 ~65535pulse 20000

Travel value per pulse

Unit magnification(Am)

1 10 100 1000

1

Pulse output mode

0:PLS/SIGN mode 1:CW/CCW mode 2:A-phase/B-phase mode (Magnification of 4) 3:A-phase/B-phase mode (Magnification of 1)

1

1 Change among

sequencer is

impossible.

Direction of rotation 0: Present value increases when forward pulse is output 1: Present value increases when reverse pulse is output 0

Speed control

0.01 ~ 6000000.00

µ/min

0.001 ~ 600000.000

inch/min

0.001 ~ 600000.000

degree/min

1 ~ 1000000

pulse/s

200000

Acceleration time [ 0] 1 ~65535ms/1 ~ 8388608ms 1000 Deceleration time [ 0] 1 ~65535ms/1 ~ 8388608ms 1000 Starting bais speed

0.01 ~ 6000000.00

µm/min

0.001 ~ 600000.000

inch/min

0.001 ~ 600000.000

degree/min

1 ~ 1000000

pulse/s

0

2 Change among

sequencer is

possible. Stepping motor mode

0:standard mode 1: Stepping motor mode 0

3.3.2 The basic parameter for a starting point return

Unit

Setting range Initial

Item mm inch degree pulse Value

Home position return method

0:Near-zero point dog method 1:Stopper stop (1) (caused by time-out of the dwell timer) 2:stopper stop(2) (caused by the zero point signal when in contact with stopper 3:Stopper stop (3) (method without near-zero point dog) 4:Count method (1) (zero point signal is used) 5:Count method (2) (zero point signal is not used)

0

Home position return direction

0:Forward direction (address increases) 1:Reverse direction (address decreases) 0

Zero position address -214748364.8 ~

214748364.7 µm -21474.83648 ~

21474.83647inch 0 ~

359.99999degree -2147483648 ~

2147483647pulse 0

Home position return speed

0.01 ~ 6000000.00

mm/min

0.001 ~ 600000.000

inch/min

0.001 ~ 600000.000

degree/min

1 ~ 1000000

pulse/s

1

Creep speed

0.01 ~ 6000000.00

mm/min

0.001 ~ 600000.000

inch/min

0.001 ~ 600000.000

degree/min

1 ~ 1000000

pulse/s

1

Home position return retry 0:Home position return is not retried in accordance with the upper/lower limit switch. 1:Home position return is retried in accordance with the upper/lower limit switch. 0

3 - 6


3.3.3 Positioning data

Unit Setting Range Initial Item mm inch degree pulse value Operation pattern

00 : Positioning end 01 : Continuous positioning control 11 : Continuous locus control

00

Control method

_

Acceleration time No. The acceleration time 0-3 is chosen from the inside of a basic parameter [2] 0 Deceleration time No. The acceleration time 0-3 is chosen from the inside of a basic parameter [2] 0 Positioning address Absolute

-214748364.8 ~ 214748364.7 µm

-21474.83648 ~ 21474.83647inch

0 ~ 359.99999degree

-2147483648 ~ 2147483647pulse 0

Incremental (other than speed/position switching control)

-214748364.8 ~ 214748364.7 µ m

-21474.83648 ~ 21474.83647inch

-21474.83648 ~ 21474.83647degree

-2147483648 ~ 2147483647pulse

0

Positioning travel value

Speed/ position switching control

0 ~ 214748364.7 µ m

0 ~ 21474.83647inch

0 ~ 21474.83647degree

0 ~ 2147483647pulse 0

Absolute 0 ~

359.99999degree 0 ARC. address The auxiliary or central point

Incremental

-214748364.8 ~

214748364.7 µm

-21474.83648 ~

21474.83647inch -21474.83648 ~ 21474.83647degree

-2147483648 ~

2147483647pulse 0

0.01 ~6000000.00 mm/min

0.001 ~600000.000 inch/min

0.001 ~600000.000 degree/min

1 ~ 1000000 pulse/s

Commanded speed

-1(current speed: the same speed as the previous positioning data no.)

0

Dwell time 0 ~ 65535ms(the completion signal of positioning turns on this time). Or it is jump place data No.1-600 at the time of a JUMP command. 0

M code 0 ~ 32767(Or it is data No.1-10 of Conditions JUMP at the time of a JUMP command.) 0

Notation of peripheral device

Description of setting Instruction code

ABS linear 1 Linear control of axis 1(ABS) 01H INC linear 1 Linear control of axis 2(INC) 02H

Fixed-pitch feed 1 Fixed pitch feed of axis 1 03H ABS linear 2 Linear control of axis 2(ABS) 04H INC linear 2 Linear control of axis 2 (INC) 05H

Fixed-pitch feed 2 Fixed pitch feed of axis 2 06H ABS circular interpolation

Circular interpolation control by auxiliary point designation(ABS)

07H

INC circular interpolation

Circular interpolation control by auxiliary point designation (INC)

08H

ABS circular right Circular interpolation control by center point designation(ABS, CW)

09H

ABS circular left Circular interpolation control by center point designation (ABS, CCW)

0AH

INC circular right Circular interpolation control by center point designation (INC, CW)

0BH

INC circular left Circular interpolation control by center point designation (INC, CCW)

0CH

Forward speed control speed control(forward) 0DH Reverse speed control speed control (reverse) 0EH

Forward speed/ position

speed/ position switching control (forward) 0FH

Reverse speed/ position

speed/ position switching control (Reverse) 10H

Present value change

Present value change 11H

JUMP instruction JUMP instruction 12H

3 - 7


Data No.

Pattern Control method

Acc [ms]

Dec [ms]

Address [µm]

Command speed

[mm/min]

Dwell time [ms ]

M code

1 0: End 1:ABSlinear 1 0:100 0:100 50000.0 2000.00 0 02 0: End 1:ABSlinear1 0:100 0:100 75000.0 2000.00 0 03 0: End 1:ABSlinear1 0:100 0:100 100000.0 2000.00 0 04 0: End 1:ABSlinear1 0:100 0:100 150000.0 2000.00 0 05 0: End 1:ABSlinear1 0:100 0:100 200000.0 2000.00 0 06 0: End 1:ABSlinear1 0:100 0:100 25000.0 2000.00 0 07 0: End 0:No axes 0:100 0:100 0.0 0.00 0 08 0: End 0:No axes 0:100 0:100 0.0 0.00 0 09 0: End 0:No axes 0:100 0:100 0.0 0.00 0 0

10 0: End 0:No axes 0:100 0:100 0.0 0.00 0 0

Example of a positioning data setting

3 - 8


3.4 Position command interface

Conventionally, the pulse train was the most common type of position command output from the position command output from the positioning controller to the servo amplifier. Recently, as software and digital control have come to be widely adopted, using microprocessors (CPU) in the control unit, the style of position command is changing; the ultimate type of control system integrates the positioning controller and the servo amplifier by connecting of sophisticated and highly accurate positioning systems. If a pulse train is used as the position command, there are several types of interface. A summary of the types of position command interface, the corresponding models, and the features of each type of interface is presented below.

Bus connection ------ [Positioning command equipment]

(SSC network correspondence) A171SH, A172SH, A173SH, A273 AD75M, A1SD75M;

(Servo amplifier) Position commandinterface

MR – J2B, MR - HBN Pulse sequence system ------ (positioning control equipment) (General-purpose interface) FX – 1GM, FX – 10GM, FX-20GM, AD75P, A1SD75P (Servo Amplifier) MR – J2A, MR – J2SA, MR – HAN; Point-of-contact system (Servo amplifier with a built-in positioning function) MR – J2C, MR - HACN

(The type of pulse train interface) (a) Forward and reverse pulse train system, and a pulse train and a direction distinction signal system. There are a system inputted from a separate terminal by the rotation direction as a method of specifying the rotation direction of a motor, and a system switched with the rotation direction distinction signal in a pulse sequence. Moreover, it becomes 2 phase pulse train system when inputting a direct pulse sequence from a synchronous encoder.

Pulse train for forward rotation

Forward rotation

Reverse rotation

Pulse train for reverse rotation

Pulse train Phase A pulse train

Direction determination sign

Phase B pulse train

2phase pulse train method Forward/ reverse rotation pulse train method of rotation

Direction determination sign method

Fig. 3.4 Command system of rotation direction. (b) An open collector system and a differential driver system

3 - 9


These two kinds exist as hardware of an interface. Although the easy open collector system was conventionally in use, recently, the differential driver system has become popular since it can handle high speed pulse trains and improve the noise resistance. In connection with our company AD75, the differential formula is recommended.

[The example of hardware composition ]

Position controller

Servo amplifier

Open-collector type

Equivalent to SN75113

Driver Receiver

Differential driver type (Max 10M)

Position controller

Servo amplifier

Fig. 3.5 Example of hardware of pulse sequence

[Pulse train type]

Pulse train

Command

Open-collector Type

Differential driver type

Pulse train

Pulse train

Fig. 3.6 Pulse sequence form

3 - 10


3.5 The Basic of the Positioning Control Using a positioning controller

3.5.1 The direction of a machine motion and the servo motor rotation direction

The rotation direction of a servomotor has determined the counterclockwise rotation as right rotation in view of the load side. Moreover, the “positive” direction of mechanical motion is usually defined as the direction in which coordinates value increase. In order to unite the move direction of a machine, and the rotation direction of a servo motor, when the rotation direction of a servo motor needs to be changed, the rotation direction is set up and changed with the parameter of positioning controller etc. Since normal operation becomes impossible, a change of the rotation direction by exchange of direction of a servo motor terminal cannot be made. The change method of this rotation direction is the same even if the model of positioning controller is different. Moreover, to check the direction of motor rotation, run the motor by using JOG functions.

Ball Screw Table

Servomotor

The direction in which the table is moved by the ball screw when the motor rotates in the forward direction.

The direction in which the coordinate values of the machine position increase

Home Position

Forward direction (CCW)

Fig. 3.7 Rotation direction of servo motor Fig. 3.8 Example of setting of rotation direction

3 - 11


3.5.2 The type of home position return

(1) The type of home position return

Type of home position return

Type of zero point Operation

Near –zero point dog

signal

Machine home

position

(first zero point)

The near-zero point signal OFF → ON, it slows down at creep

speed, and after The near-zero point ON → OFF, while stopping

an output pulse with the zero signal from Servo amplifier, a clear

signal is outputted, a deviation counter collects, a pulse is made

into zero, and a home position return is completed.

High-speed home

position return

Machine home

position

(first zero point)

Creep speed is not used but the home position return to the

machine starting point only at home position return speed (high-

speed). The first time needs to define the machine starting point

by dog type home position return.

Home position return for

programming

Programming home

position

(second zero point)

The home position return which returns to the program starting

point (standby position) set up with the parameter at home

position return speed.

Dog type home position return, high-speed home position return and home position return for programming.

man

ual

- au

tom

atic

Ze

ro

poin

tre

turn

A

utom

atic

Zer

o po

int r

etur

n

Creep speed

High-speed home position return

Machine home position return

home position return for programming home position return speed

Dog type home position return

(first home position)

(The second home position)

home position return for programming

Zero-point signal

Machine home point

(to be set by parameter)

Home position shift amountNear-zero point dog

3 - 12


(2) The type of the home position return method

There are the following four kinds of the home position return methods.

home position return methods The operation pattern of a home position return

op

erat

ion The near-zero point dog signal OFF→ON, it slows

down at creep speed, and after the near-zero point dog signal ON→OFF, while stopping an output pulse with the zero signal from Servo amplifier, a clear signal output is carried out, a deviation counter collects, a pulse is made into zero, and a starting point return is completed.

Dog type

home

position

return

feat

ure Although cautions are required for the determination of

dog length or an attachment position enough, there is a point with sufficient unreasonableness not starting a machine with the sufficient repetition accuracy of a starting point return etc.

Correspondence model: AD75, motion series

ope

ratio

n

If a Dog signal turns on, while slowing down at home position return speed, the count start of the zero signal is carried out. Shortly after a zero signal serves as the number of times of a setup, a pulse sequence signal output is suspended, a clear signal is outputted to Servo amplifier, a servomotor is stopped, and it considers as the home position.

The time of the number of zero signal counts (setting value =4) is shown in the following figure.

Dog type

home

position

return(2)

Fe

atur

e

Cautions are not comparatively needed for the determination of Dog length or an attachment position. However, variation arises at the time of a count start with the accuracy and starting point return speed of repetition operation, such as a switch used for detection of dog point. Since repetition accuracy of a home position return is worsened by this, cautions are required.

Correspondence model: FX series

Ope

ratio

n

If a Dog signal turns on, it will slow down at creep speed from home position return speed. Continuation starting of the home position return on near-dog signal ON and a home position return can also be performed. After the amount part movement of movements specified from near-dog signal ON, if the first zero signal is detected, a pulse signal output will be suspended immediately and a clear signal will be outputted to Servo amplifier. And a servomotor is stopped and it considers as the home position.

Count type

home

position

return (1)

Feat

ure

Cautions are not comparatively needed for the determination of dog length or an attachment position. However, variation arises at the time of a count start with the accuracy and home position return speed of repetition operation, such as a switch used for detection of dog. Since repetition accuracy of home position return is worsened by this, cautions are required. Correspondence model: AD75, motion series

Ball screw

Stroke end in the forward direction

Machine home position

Near-zero point dog

Home position return

Home position return direction Creep speed

Operation pattern

Stroke end in the reverse direction Near-zero

point dog

Table

ServomotorForward direction

Zero-point signal

Clear signal

Creep speed


Near-zero dog signal

Operation pattern Machine home position

3 4 2 1 Zero-point signal

Clear signal

t The amount of movements after near-dog signal ON(Move distance is set up with a parameter.)

Creep speed

The amount of movements after near-dog signal ON


Zero point

Near-zero dog off on

The zero of the beginning after near-zero dog ON the amount of movements

near-zero dog signal should take sufficient distance from the present position.

V

3 - 13


Home position return method The example of the operation pattern of the home position return

Ope

ratio

n

If a Dog signal turns on, it will slow down at creep speed from home position speed. Continuation starting of the home position return on near-zero dog signal ON and the home position return can also be performed. After the amount part movement of movements specified from near-zero dog signal, a pulse signal output is suspended immediately and a clear signal is outputted to Servo amplifier. And a servomotor is stopped and it considers as the home position.

Count type

home

position

return (2)

F

eatu

re

Cautions are not comparatively needed for the determination of Dog length or an attachment position. However, variation arises at the time of a count start with the accuracy and starting point return speed of repetition operation, such as a switch used for detection of Dog. Thereby, since repetition accuracy of the home position return is worsened, the error whose cautions are about 1 required occurs.

Correspondence model: AD75 series

o

pera

tion

If a near-zero dog signal turns on, while slowing down at creep speed from home position return speed, the count of lapsed time is started. A stopper is made to dash and suspend a machine, a pulse sequence signal output is suspended after setting time (dwelling time) progress, and a clear signal is outputted to Servo amplifier. And a servomotor is stopped and it considers as the starting point. If it is not after setting time (dwelling time) progress even if a Dog signal turns off on the way, it will not become the completion of a home position return.

Stopper

type home

position

return (1)

Fea

ture

Cautions are required for the determination of Dog length, creep speed, and setting time (dwelling time) enough. It is necessary to make creep speed sufficiently low in order to lessen the shock at the time of stopping, and it needs to apply torque restrictions to take the intensity of a stopper or a machine into consideration enough. Setting time (dwelling time) seasons time until a machine reaches a stopper with time for fault load protection of Servo amplifier to operate, and is set as it. Furthermore, since distortion occurs and the repetition accuracy of a home position return becomes bad in order to make a stopper dash and suspend a machine, cautions are required.


Near-zero point dog

stopper

Dwelling time count Dwelling time count

end (the completion of home position return)

Torque limit


V

t

Creep speed

Home position speed

Near-zero dog signal off on

The amount of movements after near-dog signal ON(Move distance is set up with a parameter.)

The amount of movements after near-dog signal ON

Near-zero dog signal off should take sufficient distance from the present position.

3 - 14


Ope

ratio

n

If a Dog signal turns on, it will slow down at home position return speed, and will move further. A stopper is made to dash and suspend a machine, a setting torque restriction value is reached from Servo amplifier, and a pulse output stops and carries out the completion of a home position return from a controller by the zero signal with the signal (under torque restrictions) which checked the stop state.

Stopper

type home

position

return (2)

F

eatu

re

The same cautions as stopper type home position return (1) is needed. Moreover, if the above-mentioned torque restriction signal is not inputted even if a Dog signal turns off on the way, it does not become the completion of a home position return. Setting the torque limit by AD75 or giving a linear analog command to Servo amplifier.


Home position return method The example of the operation pattern of the home position return

Ope

ratio

n

It is the starting point return method that can be performed in the case of a position detection system absolutely. Let the position be the starting point by moving a machine to arbitrary positions by JOG operation etc., and performing a starting point return. (A motor does not move)

Data set type

home position

return method

Fea

ture

After a power supply turn on before performing home position return, it is necessary to pass a zero point. The error of about 1% of maximum comes out of the present value display at the time of a power supply OFF, and the present value display at the time of a power supply ON by motor rotation. The home position return data used for only selection of the home position method, and a setup of a home position address. Correspondence model: AD75, motion series

Mechanical stopper

After moving the machine to the required position in the jog mode, execute “data set” to establish this position as the home position.

JOG

Deviation counter clearance

Torque limit effective

Zero point signal

(completion ofhome positionreturn)

Torque limit

Near-zero dog



3 - 15


MEMO

3 - 16

4. MELSERVO – J2S PERFOMANCE AND FUNCTIONS

4.1 Function List The following table lists the functions of this servo. For details of the functions, refer to the corresponding chapters and sections.

Function Description (Note)

Control mode Remark

Position control mode This servo is used as position control servo. P Speed control mode This servo is used as speed control servo. S

Torque control mode This servo is used as torque control servo. T

Position/speed control change mode

Using external input signal, control can be switched between position control and speed control.

P/S

Speed/torque control change mode Using external input signal, control can be switched between speed control and torque control.

S/T

Torque/position control change mode

Using external input signal, control can be switched between torque control and position control.

T/P

High-resolution encoder High-resolution encoder of 131072 pulses/rev is used as a servo motor encoder.

P, S, T

Absolute position detection systemMerely setting a home position once makes home position return unnecessary at every power-on.

P

Gain changing function You can switch between gains during rotation and gains during stop or use an external signal to change gains during operation.

P, S

Adaptive vibration suppression control

Servo amplifier detects mechanical resonance and sets filter characteristics automatically to suppress mechanical vibration.

P, S, T

Low-pass filter Suppresses high-frequency resonance which occurs as servo system response is increased.

P, S, T

Machine analyzer function Analyzes the frequency characteristic of the mechanical system by simply connecting a servo configuration software-installed personal computer and servo amplifier.

P

Machine simulation Can simulate machine motions on a personal computer screen on the basis of the machine analyzer results.

P

Gain search function Personal computer changes gains automatically and searches for overshoot-free gains in a short time.

P

Slight vibration suppression control

Suppresses vibration of 1 pulse produced at a servo motor stop. P

Electronic gear Input pulses can be multiplied by 1/50 to 50. P Parameters No. 3, 4

Auto tuning Automatically adjusts the gain to optimum value if load applied to the servo motor shaft varies. Higher in performance than MR-J2 series servo amplifier.

P, S

Position smoothing Speed can be increased smoothly in response to input pulse. P Parameter No. 7

S-pattern acceleration/ deceleration time constant

Speed can be increased and decreased smoothly. S, T Parameter No. 13

Regenerative brake option Used when the built-in regenerative brake resistor of the servo amplifier does not have sufficient regenerative capability for the regenerative power generated.

P, S, T

Brake unit Used when the regenerative brake option cannot provide enough regenerative power. Can be used with the MR-J2S-500A MR-J2S-700A.

P, S, T

4 - 1


4 - 2

Function Description (Note)

Control mode Remark

Return converter Used when the regenerative brake option cannot provide enough regenerative power. Can be used with the MR-J2S-500A MR-J2S-700A.

P, S, T

Alarm history clear Alarm history is cleared. P, S, T Parameter No. 16

Restart after instantaneous power failure

If the input power supply voltage had reduced to cause an alarm but has returned to normal, the servo motor can be restarted by merely switching on the start signal.

S Parameter No. 20

Command pulse selection Command pulse train form can be selected from among four different types.

P Parameter No. 21

Input signal selection Forward rotation start, reverse rotation start, servo-on and other input signals can be assigned to any pins.

P, S, T Parameters No. 43 to 48

Torque limit Servo motor-generated torque can be limited to any value. P, S Parameter No. 28

Speed limit Servo motor speed can be limited to any value. T Parameter No. 8 to 10,72 to 75

Status display Servo status is shown on the 5-digit, 7-segment LED display P, S, T

External I/O signal display ON/OFF statuses of external I/O signals are shown on the display. P, S, T

Output signal (DO) forced output

Output signal can be forced on/off independently of the servo status. Use this function for output signal wiring check, etc.

P, S, T

Automatic VC offset Voltage is automatically offset to stop the servo motor if it does not come to a stop at the analog speed command (VC) or analog speed limit (VLA) of 0V.

S, T

Test operation mode Servomotor can be run from the operation section of the servo amplifier without the start signal entered.

P, S, T

Analog monitor output Servo status is output in terms of voltage in real time. P, S, T Parameter No. 17

Servo configuration software Using a personal computer, parameter setting, test operation, status display, etc. can be performed.

P, S, T

Alarm code output If an alarm has occurred, the corresponding alarm number is output in 3-bit code.

P, S, T

Note: P: Position control mode, S: Speed control mode, T: Torque control mode

P/S: Position/speed control change mode, S/T: Speed/torque control change mode, T/P: Torque/position control change mode

4.2 Servo system with auxiliary equipment

MR-J2S series Servo amplifier has come to be able to perform all operations, such as connection with external

apparatus, a monitor and diagnosis, and setup parameter, from the button front of amplifier, as shown in the

following figure. Therefore, those works can be easily done also in the state of wearing in a board.


(1) MR-J2S-100A or less

(Note2) 3-phase 200V to 230VAC power supply or 1-phase 230VAC power

l

No-fuse (NFB) or fuse

Magnetic contactor(MC)

To CN2

To CN3

To CN1B

Junction terminal

To CN1A

L 1 L 2

L 21

L 11

Protective earth(PE)

Servo

Personal computer

U V W

Servo fsoftware

MRZJW3-SETUP121E

Servo f

Regenerative brake option

D

P

C

CHARGE

Options and auxiliary

No-fuse

Magnetic

Servo configuration

Regenerative brake Remark

Control circuit terminal

(Note1) Encoder cable

Options and auxiliary Remark

Cable

Command

(Note1)Power supply

L 3

Note: 1. The HC-SFS, HC-RFS series have cannon 2. A 1-phase 230VAC power supply may be used with the servo amplifier of MR-J2S-70A or less. Connect the power L 1 and L 2 terminals and leave 3 open.

Power factor improving reactor (FR-BAL)

Power factor improving

4 - 3


(2) MR-J2S – 200A or more

Power factor improving reactor (FR-BAL)

3-phase 200V to 230VAC power

No-fuse breaker (NFB) or fuse

Magnetic contactor (MC)

To CN2 To CN3

To CN1B

Junction block

To CN1A

L1 L2 L3

L21 L11

Servo lifi

Regenerative brake

P CU V W

Options and auxiliary

No-fuse

Magnetic

Servo configuration

Regenerative brake

Remark Options and auxiliary Remark

Personal computer

ServoconfiguratiosoftwareMRZJW3-SETUP121E

Cable

Command

Power factor improving

4 - 4


4.3 Installations and Operation If a product is purchased, it will operate by building a servomotor and Servo amplifier into a machine and a control board. Although these works is done on a product according to attached "handling description", according to a work procedure, the flow of the whole work in the 4.3.1 and clause is explained to the 4.3.2 about the point of each work in order.

4.3.1 The flow of the work to install and operation

The usual work Test operationⅠ Test operation III

Wiring Wiring (Not include motor)

4.3.3、4.3.4

(Wiring between a motor and amplifier )

Turn on power supply Turn on power supply Turn on power supply

4.3.5

Parameter setup

4.3.8

Parameter setup Parameter setup

Output signal check

4.3.9

Input/Output signal check

Manual operation

4.3.10

ＪＯＧ Operation Motor-less operation

4.3.13 4.3.13


4.3.11


Automatic operation

4.3.12

Automatic operation

It is the usual work proce-

dure. The point is explained t

o 4.3.2 clause shift.。

Easy operation of the machine

incorporating a motor indepen-

dent or the motor can be per-

formed without the wiring fro

m external instruction equipmen

t.

It perform only to check a

machine of operation before

wiring convenient for operation

to be well impossible from an

operation board, and check

The check of only the circu

m- ference of the electric instr

uc- tion without motor of ope

ration can be performed. In or

der to perform starting poi

nt return and automatic operati

on, it is necessary to prepare t

he electric virtual starting poi

nt.

One positioning operation is

made without the wiring from

external instruction equipment

to the machine incorporating

a motor independent or the

motor.

It perform only to check a

machine of operation before

wiring convenient for operation

to be well impossible from an

operation board, and check

only by Servo.

Test operation II

A personal computer (Servo setup software)

is connected.

Turn on power supply

Parameter setup

4.3.13

Position Operation

4.3.2 Installation

4 - 5


4.3.2 INSTALLATION

(1) Environmental conditions

Environment Conditions

[ ] 0 to 55 (non-freezing) Operation

[ ] 32 to 131 (non-freezing)

[ ] 20 to 65 (non-freezing)

Ambient temperature

Storage [ ] 4 to 149 (non-freezing)

Operation Ambient humidity Storage

90%RH or less (non-condensing)

Ambience Indoors (no direct sunlight) Free from corrosive gas, flammable gas, oil mist, dust and dirt

Altitude Max. 1000m (3280 ft) above sea level

[m/s2] 5.9 [m/s

2] or less

Vibration [ft/s

2] 19.4 [ft/s

2] or less

(2) Installation direction and clearances

CAUTION

The equipment must be installed in the specified direction. Otherwise, a fault may occur. Leave specified clearances between the servo amplifier and control box inside walls or other equipment.

(a) Installation of one servo amplifier

Control box Control box

10mm (0.4 in.) or more


40mm (1.6 in.) or moreServo amplifier


Wiring clearance 70mm (2.8 in.) Top

Bottom

4 - 6


(b) Installation of two or more servo amplifiers Leave a large clearance between the top of the servo amplifier and the internal surface of the control box, and install a fan to prevent the internal temperature of the control box from exceeding the environmental conditions.

Control box






Servoamplifier

(c) Others When using heat generating equipment such as the regenerative brake option, install them with full consideration of heat generation so that the servo amplifier is not affected. Install the servo amplifier on a perpendicular wall in the correct vertical direction.

(3) Keep out foreign materials

(a) When installing the unit in a control box, prevent drill chips and wire fragments from entering the servo amplifier. (b) Prevent oil, water, metallic dust, etc. from entering the servo amplifier through openings in the control box or a fan

installed on the ceiling. (c) When installing the control box in a place where there are toxic gas, dirt and dust, provide positive pressure in the

control box by forcing in clean air to prevent such materials from entering the control box.

(4) Cable stress

(a) The way of clamping the cable must be fully examined so that flexing stress and cable's own weight stress are not applied to the cable connection.

(b) In any application where the servo motor moves, the cables should be free from excessive stress. For use in any application where the servo motor moves run the cables so that their flexing portions fall within the optional encoder cable range. Fix the encoder cable and power cable of the servomotor.

(c) Avoid any probability that the cable sheath might be cut by sharp chips, rubbed by a machine corner or stamped by workers or vehicles.

(d) For installation on a machine where the servomotor will move, the flexing radius should be made as large as possible. Refer to section 12.4 for the flexing life.

4 - 7


[The servo motor installation.]

(1) Environmental condition

Environment Conditions Ambient temp. 0 to +40 (Non- freezing)

Ambient humidity 80% RH or less (Non-condensing)

Storage temp.

-15 to +70 (Non- freezing)

Storage humidity 90% RH or less (Non-condensing)

Ambient Indoors (no direct sunlight) Free from corrosive gas, flammable gas, oil mist, dust and dirt

Altitude Max. 1000m(3280 ft) above sea level

HC-AQ series

HC-KF series HC-MF series HA-FF series HC-UF13～73

HC-KFS series HC-MFS series HC-UFS13～73

X,Y：49m/s2(5G)

HC-SF81 HC-SF52～152 HC-SF53～153 HC-RF Series HC-UF72・152

HC-SFS81 HC-SFS52～152 HC-SFS53～153 HC-RFS series HC-UFS72・152

X,Y：24.5m/s2(2.5G)

HC-SF121・201 HC-SF202・352 HC-SF203・353 HC-UF202～502

HC-SFS121・201 HC-SFS202・352 HC-SFS203・353 HC-UFS202

X：24.5m/s2(2.5G) Y：49m/s2(5G)

HA-LH11K2 ～22K2

HC-SF301 HC-SF502・702 HC-SFS301 X：24.5m/s2(2.5G)

Y：29.4m/s2(3G)

Vibration

HA-LF30K24～55K24 X,Y:9.8m/s2(2G)

The amplitude of each oscillating conditions is as follows.

Speed [r/min]

200

100

80

60

50

40

30

20

500 1000 1500 2000 2500 3000 3500

[μm]

Vib

ratio

n am

plitu

de

(bot

h am

plitu

des)

Vibration

Y X

Servomotor

4 - 8


(2) Installation orientation The following table lists directions of installation:

Servomotor series Direction of installation Remarks HC-KF HC-MF HA-FF HC-SF HC-RF HC-UF HC-KFS HC-MFS HC-SFS HC-RFS HC-UFS

HC-AQ

For installation in the horizontal direction, it is recommended to set the connector section downward.

HA-LH

May be installed in any direction

HA-LF Horizontal direction with the legs downward. Use either the legs or flange for installation

(3) Transportation Do not hold encoder or shaft to carry the servomotor.

(4) Load mounting precautions a. When mounting a pulley to the servo motor shaft provided with a keyway, use the screw hole in the

shaft end. To fit the pulley, first insert a double-end stud into the screw hole of the shaft, put a washer

against the end face of the coupling, and insert and tighten a nut to force the pulley in.

b. For the servomotor shaft with a keyway, use the screw hole in the shaft end. For the shaft without a

keyway, use a friction coupling or the like.

c. When removing the pulley, use a pulley remover to protect the shaft from impact.

d. To ensure safety, fit a protective cover or the like

on the rotary area, such as the pulley, mounted to

the shaft. Servomotor

Double-end stud

Nut

WasherPulley

e. When a threaded shaft end part is needed to mount

a pulley on the shaft, please contact us.

f. During assembling, the shaft end must not be

hammered.

g. To orientation of the encoder on the servomotor

cannot be changed.

h. For installation of the servo motor, use spring

washers, etc. and fully tighten the bolts so that they

do not become loose due to vibration.

4 - 9


(5) Permissible load for the shaft (a) Use a flexible coupling and make sure that the misalignment of the shaft is less than the

permissible radial load;

(b) When using a pulley, sprocket or timing belt, select a diameter that will fit into the permissible radial load.

(c) Do not use a rigid coupling as it may apply excessive bending load to the shaft, leading to shaft breakage.

Permissible Radial Load Permissible Thrust Load Servomotor

(note 1) L [] [N] (Note2) [kgf] [N] (note2) [kgf]

053・13 25 88 9.0 59 6.0 23・43 30 245 25.0 98 10.0

HC-MF HC-MFS

73 40 392 40.0 147 15.0 053 30 108 11.0 98 10.0 13 30 118 12.0 98 10.0

23・33 30 176 18.0 147 15.0 HA-FF

43・63 40 323 33.0 284 29.0 81 55 980 100.0 490 50.0

121～301 79 2058 210.0 980 100.0 52～152 55 980 100.0 490 50.0 202～702 79 2058 210.0 980 100.0 53～153 55 980 100.0 490 50.0

HC-SF HC-SFS

203・353 79 2058 210.0 980 100.0 103～203 45 686 70.0 196 20.0 HC-RF

HC-RFS 353・503 63 980 100.0 392 40.0 72・152 55 637 65.0 490 50.0

202 65 882 90.0 784 80.0 352・502 65 1176 120.0 784 80.0

13 25 88 9.0 59 6.0 23・43 30 245 25.0 98 10.0

HC-UF HC-UFS

73 40 392 40.0 147 15.0 11K2 85 2450 250 980 100.0

HA-LH 15K2・22K2 100 2940 300 980 100.0

HC-KF HC-KFS

23・43 30 245 25.0 98 10.0

0135 16 34 3.5 14 1.5 0235 16 44.0 4.5 14 1.5 HC-AQ 0335 16 49 5.0 14 1.5

30K24・37Ｋ24 140 3234 330 1470 150 HA-LF

45K24・55K24 140 1900 500 1960 200

Note1. For the symbols in the table, refer to the following diagram:

Radial Load

Thrust load

L

L: Distance from flange mounting surface to load center

2. It is a reference value.

4 - 10


(6) Protection from oil and water (a) The servomotor of a right table is not

waterproofing structure. The Oil and water

should get down to a servomotor and please do

not start. Especially, HC-AQ, HC-KF, HC-MF,

HC-KFS, HC-MFS should not require the oil and

water for an axial penetration part.

Servo motor series Protection HC-KF・HC-MF HA-LF・HA-FF

IP44

HC-AQ・HC-KFS・HC-MFS IP55 HA-LH JP44

Servomotor

Oil or water

Height above oil level

h

Lip V - ring

ServomotorGear

(b) When the gearbox is mounted horizontally, the oil level in the gearbox should always be lowerthan the oil seal lip on the servo motor shaft. If it is higher than the seal lip, oil will enter the servomotor, leading to a fault. Also, provide a breathing hole in the gearbox to hold the internal pressure low. The HC-MF series servomotor is not equipped with a V-ring or an oil seal and cannot beused with the gearbox as described above. Oil should be shut off on the gearbox side. The HA-FF series servomotor equipped with an oil seal is available. Please contact Mitsubishi.

Servomotor Height level h

(mm) Servomotor

Height level h (mm)

053, 13 8 72 , 152 20

23 , 33 12 202 ~ 502 25 HA-FF

43, 63 14 13 12

81 20 23 , 43 14

121 ~ 301 25

HC-UF HC-UFS

73 20

52 ~ 152 20 11K2 30

202 ~ 702 25 HA-LH

15K2 , 22K2 40

53 ~ 153 20 30K24 , 37K24 45

HC-SF HC-SFS

203 ~ 353 25 HA-LF

45K24 , 55K24 48 HC-RF

HC-RFS 103 ~ 503 20

4 - 11


(c) When installing the servomotor horizontally, face the power cable and encoder cable downward. When installing the servomotor vertically or obliquely, provide a trap for the cable.

Cable trap

cover

(Incorrect) Capillary phenomenon

Oil/water pool

Servo motor

(d) Do not use the servomotor with its cable socked in oil or water. (Figure on the right)

(e) When the servomotor is to be installed with the shaft end at top, provide measures to

Gear Lubricating oil

Servomotor

prevent oil from entering the servomotor from the gearbox, etc.

(7) Cooling fan

The HA-LH and HA-LF servomotors have a cooling fan. Leave the following distance between the servomotor’s suction face and the wall.

Cooling fan Wind

L or longer

Servomotor

Servomotor series Distance L

HA-LH 50 mm HA-LH 150 mm

4 - 12


(8) Cable stress a. Please fully consider the clamp method of a cable and crookedness stress and cable prudence

stress do not join a cable connection part.

b. Please an impossible stress does not join a cable for the use which a servo motor moves. When

a servo motor moves, a cable crookedness part should become within the limits of the detection

machine cable of an option -- wiring of a detection machine cable and a servo motor is

contained by cable raise in basic wages. Please fix the detection machine cable of servo motor

attachment, and a power supply cable.

c. The crookedness life of a detection machine cable is shown in the following figure. Please see a

margin somewhat from this in fact. When you attach in a machine which a servo motor moves,

please enlarge a crookedness radius as much as possible.

1X107

5X1071X108

5X106

1X106

5X105

1X105

5X104

1X104

5X103

1X103

4 7 10 20 40 70 100 200

a

b

Notes . This graph is a calculation value. It is not a guarantee value. Please see a margin somewhat from this in fact.

4 - 13


4.3.3 Wiring system and Power-on sequence (1) The main circuit wiring system and a power-on procedure

(a) The following figure show the wiring of a power supply of servo Amplifier. The main circuit power supply (3 phase,

200 VAC(L1, L2, L3), single phase 230VAC(L1, L2)) connect with the electromagnetic contactor. Configure up

an external sequence to switch off the magnetic contactor as soon as an alarm occurs.

(b) Please supply to the control circuit power supply L11, and that L21 is simultaneous with the main circuit power

supply or the point. If the main circuit power supply is not switched on, the warning will be displayed on a display

part, if the main circuit power supply is switched on, warning will disappear and will operate normally.

(c) Servo amplifier can receive a Servo-on signal (SON) in about 1s after the main circuit power up. Therefore, if

SON is turned on simultaneously with power up, a base circuit turns on 3 phase power supply after about 1s, and

further, in about 20ms, completion signal of preparation (RD) is turned on, making servo amplifier ready operate.

(d) If a reset signal (RES) is turned on, it becomes base interception and the servomotor shaft coasts.

(2) The example of connection

A power supply and a main circuit should wire, as shown in the following figure. Please be sure to use a no fuse breaker

(NFB) for the input line of a power supply. When you correspond to UL/C-UL standard, please use the fuse corresponding

to this standard.

RA OFF ON

MCMC

SK

NFB MC

L1

L2

L3

L11

L21

EMG

SON

SG

VDD

COM

ALM RA Alarm

Emergency stop Servo on

3 phase

Note 2

Emergency stop

200-230VAC

Single phase AC230V

Note 1

Servo Amplifier

Note 1. 1-phase 230V power supply may be used with the servo amplifier of MR-J2S-70A or less. Connect the

power supply to L1 and L2 terminals and leave L3 open. 2. Trouble(Alarm) is connected with COM in normal alarm-free condition. When this signal is switched

off, the output of controller should be stopped by the sequence program.

Figure 4.1 Main circuit wiring

4 - 14


(3) Timing chart

20ms 20ms 20ms 10ms 10ms

10ms10ms

10ms

60ms

60ms

SON

(1s) ON

OFF ON

OFF ON

OFF ON

OFF

ON OFF

Basic circuit

Servo on (SON) Reset (RES)

Ready (RD)

Power supply

Notes 1. A 0.8s failure signal outputs at the time of a power supply turn on ( OFF between ALM-SG).

2. The Servo on signal could be ON once power supply was turned on.

3. An alarm signal is turned on when the servo system was normal.

Fig. 4.2 Timing chart of power up

(4) The alarm occurrence timing chart

When an alarm occurs in the servo amplifier, the base circuit is shut off and the servomotor

is coated to a stop. Switch off the main circuit power supply in the external sequence. To

reset the alarm, switch the control circuit power supply off, then on. However, the alarm

cannot be reset unless its cause of occurrence is removed.

Alarm name Alarm code Alarm name Alarm code Memory error 1 ＡＬ12 Motor output ground

fault ＡＬ24

Clock error ＡＬ13 Overvoltage ＡＬ33 Memory error 2 ＡＬ15 Parameter error ＡＬ37 Encoder error 1 ＡＬ16 Overload 1 ＡＬ50 Board error 2 ＡＬ17 Overload 2 ＡＬ51 Encoder error 2 ＡＬ20 Watchdog 88888

4 - 15


ONOFFON

OFF

ONOFFON

OFFON

OFFON

OFF

1s

Brake operation

50ms or more 60ms or moreAlarm occurs.

Remove cause of trouble.

Brake operation

Power off Power on

ValidInvalid

Main circuitcontrol circuitpower supplyBase circuit

Dynamic brake

Servo-on(SON)

Reset(RES)

Ready(RD)Trouble(ALM)

Fig. 4.3 Alarm occurrence timing chart

(a) Overcurrent, overload 1 or overload 2 If operation is repeated by switching control circuit power off, then on to reset the overcurrent (AL.32), overload 1 (AL.50) or overload 2 (AL.51) alarm after its occurrence, without removing its cause, the servo amplifier and servomotor may become faulty due to temperature rise. Securely remove the cause of the alarm and also allow about 30 minutes for cooling before resuming operation.

(b) Regenerative alarm If operation is repeated by switching control circuit power off, then on to reset the regenerative (AL.30) alarm after its occurrence, the external regenerative brake resistor will generate heat, resulting in an accident.

(c) Instantaneous power failure Undervoltage (AL.10) occurs if power is restored after a 60ms or longer power failure of the control power supply or after a drop of the bus voltage to or below 200VDC. If the power failurepersists further, the control power switches off. When the power failure is reset in this state, thealarm is reset and the servomotor will start suddenly if the servo-on signal (SON) is on. To prevent hazard, make up a sequence that will switch off the servo-on signal (SON) if an alarm occurs.

(d) In position control mode (incremental) When the alarm occurs, the home position is lost. When resuming operation after deactivating the alarm, make the home position return.

4 - 16


(5) Common line

The following diagram shows the power supply and its common line.

DC24VCN1ACN1B

CN1ACN1B

DO-1

SG

OPC

PG NG

SG

P15R

LG

TLAVC etc.

SD

OP

MRMRR

SM

DI-1

COMVDD

ALM .etc

LGSD

RDPRDN

SDPSDN

LG

CN3

RA

CN2

SD

MO1MO2

LG

SG

TXD

RXD RS-232C

RS-422

(Note)

Analog input( 10V/max. current)

Servo motor

Ground

SDLG

Servo motor encoder

Isolated15VDC 10%30mA

LA etc.

Analog monitor output

SON, etc.

PP NP

LG

Note: For the open collection pulse train input. Make the following connection for the different line driver pulse train input.

Differential linedriver output35mA max.

LARetc.

Fig. 4.4 Connection of common line

4 - 17


(6) Interface power supply Although DC24V are used as a power supply for digital input-and-output signals, when using the power supply VDD with

built-in amplifier, VIN-VDD is connected externally. When power supply capacity runs short, an external power supply

can be used.

For use of internal power supply For use of external power supply

VDD

COM

24VDC

SGTR

Servo amplifier

R: Approx. 4.7

SON, etc.(Note)For a transistor

Approx. 5mA

V CES 1.0VI CEO 100 A

Switch

COM

SG

Switch

SON, etc.

24VDC200mA or more

Servo amplifier

R: Approx. 4.7

VDD24VDC

Do not connectVDD-COM.

Note: This also applies to the use of the external power supply.

Fig. 4.5 Connection of interface power supply

4 - 18


4.3.4 Standard connection example

(1) Position control mode (1-1) Connection of all input-and-output signals

VDD

RA1 RA2 RA3

18

15

5

14

8

9

16

17

1

11

EMG

SON

RES

PC

TL

LSP

LSN

SD

SG

P15R

LG

10

12

ALM

19 ZSP

6 TLC

14

7

16

17

4

LA

LAR

LB

LBR

LG

OP

P15R

SD

1

6

CN1B

CN3

13 COM

3

TLA

CN1A

4

13

3

SDLG

14

MO1LG

MO2

A

A

COMINP

LZ

CR

PG

NPNG

RD

SG

PP

LZR

SDLG 1

26 8

24 5 21

4 22

7

23 3

25 6

1

20 12 14

35 16

DOG

COM

RLS

STARTCHG

FLS 13 15

11

STOP

COM

2

36

19

DC24V

Positioning module

Ready COM INPS

PGO(24V)PGO(5V)

PGO COMCLEAR

CLEAR COM

PULSE FPULSE FPULSE RPULSE R

PULSE F

PULSE R

(Note 10) 10m(32ft) max.Servo amplifier

CN1A CN1B

Trouble Zero speed

Limiting torque

Encoder A-phase pulse(differential line driver)

Encoder B-phase pulse(differential line driver)

Control common

Encoder Z-phase pulse(open collector)

Plate

Plate

Emergency stop

Servo-on Reset Proportion controlTorque limit selection

Forward rotation stroke end Reverse rotation stroke end

Upper limit setting Analog torque limit ±10V/max. torque

Servo configuration software

Personal computer

Communication cable

Monitor outputMax. 1mA Reading in bothdirections

2m(6.5ft) max.

10k

10k Plate

19918

515

2

10

123

8

13

Plate

2m(6.5ft) max.

PULSE COM

PULSE COM

Fig. 4.6 Connection of position control (I)

4 - 19


(1-2) Connection of the minimum required input-and-output signal In order to operate a motor, below the minimum needs to be connected. Connection of an output signal is

unnecessary.

a) Servo on ------

Since it is a signal for employing the main circuit efficiently, it is required before operation to surely turn

on. If turned on, it will be in a Servo lock state.

b) Forward and reverse rotation stroke end ------

Usually, it connects with limited switch (LS) in a machine end. If turned off, it will not move in the

direction. It moves to an opposite direction. When there is no machine end LS like roll feeder, please

always short-circuit between SG.

c) Forward and reverse pulse train ------

If a pulse train is inputted, a motor will move according to the frequency and the number of pulses. A

Servo lock will be stopped and carried out if there is no input.

d) Reset ------

It is used for release of alarm. Since, as for alarm release, the main circuit power supply OFF can also be

performed, it is not an absolutely required signal. Moreover, if a reset signal is turned on, a Servo lock

will be canceled and it will become a motor free-lancer.

e) Emergence stop ------

Please be sure to connect an emergency stop signal (EMG) with SG with an emergency

stop switch (B point of contact) too hastily at the time of operation.

VDD

18

CN1A

15

5

14

8

9

16

17

EMG

SON

RES

PC

TL

LSP

LSN

SG 10

ALM

19 ZSP

6 TLC

Servo amplifier

CN1B

CN2

CN1B

Servo

motor

Servo on reset

13 COM

3

OPC

COM

PP

SG

NP

CRSG

SD

11

10

20plate

9

3

2

8

Forward pulse train

Forward rotation stroke end

Reverse pulse train

Emergence stop

Reverse rotation stroke end

Encoder cable

<note 1>

<Note 1> This figure is connection of an open collector system. Refer to 4 - 20 pages of the connection of a differential line driver system.

Fig. 4.7 Connection at time of position control (II)

4 - 20


(1-3) Connection of the minimum required input-and-output signal operating by AD75 / A1SD75 a) Servo on b) Forward and reverse rotation stroke end c) Forward and reverse pulse train - - As shown in the following figure, it connects with the

terminal of AD75 / A1SD75. d) Reset e) Clear --- It is used for the counter clearance at the time of a zero return. f) Zero pulse --- It is used as a starting point signal at the time of a zero return. g) Ready -- A Servo on state is outputted to AD75, and it is used as an interchange lock signal. h) Emergence stop --Please be sure to connect an emergency stop signal (EMG) with SG

with an emergency stop switch (B point of contact) too hastily at the time of operation.

VDD

18

15

5

14

8

9

16

17

EMG

SON

RES

PC

TL

LSP

LSN

SG 10

ALM

19 ZSP

6 TLC

Servo amplifier

CN1B

CN2

CN1B

Servo

motor

Servo on Reset

Reverse Rotation strike end

13 COM

3

Encoder Cable

COM

INP

LZ

CR

PG

NP

NG

19

9

18

5

15

2

10

12

3

RD

8

SG

PP

LZR

SD

LGplate

CN1A

13

1

26 8

24 5 21

4 22

READY

COM

INPS

7

CLEAR 23 3

25 6

1

20 2

PGO(24V) PGO(5V)

PGO COM CLEAR COM PULSE F- PULSE F+ PULSE R- PULSE R+

PULSE F PULSE R

19

Position module

Emergency stop

Forward Rotation strike end

AD75P ｡ ( A1SD75P ｡ ) 10 M or less

※The connection details about AD75/AISD75 should refer to the description of AD75/AISD75.

Fig. 4.8 Connection of position control (III).

4 - 21


(1-4) Connection of the minimum required input-and-output signal by operating in FX-10GM a) Servo on b) Forward and reverse rotation stroke end c) Forward and reverse pulse train --- As shown in the following figure, it connects with the

terminal of FX-10GM. d) Reset c) Clear --- It is used for the counter clearance at the time of a zero return. d) Zero pulse --- It is used as a starting point signal at the time of a zero return.

VDD

18

15

5

14

8

9

16

17

EMG

SON

RES

PC

TL

LSP

LSN

SG 10

ALM

19 ZSP

6 TLC

Servo amplifier

CN1B

CN2

CN1B

Servo motor

Servo on Reset

Forward rotation strike end

Reverse rotation strike end

13 COM

3

Encoder cable

INP

RD

CN1A

2 (

COM

P15R

OP

LG

OPC

COM

PP

SG

NP

CR

SG

SD

18

19

9

4

14

1

11

9

3

10

2

8

20plate

COM2 SVRDY COM2

COM4 PG0 24 + VC FP

COM5 RP CLR COM3

12

1

2

14

13

7 ,178 ,186

9 ,1916

3

4

11

5

15

SVEND

FPO

RPO

FX-10GM Position module

M or less

Emergency stop

g) Ready --- A Servo on is outputted to FX-10GM, and it is used as an interchange lock signal.

h) Emergence stop -- Please be sure to connect an emergency stop signal (EMG) with SG with an emergency stop switch (B point of contact) too hastily at the time of operation.

* The connection details about FX-10GM should

refer to the description of FX-10GM.

Fig. 4.9 Connection of position control (IV)

4 - 22

4. MELSERVO – J2S PERFORMANCE AND FUNCTIONS

[ Supplementary explanation ] 1. The kind of pulse train input As for an instruction pulse, it is common to forward or reverse pulse train by the open collector system or the differential system, and when it is FX-10GM, FX-20GM, and AD75 P/A1SD75P, it is equivalent to this. The following pulse train can also respond with MR-J2-Super series amplifier to set the command pulse train form in parameter No. 21.

(1) Input pulse waveform selection

Pulse train form Forward rotation command

Reverse rotation command

Pr. 21 setting Remarks

Forward rotation pulse train Reverse rotation pulse train

0 0 1 0

AD71 (A phase)/A1SD71 FX-20GM/10GM(Default setting)

Pulse train + sign

0 0 1 1

AD71 (B phase)/A1SD71(Default setting) FX-20GM/10GM

A-phase pulse train B-phase pulse train

0 0 1 2

Forward rotation pulse train Reverse rotation pulse train

(Default setting) 0 0 0 0

AD75(A phase), A1SD75(A phase) (Default setting)

Pulse train + sign

0 0 0 1

AD75(B phase), A1SD75(B phase)

A-phase pulse train B-phase pulse train

0 0 0 2

PP

NP

Neg

ativ

e lo

gic

PP

NP L H

PP

NP

PP

Posi

tive

logi

c

NP

PP

NP H L

(Note) Arrow or in the table indicates the timing of importanting a pulse train.

PP

NP

(2) The kind of hardware Selection of the next composition can be performed according to the hardware of command unit.

(a) Open collector system (b) Differential line drive system

1.2K Ω

SG

SD

Servo amplifier

VDD

PP

NP

OPC

1.2K Ω

PP

NP

Servo amplifier

P G

N G

SD

2. Torque limit

Whenever it sets up parameter No.28 (internal torque 1), the maximum torque is restricted during operation.

4-23


(2) Speed control mode (2-1) Connection of all input-and-output signal.

RA1 RA2 RA3

1810

SP1SG

CN1A

155

14

89

1617

1

11

EMGSONRES

ST1ST2LSPLSN

SD

SGP15R

LG

10

2

ALM

19 ZSP

6 TLC

155

14

716

17

4

LZLZRLALARLBLBRLGOPP15RSD

1

6

CN3

13

8

7SP2

VC

12TLA

19

18 SA

RD

RA5 RA4

CN1A

3 VDD

COM

9 COM

4

13

3

SDLG

14

MO1LGMO2

CN3

A

A

Speed selection 1

Emergency stopServo-on Reset

Forward rotation start Reverse rotation start

Forward rotation stroke end Reverse rotation stroke end

Speed selection 2

10m(32ft) max.

Upper limit setting

(Note 10) Analog torque limit 10V/max. torque

Upper limit setting

Analog speed command 10V/rated speed

2m(6.5ft) max.

PlatePlate


Personal computer

CN1B

Trouble Zero speed

Limiting torque

Speed reached

Ready

Control commonEncoder Z-phase pulse(open collector)

Encoder Z-phase pulse(differential line driver)

Encoder A-phase pulse(differential line driver)

Encoder B-phase pulse(differential line driver)

PlateCommunication cable 2m(6.5ft) max.

Monitor outputMax. 1mA Reading inboth directions

10k

10k

Servo amplifier

CN1B

(note1) This figure is connection at the time of 0 - +10V instructions.

Fig. 4.10 Connection of speed control (I).

4-24


Connection of the minimum required input-and-output signal In order to operate a motor, below is the minimum signal that needs to be connected. Connection of an output signal is unnecessary. a) Servo on ---- Since it is a signal for employing the main circuit efficiently, it is required

before operation to surely turn on. If turned on, it will be in a Servo lock state. b) Speed selection ---- It chooses whether speed commands are made into a parameter setting

value or an external analog setting value. The following figure is the case where it is based on external analog speed instructions.

c) Forward and reverse starting ---- It is used as a starting signal. d) Reset ------ It is used for release of alarm. Since, as for alarm release, the main circuit

power supply OFF can also be performed, it is not an absolutely required signal. Moreover, if a reset signal is turned on, a Servo lock will be canceled and it will become a motor free-lancer.

e) Emergence stop ------ Please be sure to connect an emergency stop signal (EMG) with SG with an emergency stop switch (B point of contact) too hastily at the time of operation.

Encoder cable

30m or less

2m or less

10m or less

Personal Computer Servo configuration

Software

18

10

SP1

SG

CN1A

15

5

14

8

9

16

17

Plate

1

11

EMG

SON

RES

ST1

ST2

LSP

LSN

SD

SG

P15R

LG

10

2

ALM

19 ZSP

6 TLC

Servo amplifier

CN1B

CN2

CN3

Speed selection 1

13

CN1B

Servo Motor

+

8

7SP2

VC

12TLA

Analog speed command +10 V/Max. torque

3 VDD

COM

Upper limit setting

Communication cable

Emergency stop Servo on Reset Speed selection 2

Forward rotation start Reverse rotation start

<Note１>

<Note 1>This figure is connection at the time of 0 - +10V commands.

4-25


Fig. 4.11 Connection at time of speed control ( II )

[Supplementary explanation] Composition of a speed command circuit (1) Speed selection (SP1, SP2)

Motor speed is decided by the setting value of a parameter (SC1, SC2, SC3), or the analog value from the outside, and chooses either by the change of a speed setting selection signal.

Speed command SP1 SP2

Parameter Low (SC1) ON OFF

Middle (SC2) OFF ON

Setting speed High (SC3) ON ON

External speed command (VC) OFF OFF

(2) Starting signal (ST1, ST2) Forward and reverse starting signal (ST1, ST2) perform starting and a stop of a motor. If ST1 and ST2 are both turned off or turned on, a slowdown and the stop of are done and it will be in a Servo lock state. When performing a speed setup on external analog voltage, the relation between the motor rotation direction, and voltage polarity and a starting signal becomes as follows.

Polarity of analog voltage (VC) Forward rotation start ST1 ON

Reverse rotation start ST2 ON

+ Forward rotation Reverse rotation

- Reverse rotation Forward rotation

(3) The example of external wiring The composition of the speed command circuit by external analog voltage is shown. When forward and reverse operation of the polarity of analog voltage are as following:

Servo amplifier

Fig. 4.12 Composition of speed command circuit I

ST1 8

ST2 9

CN1

SG 10

P15R 11

VC 2

LG 1

SD

1KΩ

2KΩ

Forward rotation start

Speed comman

Reverse rotation start

(4) Torque Limit By setting parameter No. 28 (internal torque limit 1), torque is always limited to the maximum value during operation.

4-26


(3) Torque control mode

Connection of all input-and-output signals

RA1

RA2

RA3

1810

SP1SG

15514

9810

1

11

EMGSONRES

RS1RS2SG

SD

P15R

LG12

ALM

19 ZSP

6 VLC

155

14

716

17

4

LZLZRLALARLBLBRLGOP

P15RSD

1

6

CN1B

CN3

13

8

7SP2

TC

2VLA

19 RD RA4

CN1A

3 VDD

COM

9 COM

4

13

3

SDLG

14

MO1LGMO2

CN3A

A

Speed selection 1

Servo amplifier

CN1A

CN1B

10m(32ft) max.

Plate

( Emergency stop Servo-on Reset

Forward rotation startReverse rotation start

Speed selection 2

Upper limit setting

Analog speed limit 0 to 10V/ rated speed

Upper limit setting

Analog torque command 8V/ max. torque


Personalcomputer

Communication cable 2m(6.5ft) max.

Plate

Plate

Monitor output Max. 1mA Reading in bothdirections

10k

10k

2m(6.5ft) max.

Control common Encoder Z-phase pulse(open collector)

Encoder Z-phase pulse(differential line driver) Encoder A-phase pulse(differential line driver) Encoder B-phase pulse(differential line driver)

Trouble Zero speed Limiting torque

Ready

<Note 1>This figure is connection at the time of 0 - +8V com

Fig. 4.13 Connection of torque control

4-27


[Supplementary explanation] (1) Composition of the torque control circuit

(a) Torque command and generated torque

A relationship between the applied voltage of the analog torque command (TC) and the torque generated by the servo motor is shown below. The maximum torque is generated at 8V. Note that the torque generated at 8V input can be changed with parameter No. 26.

Generated torque limit values will vary about 5% relative to the voltage depending on products. Also the generated torque may vary if the voltage is low ( 0.05 to 0.05V) and the actual speed isclose to the limit value. In such a case, increase the speed limit value.

Torque limit and torque control Since the torque that a motor generates is proportional to current, if the current of AC servomotor is

controlled, the torque that a motor generates is controllable free. Usually, although AC servo motor (synchronized type) has a little more than 300% of the maximum

torque, while controlling a position and speed, it calls it "torque limited" to limit so that torque may not occur beyond arbitrary values.

On the other hand, the torque control that is controlled so that the generating torque of motor keeps it constant to the value always exists.

Torque limited is used for protection of a slowdown machine, limited of the power at the time of forcing operation.

A torque control rolls round, and it is used, when setting always constant the power (tension) of joining material, even if speed changes. It depends for speed on generating torque and load torque.

The following table indicates the torque generation directions determined by the forward rotation selection (RS1) and reverse rotation selection (RS2) when the analog torque command (TC) is used.

(Note) External input signals Rotation direction Torque control command (TC)

RS2 RS1 Polarity 0V Polarity

0 0 Torque is not generated. Torque is not generated.

0 1 CCW (reverse rotation in driving mode/forward rotation in regenerative mode)

CW (forward rotation in driving mode/reverse rotation in regenerative mode)

1 0 CW (forward rotation in driving mode/reverse rotation in regenerative mode)

CCW (reverse rotation in driving mode/forward rotation in regenerative mode)

1 1 Torque is not generated.

Torque is not generated.

Torque is not generated.

Note. 0: RS1/RS2-SG off (open) 1: RS1/RS2-SG on (short)

Generally, make connection as shown below:

RS1RS2SGTCLGSD

8 to 8V

Servo amplifier

(b) Analog torque command offset Using parameter No. 30, the offset voltage of 999 to 999mV can be added to the TC applied voltage as shown below.

0 8( 8)

Max. torque

Gen

erat

ed to

rque

TC applied voltage [V]

Parameter No.30 offset range 999 to 999mV

4-28


(2) Torque limit

By setting parameter No. 28 (internal torque limit 1), torque is always limited to the maximum value during operation. A relationship between limit value and servo motor-generated torque is as in (5) in section 3.4.1. Note that the analog torque limit (TLA) is unavailable.

(3) Speed limit (a) Speed limit value and speed

The speed is limited to the values set in parameters No. 8 to 10, 72 to 75 (internal speed limits 1 to 7) or the value set in the applied voltage of the analog speed limit (VLA). A relationship between the analog speed limit (VLA) applied voltage and the servo motor speed is shown below. When the motor speed reaches the speed limit value, torque control may become unstable. Make the set value more than 100r/m greater than the desired speed limit value.

100 10

Rated speed

Speed [r/min] CCW direction

CW direction VLA applied voltage [V]

Forward rotation (CCW)

Reverse rotation (CW)Rated speed

(b) The following table indicates the limit direction according to forward rotation selection (RS1) and reverse

rotation selection (RS2) combination: (Note) External input signals Speed limit direction

Analog speed limit (VLA) RS1 RS2 Polarity Polarity

Internal speed commands

1 0 CCW CW CCW 0 1 CW CCW CW

Note.0: RS1/RS2-SG off (open) 1: RS1/RS2-SG on (short)

Generally, make connection as shown below: Generally, make connection as shown below:

SP1SP2SG

P15RVCLGSD

2k2k

Servo amplifier

Japan resistorRRS10 or equivalent

4-29


Speed selection 1 (SP1), speed selection 2 (SP2) and the speed selection 3 (SP3), and speed limit value Choose any of the speed settings made by the internal speed limits 1 to 7 using speed selection 1(SP1), speed selection 2(SP2) and speed selection 3(SP3) or the speed setting made by the speed limit command (VLA), as indicated below.

(Note) Input signals Setting of parameter

No. 43 to 48 SP3 SP2 SP1 Speed limit value

0 0 Analog speed command (VLA) 0 1 Internal speed command 1 (parameter No. 8) 1 0 Internal speed command 2 (parameter No. 9)

When speed selection (SP3) is not used (initial status)

1 1 Internal speed command 3 (parameter No. 10) 0 0 0 Analog speed command (VLA) 0 0 1 Internal speed command 1 (parameter No. 8) 0 1 0 Internal speed command 2 (parameter No. 9) 0 1 1 Internal speed command 3 (parameter No. 10) 1 0 0 Internal speed command 4 (parameter No. 72) 1 0 1 Internal speed command 5 (parameter No. 73) 1 1 0 Internal speed command 6 (parameter No. 74)

When speed selection (SP3) is made valid

1 1 1 Internal speed command 7 (parameter No. 75)

Table 4.3 SP1, SP2 and SP3, and speed instruction value

Note.0: SP1/SP2/SP3-SG off (open) 1: SP1/SP2/SP3-SG on (short)

When the internal speed limits 1 to 7 are used to command the speed, the speed does not vary with the ambient temperature.

(c) Limiting speed (VLC) VLC-SG are connected when the servo motor speed reaches the limit speed set to any of the internal speed limits 1 to 3 or analog speed limit.

4-30


4.3.5 Power supply turned on

(1) Checking Please check again the installation and wiring which were performed by 4.3.2 & 4.3.3 before the power supply was turned on.

(1-1) Installation Check that the installation has been carried out as described in section 4.3.2. During the check, pay special attention to the effects of heat generated in the panel on the ambient temperature of the servo amplifier, to contact between the cable and heat generating devices, and to oil and water proofing of the servomotor. (1-2) Wiring Check that the wiring has been carried out as described in Section 4.3.3. During the check, pay special attention to the main circuit connections. The following points are the major check points. Also refer to the instruction manuals and technical literature for the relevant equipment for further details and specific check points.

(2) Wiring Please carry out the next check before operating.

a) Connect the right power supply to the power supply

input terminal (L1, L2, L3) of Servo amplifier. Servo amplifier

Servo amplifier

b) The power supply wires (L1, L2, and L3) must not be

connected to the output terminals for the motor (U, V, W).

The servomotor power supply terminals (U, V, W) of the

servo amplifier match in phase with the power input

terminals (U, V, W) of servomotor.

c) Don't short-circuit the power supply terminal (U-V-W)

for servomotors and power supply input terminal (L1, L2,

L3) of Servo amplifier.

d) Ground the Servo amplifier servomotor certainly.

e) When you use a regeneration option, remove the lead

between D-P of a control circuit terminal stand. Moreover,

use the twist line. Servo amplifier

C O M (24VDC)

Control output signal RA

f) When you use a stroke and a limit switch, between LSP-

SG and between LSN-SG should be a short circuit in the

operation state.

4-31


g) The voltage which surpasses DC24V doesn't join the

pin of connector CN1A & CN1B.

h)Don't mistake direction of the diode for surge absorption attached in DC relay for a control output. It breaks down, a signal is no longer outputted, and operation of protection circuits, such as an emergency stop, may become impossible.

Servo amplifier

SD

SG

i) Don't short-circuit SD and SG of connector CN1A & CN1B. j) The wiring cables are free from excessive force

(3) Environment Signal cables and power cables are not shorted by wire off cuts, metallic dust or the like.

(4) Machine a) The screws in the servo motor installation part and shaft-to-machine connection are tight. b) The servomotor and the machine connected with the servomotor can be operated.

4-32


(5) Power on After thoroughly checking the checking point, a power supply will be switched on in the following procedure.

a) Make sure the SON signal is OFF. ↓

b) Turn ON the power supply circuit breaker. ↓

c) Press the operating preparation button to Turn on the servo power before or simultaneously with the power supply to the command unit such as positioning control unit.

turn the input side MC ON ↓

d) Turn ON the power to the command unit. ↓

e)

f)

g)

h)

<ReferencRefer to th

Set parameters. Section 4.3.8
↓
.

Check the I/O signals. Section 4.3
↓
Turn the SON signals ON. * Make sure that the speed and position commands from the command unit are “0”

before turning this signal ON. ↓

Manual operation. Section 4.3.9

e> e Section 4.3.14 for the operation procedure in each operation mode.

4-33


4.3.6 Display and operation (1) Display Use the display (5-digit, 7-segment LED) on the front panel of the servo amplifier for status display, parameter setting, etc. Set the parameters before operation, diagnose an alarm, confirm external sequences, and/or confirm the operation status. Press the "MODE" "UP" or "DOWN" button once to move to the next screen. To refer to or set the expansion parameters, make them valid with parameter No. 19 (parameter write disable).

Cumulative feedbackpulses [pulse]

Motor speed[r/min]

Droop pulses [pulse]

Cumulative commandpulses [pulse]

Command pulsefrequency [kpps]

Speed command voltageSpeed limit voltage[mV]

Torque limit voltageTorque command voltage

Regenerative loadratio [%]

Effective load ratio[%]

Peak load ratio[%]

Within one-revolutionposition low [pulse]

ABS counter[rev]

Load inertia momentratio [times]

Sequence

External I/Osignal display

Output signalforced output

Test operation Jog feed

Test operation Positioning operation

Test operation Motor-less operation

Software version L

Software version H

Automatic VC offset

Current alarm

Last alarm

Second alarm in past

Third alarm in past

Fourth alarm in past

Fifth alarm in past

Sixth alarm in past

Parameter error No.

Parameter No. 0

Parameter No. 1

Parameter No. 18

Parameter No. 19

Parameter No. 20

Parameter No. 21

Parameter No. 48

Parameter No. 49

(Note)

Note: The initial status display at power-on depends on the control mode.Position control mode: Cumulative feedback pulses(C), Speed control mode: Motor speed(r),Torque control mode: Torque command voltage(U)Also, parameter No. 18 can be used to change the initial indication of the status display at power-on.

MODEbutton

DOWN

UP

Status display Diagnosis Basicparameters

Expansionparameters 1Alarm Expansion

parameters 2

Parameter No. 50

Parameter No. 51

Parameter No. 83

Parameter No. 84

Instantaneous torque[%]

Within one-revolutionposition, high [100 pulses]

Bus voltage [V]

Test operationMachine analyzer operation

Motor series ID

Motor type ID

Encoder ID

[mV]

5-Digit, 7-Segment LED.

MODE UP DOWN SET

Used to set date Used to change the displayor data in each mode Used to change the mode

Fig. 4.20 Display changes figure

4-34


(2) Status display list

The following table lists the servo statuses that may be shown: Refer to Appendix 2 for the measurement point.

Name Symbol Unit Description Display range

Cumulative feedback pulses

C pulse Feedback pulses from the servo motor encoder are counted and displayed. The value in excess of 99999 is counted, bus since the servo amplifier display is five digits, it shows the lower five digits of the actual value. Press the "SET" button to reset the display value to zero. Reverse rotation is indicated by the lit decimal points in the upper four digits.

99999 to

99999

Servo motor speed r r/min The servo motor speed is displayed. The value rounded off is displayed in 0.1r/min.

5400 to

5400 Droop pulses E pulse The number of droop pulses in the deviation counter is displayed. When the

servo motor is rotating in the reverse direction, the decimal points in the upper four digits are lit. Since the servo amplifier display is five digits, it shows the lower five digits of the actual value. The number of pulses displayed is not yet multiplied by the electronic gear.

99999 to

99999

Cumulative command pulses

P pulse The position command input pulses are counted and displayed. As the value displayed is not yet multiplied by the electronic gear (CMX/CDV), it may not match the indication of the cumulative feedback pulses. The value in excess of 99999 is counted, but since the servo amplifier display is five digits, it shows the lower five digits of the actual value. Press the "SET" button to reset the display value to zero. When the servo motor is rotating in the reverse direction, the decimal points in the upper four digits are lit.

99999 to

99999

Command pulse frequency

n kpps The frequency of the position command input pulses is displayed. The value displayed is not multiplied by the electronic gear (CMX/CDV).

800 to

800 Analog speed command voltage Analog speed limit voltage

F V (1) Torque control mode Analog speed limit (VLA) voltage is displayed.

(2) Speed control mode Analog speed command (VC) voltage is displayed.

10.00 to

10.00

U V (1) Position control mode, speed control mode Analog torque limit (TLA) voltage is displayed.

0 to 10V

Analog torque command voltage Analog torque limit voltage (2) Torque control mode

Analog torque command (TLA) voltage is displayed. 10

to 10V

Regenerative load ratio L % The ratio of regenerative power to permissible regenerative power is displayed in %.

0 to

100 Effective load ratio J % The continuous effective load torque is displayed.

The effective value is displayed relative to the rated torque of 100%. 0 to

300 Peak load ratio b % The maximum torque generated during acceleration/deceleration, etc.

The highest value in the past 15 seconds is displayed relative to the rated torque of 100%.

0 to

400 Instantaneous torque T % Torque that occurred instantaneously is displayed.

The value of the torque that occurred is displayed in real time relative to the rate torque of 100%.

0 to

400 Within one-revolution position low

Cy1 pulse Position within one revolution is displayed in encoder pulses. The value returns to 0 when it exceeds the maximum number of pulses. The value is incremented in the CCW direction of rotation.

0 to

99999

4-35


Name Symbol Unit Description Display range

Within one-revolution position high

Cy2 100 pulse

The within one-revolution position is displayed in 100 pulse increments of the encoder. The value returns to 0 when it exceeds the maximum number of pulses. The value is incremented in the CCW direction of rotation.

0 to

1310

ABS counter LS rev Travel value from the home position in the absolute position detection systems is displayed in terms of the absolute position detectors counter value.

32768 to

32767 Load inertia moment ratio dC 0.1

Times The estimated ratio of the load inertia moment to the servo motor shaft inertia moment is displayed.

0.0 to

300.0 Bus voltage Pn V The voltage (across P-N) of the main circuit converter is displayed. 0

to 450

(3) Changing the status display screen

The status display item of the servo amplifier display shown at power-on can be changed by changing the parameter No. 18 settings. The item displayed in the initial status changes with the control mode as follows:

Control mode Status display at Power-on Position Cumulative feedback pulse

Position/speed Cumulative feedback pulse/ Servomotor speed Speed Servomotor speed

Speed/ torque Servomotor speed/ Analog torque command voltage Torque Analog torque command voltage

Torque/position Analog torque command voltage /Cumulative feedback pulse

4-36


(4) Diagnostic mode

Name Display Description

Not ready. Indicates that the servo amplifier is being initialized or an alarm has occurred.

Sequence

Ready. Indicates that the servo was switched on after completion of initialization and the servo amplifier is ready to operate.

External I/O signal display

Refer to section 6.6. Indicates the ON-OFF states of the external I/O signals. The upper segments correspond to the input signals and the lower segments to the output signals.

Lit: ON Extinguished: OFF

The I/O signals can be changed using parameters No. 43 to 49.

Output signal (DO) forced output

The digital output signal can be forced on/off. For more information, refer to section 6.7.

Jog feed

Jog operation can be performed when there is no command from the external command device. For details, refer to section 6.8.2.

Positioning operation

The servo configuration software (MRZJW3-SETUP121E) is required for positioning operation. This operation cannot be performed from the operation section of the servo amplifier. Positioning operation can be performed once when there is no command from the external command device.

Motorless operation

Without connection of the servo motor, the servo amplifier provides output signals and displays the status as if the servo motor is running actually in response to the external input signal. For details, refer to section 6.8.4.

Test operation mode

Machine analyzer operation

Merely connecting the servo amplifier allows the resonance point of the mechanical system to be measured. The servo configuration software (MRZJW3-SETUP121E or later) is required for machine analyzer operation.

Software version Low

Indicates the version of the software.

Software version High

Indicates the system number of the software.

Automatic VC offset

If offset voltages in the analog circuits inside and outside the servo amplifier cause the servo motor to rotate slowly at the analog speed command (VC) or analog speed limit (VLA) of 0V, this function automatically makes zero-adjustment of offset voltages. When using this function, make it valid in the following procedure. Making it valid causes the parameter No. 29 value to be the automatically adjusted offset voltage. 1) Press "SET" once. 2) Set the number in the first digit to 1 with "UP"/"DOWN". 3) Press "SET".

You cannot use this function if the input voltage of VC or VLA is 0.4V or more.

4-37



Motor series

Press the "SET" button to show the motor series ID of the servo motor currently connected. For indication details, refer to the optional MELSERVO Servo Motor Instruction Manual.

Motor type

Press the "SET" button to show the motor type ID of the servo motor currently connected. For indication details, refer to the optional MELSERVO Servo Motor Instruction Manual.

Encoder

Press the "SET" button to show the encoder ID of the servo motor currently connected. For indication details, refer to the optional MELSERVO Servo Motor Instruction Manual.

4-38


(5) Alarm mode

The current alarm, past alarm history and parameter error are displayed. The lower 2 digits on the display indicate the alarm number that has occurred or the parameter number in error. Display examples are shown below.


Indicates no occurrence of an alarm.

Current alarm

Indicates the occurrence of overvoltage (AL.33). Flickers at occurrence of the alarm.

Indicates that the last alarm is overload 1 (AL.50).

Indicates that the second alarm in the past is overvoltage (AL.33).

Indicates that the third alarm in the past is undervoltage (AL.10).

Indicates that the fourth alarm in the past is overspeed (AL.31).

Indicates that there is no fifth alarm in the past.

Alarm history

Indicates that there is no sixth alarm in the past.

Indicates no occurrence of parameter error (AL.37).

Parameter error

Indicates that the data of parameter No. 1 is faulty.

Functions at occurrence of an alarm (a) Any mode screen displays the current alarm. (b) The other screen is visible during occurrence of an alarm. At this time, the decimal point in the fourth digit flickers. (c) For any alarm, remove its cause and clear it in any of the following methods (for clearable alarms, refer to Section

10.2.1): (a) Switch power OFF, then ON. (b) Press the "SET" button on the current alarm screen. (c) Turn on the alarm reset (RES) signal.

(d) Use parameter No. 16 to clear the alarm history. (e) Pressing "SET" on the alarm history display screen for 2s or longer shows the following detailed information

display screen. Note that this is provided for maintenance by the manufacturer.

(f) Press "UP" or "DOWN" to move to the next history.

4-39


(6) Operation of a display part

The LED display and push button (the following figure) of the front of amplifier perform a display and a setup of a parameter. An operation procedure is explained below.

(6-1) Power ON

(a) Switched Off the Servo On (SON) signal.

(b) It displays the C (return pulse accumulation) to a display part to switch on a power supply (NFB).

(in the case of position control mode)

(6-2) SON signal ON

5-digit, 7-segment LED MODE UP DOWN SET

Information: The initial display while the power supply on changed by control mode. In the case of position control mode : C (return pulse accumulation) In the case of speed control mode : r (motor rotation speed) In the case of torque-control mode: U (torque instruction voltage) Moreover, the initial display at the time of a power supply ON can be changed by parameter No.18.

If a Servo ON signal (SON) is turned on, it will be in the state which can be operated and a servo motor axis will lock. (Servo lock state) When not carrying out a Servo lock, it is not in the Servo lock state. Please check an external sequence by diagnostic display. The check method as following:

MODE Pushed once

SON signal ON

It will become this display if a Sir bone is carried out.

Power ON

4-40


(6-3) State display The initial display of a state display changes with control modes. In the case of position control mode, if the state where it is displayed first pushes <DOWN> by "return pulse accumulation", the contents of a display will shift downward from on Fig. 4.20. <UP> If a switch is pushed, it will return upwards. It can choose in parameter No. 18 to give the first indication arbitrary contents.

(6-4) Diagnostic display If the <MODE> button is pushed from state display mode, it will move to diagnostic display mode. <UP> It unites with contents to see with the <DOWN> button.

(6-5) The display of alarm present alarm (error excessive)

↓ * A display blinks.

( UP )

↓

Alarm of once ago (over-voltage)

↓

( UP )

↓

Alarm of twice ago (With no alarm gen-

erating)

Alarm was occurred (over-speed during running) (Note) Although other displays can be seen also in al

arm generating, the decimal point of the 4th figure blinks by the case in every display mode.

Under example alarm generating When the rate of

effective load is seen the decimal point of the 4th

figure blinks.

A L 5 2

A 0 3 3

A 1 - -

A L 3 1

J 1 2 0

If <MODE> button is again pushed from diagnostic display mode, the pre-sentalarm code will be displayed to see the contents of alarm history. When thepresent alarm is not generated, it displays

If <UP>button is pushed, the alarm code

of 1 time ago is displayed, and a his-

t ory can be seen before 6 times. As fo

r an alarm history, after a power suppl

y OFF is saved.

(6-6) During operation at the alarm

generating time.

If alarm was happened during operation,

once alarm will be displayed from

every display screen.

A L - -

4-41


4.3.7 PARAMETER

Digital Servo carries out a digital setup of gain adjustment, offset adjustment of an analog input-and-output signal, etc. which were performed by conventional analog Servo with a parameter. Moreover, the change of a function is performed outside selection in the control mode of a position / speed / torque. The parameter table of MR-J2S type Servo amplifier is shown in the following table. (1) Parameter List (The details of the operation method refer to the section 4.3.8)

The sign of the control mode column expresses the parameter used in each mode. ( S : Position control mode , S: Speed control mode , T: Torque control mode)

Table 4.7 Parameter table

No. Symbol Name Control mode Initial value

Unit Setting Range

0 *STY Control mode, regenerative brake option selection P, S, T 0000 0 ~ 0605h

1 *OP1 Function selection 1 P, S, T 0002 0 ~ 1013h

2 ATU Auto tuning P, S 0105 1 ~ 040Fh

3 CMX Electronic gear numerator p 1 1 ~ 65535

4 CDV Electronic gear denominator P 1 1 ~ 65535

5 INP In-position range P 100 pulse 0 ~ 10000

6 PG1 Position loop gain 1 P 35 rad/s 4 ~ 2000

7 PST Position command acceleration/deceleration time constant

P 3 ms 0 ~ 20000

8 SC1 Internal speed command 1 S 100 r/min 0 ~ max speed

Internal speed command１ T 100 r/min 0 ~ max speed


Internal speed command 2 T 500 r/min 0 ~ max speed


Internal speed command 3 T 1000 r/min 0 ~ max speed

11 STA Acceleration time constant S, T 0 ms 0 ~ 20000

12 STB Deceleration time constant S, T 0 ms 0 ~ 20000

13 STC S - pattern acceleration/deceleration time constant

S, T 0 ms 0 ~ 1000

14 TQC Torque command time constant T 0 ms 0 ~ 20000

15 *SNO Station number setting P, S, T 0 station 0 ~ 31

16 *BPS Communication baudrate selection, alarm history clear

P, S, T 0000 0 ~ 1113h

17 MOD Analog monitor output P, S, T 0100 0 ~ 4B4Bh

18 *DMD Status display selection P, S, T 0000 0 ~ 001Fh

19 *BLK Parameter block P, S, T 0000 0 ~ 100Eh

B

as

ic

P

ar

am

et

* : It becomes effective by power supply OFF/ON after parameter setting change.

4-42


The sign of the control mode column expresses the parameter used in each mode. (P: Position control mode, S: Speed control mode , T: Torque control mode)

No. Symbol Name Control mode Initial value Unit Setting Range

20 * OP2 Function selection 2 P, S, T 0000 0 ~ 0111h

21 * OP3 Function selection 3 (Command pulse selection) P 0000 0 ~ 0012h


23 FFC Feed forward gain P 0 % 0 ~ 100

24 ZSP Zero speed P, S, T 50 r/min 0 ~ 10000

25 VCM Analog speed command maximum speed S (Note1) 0 (r/min) 1 ~ 50000

Analog speed limit maximum speed T (Note1) 0 (r/min) 1 ~ 50000

26 TLC Analog torque command maximum output T 100 % 0 ~ 1000

27 *ENR Encoder output pulses P, S, T 4000 pulse 5 ~ 16384

28 TL1 Internal torque limit 1 P, S, T 100 % 0 ~ 100

29 VCO Analog speed command offset S (Note 2) mV -999 ~ 999

Analog speed limit offset T (Note 2) mV -999 ~ 999

30 TLO Analog torque command offset T 0 mV -999 ~999

Analog torque limit offset S 0 mV -999 ~999

31 MO1 Analog monitor ch1 offset P, S, T 0 mV -999 ~999

32 MO2 Analog monitor ch2 offset P, S, T 0 mV -999 ~999

33 MBR Electromagnetic brake sequence output P, S, T 100 ms 0 ~1000

34 GD2 Ratio of load inertia moment to servo motor inertia moment

P, S, T 70 0.1 times 0 ~3000

35 PG2 Position loop gain 2 P 35 rad/s 1 ~ 500

36 VG1 Speed loop gain 1 P,S 177 rad/s 20 ~ 8000

37 VG2 Speed loop gain 2 P,S 817 rad/s 20 ~ 20000

38 VIC Speed integral compensation P,S 48 ms 1 ~ 1000

39 VDC Speed differential compensation P,S 980 0 ~1000

40 For manufacturer setting 0

41 *DIA Input signal automatic ON selection P, S, T 0000 0 ~0111h

42 *DI1 Input signal selection1 P, S, T 0003 0 ~0015h

43 *DI2 Input signal selection2 (CN1B- Pin 5) P, S, T 0111 0 ~0DDDh






49 *DI2 output signal selection 1 P, S, T 0000 0 ~0551h

Ex

pa

ns

io

n

Pa

ra

me

te

rS

1

Note) 1. It is the Servo motor rated rotation speed 2. It changes with Servo amplifier. * : It becomes effective by power supply OFF/ON after parameter setting change.

4-43


The sign of the control mode column expresses the parameter used in each mode. ( P: Position control mode , S: Speed control mode , T, Torque control mode)

No. Symbol Name Control mode Initial Value Unit Setting Range




53 * OP8 Function selection8 P, S, T 0000 0 ~ 0110h

54 * OP9 Function selection9 P, S, T 0000 0 ~ 1101h

55 * OPA Function selection A P 0000 1 ~ 0010h

56 SIC Serial communication time-out selection P, S, T 0 s 1 ~ 60


58 NH1 Machine resonance suppression filter1 P, S, T 0000 0 ~ 030Fh

59 HH2 Machine resonance suppression filter2 P, S, T 0300 0 ~ 030Fh

60 LPF Low pass filter, adaptive vibration suppression P, S, T 0000 0 ~ 1210h

61 GB2B Ratio of load inertia moment to servo motor inertia moment 2

P, S 70 0.1 times 0 ~ 3000

62 PG2B Position control gain 2 change ratio P 100 % 10 ~200

63 VG2B Speed control gain 2 change ratio P, S 100 % 10 ~ 200

64 VICB Speed integral compensation changing ratio P, S 100 % 50 ~ 1000

65 *CDP Gain change selection P, S 0000 0 ~ 0604h

66 CDS Gain change condition (note 3) P, S 10 0 ~ 9999

67 CDT Gain changing time constant P, S 1 ms 0 ~ 100


69 CMX1 Command pulse multiplying factor numerator 2 P 1 0 ~ 65535



72 SC4 Internal speed command 4 S, T 200 r/min 0 ~ max speed




76 Tl1 Internal torque limit 2 P, S, T 100 % 0 ~ 100









E

xp

an

si

on

P

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am

et

er

2

Note) 1. It is the servomotor rated rotation speed.

2. It changes with Servo amplifier.

3. It is based on a setup of parameter No.65.

* : It becomes effective by power supply OFF/ON after parameter setting change.

4-44


(2) Parameter setting chart

Position control mode

Speed control mode

Torque control mode Remarks

The parameter surely set up or checked before operation.

0, 1 0, 1 0, 1

The parameter surely set up according to machine specification and an operation pattern.

3, 4

The parameter set up if needed. 21 8 ~ 13 14

The parameter set up while carrying out machine operation (adjustment).

2 2

The parameter which makes a setting change of the expansion parameter.

19 19 19

(3) The parameter surely set up or checked before operation

If a setup is wrong, a motor will not move, or the parameter explained here becomes alarm. Please be sure to check

before operation, and when you differ from an initial value, change a setup.

(a) No. 0 ( * STY; Servo type)

Used to select the control mode and regenerative brake option.

Note. Application of a regeneration option. With the following table, please select the regeneration option

corresponding to each Servo amplifier, and set up a parameter.

(Note) Regeneration electric power (W)

Built-in

regeneration resistor

MR-RB032 (40Ω)

MR-RB12 (40 Ω)

MR-RB32 (40 Ω)

MR-RB30 (13 Ω)

MR-RB50 (13 Ω)

MR-J2S-10A Nothing 30

MR-J2S-20A 10 30 100

MR-J2S-40A 10 30 100

MR-J2S-60A 10 30 100

MR-J2S-70A 10 30 100 300

MR-J2S-100A 20 30 100 300

MR-J2S-200A 100 300 500

MR-J2S-350A 100 300 500

Servo ampli-fier

Notes . This value is not the permission electric power of resistance.

(b) No. 1 (* OP1; Function selection 1 )

Used to select the input signal filter, Pin CN1B-19 function and absolute position detection system.

4-45


Class No. Symbol Name and function Initial value

Unit Setting range

Control mode

Control mode, regenerative brake option selection Used to select the control mode and regenerative brake option.

Select the control mode.0:Position1:Position and speed2:Speed3:Speed and torque4:Torque5:Torque and position

0 0

Selection of regenerative brake option0:Not used1:FR-RC, FR-BU2:MR-RB0323:MR-RB124:MR-RB325:MR-RB306:MR-RB508:MR-RB319:MR-RB51

POINT

Wrong setting may cause the regenerative brake option to burn. If the regenerative brake option selected is not for use with the servo amplifier, parameter error (AL.37) occurs.

0 *STY

0000 Refer to

Name

and

function

column.

P S T

Bas

ic p

aram

eter

s

1 *OP1 Function selection 1 Used to select the input signal filter, pin CN1B-19 function and absolute position detection system.

Input signal filterIf external input signal causes chattering due to noise, etc., input filter is used to suppress it.0:None1:1.777[ms]2:3.555[ms]3:5.333[ms]

CN1B-pin 19's function selection0:Zero Speed detection signal1:Electromagnetic brake interlock signal

Selection of absolute position detection system(Refer to Chapter 15)0: Used in incremental system1: Used in absolute position detection system

0

0002 Refer to

Name

and

function

column.

P S T

(4)The parameter surely set up according to machine specification and an operation pattern if these parameters are wrong in a setup, the amount of movements of machine maybe out the range under a setting value. Please be sure to set up according to specification.

4-46


(a) No. 3, 4 (CMX, CDV ; Electronic gear) The ratio is set up by making parameter No.4 into a denominator, making parameter No. 3 as a numerator. Since the relation between machine specification and a ratio is indicated in detail in the Section 2.5.1.

Class No. Symbol Name and Function Initial value Unit Setting Range

Control Mode

3

4

CMW

CDV

Electronic gear (command pulse magnification molecule) :

The multiplier over a command pulse input is set up.

Command pulse input CMX position command f1 CDV

f2 =f1 *

1 CMX Note. < <500 is the setting range.

50 CDV

A setup of the number of input pulses per servo motor 1

rotation can be changed by the following formula.

(For example, HC-MFS servomotor : 131072pulse/rev )

CMX 131072 * [pulse/rev] CDV

Electronic gear (Command pulse magnification

denominator):

Used to set the electronic gear denominator value

1

1

1 ~ 65535

1 ~ 65535

P

P

Ba

si

c

Pa

ra

me

te

r

CMX CDV

Caution Wrong setting can lead to unexpected fast rotation, causing injury.

!

(5) The parameter set up if needed

(a) Parameter No. 8, 9 10 (SC1, SC2, SC3; Internal speed command 1, 2, 3) Used to set the internal speed command. It is unnecessary when carrying out an analog setup from the outside.

Class No Symbol Name and Function Initial value

unit Setting range

Control mode

8 SC1 Internal speed command 1. The 1st velocity of internal speed instructions is set up.

100 r/min 0 ↓

S

Internal speed command 1. The 1st velocity of internal speed instructions is set up.

Instant permission

rotation speed

T

9 SC2 Internal speed command 2. The 1st velocity of internal speed instructions is set up.

500 r/min 0 ↓

S


Instant permission

rotation speed T

10

SC3 Internal speed command 3. The 1st velocity of internal speed instructions is set up.

1000 r/min 0 ↓

S


Instant permission

rotation speed T

Basic Param

eter

4-47


(b) Parameter No. 11,12 (STA, STB; Acceleration time constant) Used to set the acceleration time required to reach the rated speed from 0 r/m in response to the analog speed command and internal speed commands 1 to 7. (Contents)

Acceleration time until it reaches rated speed, or slowdown time until it stops from rated speed is set up to speed instructions (exterior and inside 3 speed).

If the preset command speed is lower

than the rated speed, the acceleration/

Deceleration time will be shorter.

time S T B

Parameter No. 12 setting

0 r/min

Rated speed

Speed

S T A Parameter No. 11 setting

Class No

Symbol Name and function Initial value

Unit Setting Range

Control Mode

11

STA Acceleration time constant

Acceleration time until it reaches rated rotation speed from zero speed is set up to analog speed instructions and the internal speed command 1-3.

If the preset command speed is lower

than the rated speed, the acceleration/

Deceleration time will be shorter.

time S T B


0 r/min

Rated speed

Speed

S T A Parameter No. 11 setting

Example:

For the servomotor HC – MFS of 3000r/m rated speed, set 3000 (3S) to increase speed from 0r/m to 1000r/m in 1 second.

0 ms 0 ~ 20000 S, T

12 STB Deceleration time constant

Deceleration time until it reaches zero speed from

rated rotation speed is set up to analog speed

instructions and the internal speed instructions 1-3.

0

Basic Param

eter

4-48


© Parameter No.13 (STC; S-pattern acceleration/deceleration)

Class No Symbol Name and function Initial value

Unit Setting range

Control mode

13 STC S-pattern acceleration/ deceleration time constant:

Used to smooth start/stop of the servo motor

STA : Acceleration time constant (Parameter No.11) STB : deceleration time constant (Parameter No.12) STC : S-pattern acceleration/deceleration time constant (Parameter No.13)

0 ms 0 ~ 1000 S, T

B

as

ic

P

ar

am

et

er

Command speed

0r/min

Speed Servomotor

STA STC Time STC

STBSTC STC

>the range of STC if used to set

Long setting may produce an error in the time of the arc part for the setting of the S-pattern acceleration/deceleration constant. The upper limit value of the actual arc part time is limited by (Example) At setting STA=20000, STB=5000, STC=200 During acceleration: = 100[ms] < 200[ms] During deceleration: = 400[ms] > 200[ms]

STA or STB 2,000,000

2,000,000 STA or STB

2,000,000

2,000,00020000

5000

(d) Parameter No. 14 (TQC; Torque command time constant)

Class No. Symbol Name and function Initial value

Unit Setting range

Control mode

14 TQC Torque command time constant Used to set the constant of a low pass filter in response to the torque command.

Torque command

TQC TQC Time

Afterfiltered

TQC: Torque command time constant

Torque

0 ms 0 to

20000

T

Bas

ic p

aram

eter

s

4-49


(e) Parameter No. 21 (* OP3: Function selection 3 ) Used to select the input from of the pulse train input signal.

Class No Symbol Name and function Initial value

Unit Setting Range

Control Mode

21 * OP3 Function selection 3 (Command pulse selection) : Used to select the input from of the pulse train input signal

Command pulse train input from 0: Forward/reverse rotation pulse train 1: Signed pulse train 2: A/B phase pulse train

Pulse train logic selection 0: Positive Logic 1: Negative logic

0000 0000 H ~

0012 H

P E

xp

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on

P

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er

Pulse train form Waveform of input The input signal of pulse system

Forward rotation Reverse rotation Open collector Differential line drive

Forward rotation pulse train PP - SG PP - PG

Reverse rotation pulse tr in a

(Setting value: 0010) NP - SG NP - NG

Pulse train + sign PP - SG PP - PG


A phase pulse train PP - SG PP - PG

B phase pulse train


Forward rotation pulse train PP - SG PP - PG

Reverse rotation pulse train


Pulse train + sign PP - SG PP - PG


A phase pulse train PP - SG PP - PG

B phase pulse train

(setting value: 0002) NP - SG NP - NG

PP

NP

PP

NP L H

PP

NP

PP

NP

PP

NP H L

PP

NP

Positive logic N

egative logic

0 0

4-50


(6) The parameter set up while operating a machine (adjustment)

(a) Parameter No.2 (* ATU; auto tuning)

Used to set the response level, etc. for execution of auto tuning.

Class No Symbol

Name and function Initial Value

Unit Setting Control mode

2 ATU Auto tuning: Used to set the response level, for execution of auto tuning.

Auto tuning response level setting

* If the machine hunts or generates

large gear sound, decrease the set value.

* To improve performance, e. g. shorten the setting time, increase the set value.

Auto tuning selection

0105 0001H ~

040FH

P, S

Set

value

Response

level

Machine resonance frequency

guideline

1 15Hz 2 20Hz

3 25Hz

4 30Hz

5 35Hz

6 45Hz 7 55Hz 8 70Hz 9 85Hz A 105Hz B 130Hz C 160Hz D 200Hz E 240Hz F

Low response

Middle response

High response

300Hz

Set value Gain adjustment Description 0 Interpolation mode Fixes position control gain (parameter No. 6) 1 Auto tuning mode

1 Ordinary auto tuning.

2 Auto tuning mode 2

Fixes the load inertia moment ratio set in parameter No. 34. Response level setting can be change.

3 Manual mode 1 Simple manual adjustment. 4 Manual mode 2 Manual adjustment of all gain.

B

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0 0

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(7) The parameter which makes a setting change of the extended parameter

(a) Parameter No. 19 (* BLK; Parameter Block) Used to select the reference and write ranges of the parameters. If the parameter block after an adjustment end is applied, incorrect operation prevention can be performed. Since only a basic parameter (No.0-- No. 19) can be written in at the time of factory shipments, a setup is required when an extended parameter needs to be set up.

Class No Symbol Name and function Initial Value

Unit Setting range

Control mode

19 *BLK Used to select the reference and write ranges of the parameters.

The reference range and the write-in range of a parameter are chosen.

0000 0000H ~

000CH .

000EH .

100BH .

100CH .

100EH

P, S, T

Basic Param

eter

Set value Reference Write 0000 No. 0 ~ 19 No. 0 ~ 19 000A No. 19 only No. 19 only 000B No. 0 ~ 49 No. 0 ~ 19 000C No. 0 ~ 49 No. 0 ~ 49 000E No. 0 ~ 84 No. 0 ~ 84 100B No. 0 ~ 19 No. 19 only 100C No. 0 ~ 49 No. 19 only 100E No. 0 ~ 84 No. 19 only

[Reference] Parameter package initialization Doing this work changes all parameters to an initial value. Since it becomes impossible to return to the parameter before operation, it is necessary to carry

out after cautions enough. (1) pr.19 are set as "ABCD." (2) Circled Off/on the power supply. (3) Pr. 182 are set as “0112”. (4) If circled OFF/ON the power supply, package conversion of pr.0-pr.84 (foundations and

extended parameter) will be carried out at the value at the time of shipment (Table 4.7). (5) Pr. 19 are set as “0000”.

4-52


4.3.8 Parameter setting

Initial setting of the parameter value according to the conditions of operation is carried out after a power supply turned on. Since there is a parameter stated by the section 4.3.7, please set up based on design specification.

Please be sure to check about the parameter stated especially by the section 4.3.7(2).

[Operation procedure ] If the <MODE> button is further pushed from alarm mode, basic parameter mode will be displayed.

If a button<UP> is pushed, parameter No. will shift to 19 sequentially from 0 of Table 4.7. If a button<DOWN> is pushed, it will shift conversely.

Please perform the following operation to change the contents of a parameter. (a) <MODE> Display mode is united with parameter mode with this button. ↓

(b) <UP> , <DOWN> It unites with the position of parameter No. to change with this button. ↓

(C) <SET> A button is pushed twice. The setting value of specified parameter No. blinks ↓ (d) <UP> , <DOWN> The setting value under blink can be changed with a button.

↓ (e) <SET> A button is pushed and it decides.

↓ (f) OFF ⇒ ON [ a power supply ]. When a setting change of parameter No.0, 1, 15, 16, 18, and 19 is made, it is surely required refer to the section 4.3.7(1).

The following example shows the operation procedure performed after power-on to change the control mode

(parameter No. 0) to the speed control mode. Using the "MODE" button, show the basic parameter screen.

The set value of the specified parameter number flickers.

UP DOWN

The parameter number is displayed.

Press or to change the number.

Press SET twice.

Press UP once.During flickering, the set value can be changed.

Use or .

Press SET to enter.

( 2: Speed control mode)UP DOWN

To shift to the next parameter, press the UP DOWN/

button. When changing the parameter No. 0 setting, change its set value, then switch power off once and switch it on again to make the new value valid.

4-53


4.3.9 External I/O signal display

It checks to see the input-and-output signal of Servo amplifier is connected with the operation board, the circumference relay, etc. as the wiring diagram, before beginning operation.

The ON/OFF states of the digital I/O signals connected to the servo amplifier can be confirmed. (1) Operation

Call the display screen shown after power-on. Using the "MODE" button, show the diagnostic screen.

Press UP once.

External I/O signal display screen

(2) Display definition

CN1B7

CN1B9

CN1B8

CN1A14

CN1A8

CN1B4

CN1B18

CN1B14

CN1B5

CN1B17

CN1B16

CN1B19

CN1B6

CN1A19

CN1A18

Lit: ONExtinguished: OFF

Input signals

Output signals

CN1B15

Always lit

The 7-segment LED shown above indicates ON/OFF. Each segment at top indicates the input signal and each segment at bottom indicates the output signal. The signals corresponding to the pins in the respective control modes are indicated below:

4-54


(a) Control modes and I/O signals

(Note 2) Symbols of I/O signals in control modes Connector Pin No.

Signal input/output (Note 1) I/O P P/S S S/T T T/P

Related parameter

8 I CR CR/SP1 SP1 SP1 SP1 SP1/CR No.43 to 48 14 O OP OP OP OP OP OP 18 O INP INP/SA SA SA/ /INP No.49

CN1A

19 O RD RD RD RD RD RD No.49 (Note 3) 4 O DO1 DO1 DO1 DO1 DO1 DO1

5 I SON SON SON SON SON SON No.43 to 48 6 O TLC TLC TLC TLC/VLC VLC VLC/TLC No.49 7 I LOP SP2 LOP SP2 LOP No.43 to 48 8 I PC PC/ST1 ST1 ST1/RS2 RS2 RS2/PC No.43 to 48 9 I TL TL/ST2 ST2 ST2/RS1 RS1 RS1/TL No.43 to 48

14 I RES RES RES RES RES RES No.43 to 48 15 I EMG EMG EMG EMG EMG EMG 16 I LSP LSP LSP LSP/ /LSP 17 I LSN LSN LSN LSN/ /LSN 18 O ALM ALM ALM ALM ALM ALM No.49

CN1B

19 O ZSP ZSP ZSP ZSP ZSP ZSP No.1 49

Note: 1. I: Input signal, O: Output signal 2. P: Position control mode, S: Speed control mode, T: Torque control mode, P/S: Position/speed control change mode, S/T: Speed/torque

control change mode, T/P: Torque/position control change mode 3. The signal of CN1A-18 is always output.

(b) Symbol and signal names

Symbol Signal name Symbol Signal name

SON Servo-on EMG Emergency stop LSP Forward rotation stroke end LOP Control change LSN Reverse rotation stroke end TLC Limiting torque CR Clear VLC Limiting speed SP1 Speed selection 1 RD Ready SP2 Speed selection 2 ZSP Zero speed PC Proportion control INP In position ST1 Forward rotation start SA Speed reached ST2 Reverse rotation start ALM Trouble RS1 Forward rotation selection WNG Warning RS2 Reverse rotation selection OP Encoder Z-phase pulse (open collector) TL Torque limit BWNG Battery warning RES Reset

4-55


(3) Default signal indications (a) Position control mode

Lit: ONExtinguished:OFF

Input signals

Output signals

TL (CN 1 B-9) Torque limitPC (CN 1 B-8) Proportional control

CR (CN 1 A-8) ClearRES (CN 1 B-14) Reset

SON(CN 1 B-5) Servo-onLSN (CN 1 B-17) Reverse rotation stroke end

LSP (CN 1 B-16) Forward rotation stroke end

RD (CN 1 A-19) ReadyLNP (CN 1 A-18) In position

ZSP (CN 1 B-19) Zero speedTLC (CN 1 B-6) Limiting torque

DO1 (CN 1 B-4) In positionALM (CN 1 B-18) Trouble

OP (CN 1 A-14) Encoder Z-phase pulse

EMG(CN 1 B-15) Emergency stop

(b) Speed control mode

SP1 (CN 1 A-8) Speed selection 1RES (CN 1 B-14) Reset

SON (CN 1 B-5) Servo-onLSN (CN 1 B-17) External emergency stop

LSP (CN 1 B-16) Forward rotation stroke endLit: ONExtinguished: OFF

RD (CN 1 A-19) ReadySA (CN 1 A-18) Limiting speed

ZSP (CN 1 B-19) Zero speedTLC (CN 1 B-6) Limiting torque

DO1 (CN 1 B-4) Limiting speedALM (CN 1 B-18) Trouble


Input signals

Output signals

SP2 (CN 1 B-7) Speed selection 2ST1 (CN 1 B-8) For ward rotation start

ST2 (CN 1 B-9) Reverse rotation startEMG(CN 1 B-15) Emergency stop

(c) Torque control mode

RS1 (CN 1 B-9) Forward rotation selectionRS2 (CN 1 B-8) Reverse rotation selection

SP2 (CN 1 B-7) Speed selection 2SP1 (CN 1 A-8) Speed selection 1

RES (CN 1 B-14) ResetSON (CN 1 B-5) Servo-on

Lit: ONExtinguished: OFF

RD (CN 1 A-19) ReadyZSP (CN 1 B-19) Zero speed

VLC (CN 1 B-6) Speed reachedALM (CN 1 B-18) Trouble

Input signals

Output signals


EMG(CN 1 B-15) Emergency stop

4-56


4.3.10 Manual operation

Perform manual operation by using the machine operation board and check the machine status and signal such as the stroke end, etc. Carry out troubleshooting and corrections if necessary. Pay special attention to the following points during the checked.

(1) Give a low speed command to the motor and check the direction of rotation, sound,

and vibration of the motor itself; (2) Check the machine operation, paying attention to smoothness of travel,

directions of travel, looseness and abnormal sound. (3) Check the motor sound; (4) Check that the machine speed matches the set speed; (5) Check if the stoke end signals are issued correctly. Check if there are any

collisions between machine parts; (6) Check if the machine operations follow the I/O signals issued from the operation

panel correctly; (7) Check tightened parts for losseness. (8) Check the connecting cables between moving parts for insufficient or excessive

length.

* Refer to the Manul for practicing with a Training Machine for details on operations with a training machine.

4.3.11 Home Position Return After checking the machine operations by performing manul operation, execute a home position return and align the machine home position with the home position for the positioning control unit. * Refer to the Manul for practicing with a Training Machine for details on operations with a training machine.

4.3.12 Automatic Operation

Perform manual operation with a positioning program prepared for testing purposed. Check if the operations follow the program. After checking, perform continuous operation and check the load factor and machine movement.

4-57


4.3.13 Test operation mode

Motor operation without wiring to the command unit, simulated operation with the command unit and the servo amplifier but no motor, are both possible using the display of the servo amplifier. (1) Test operation I: Run the motor without commands and check the machine operations; (2) Test operation II: Input commands to the servo amplifier with no motor connected so that

monitoring is executed as if the motor were rotating. This test allows checking of the electrical system and program.

CAUTION

The test operation mode is designed to confirm servo operation and not to confirm machine operation. In this mode, do not use the servo motor with the machine. Always use the servo motor alone. If any operational fault has occurred, stop operation using the forced stop (EMG) signal.

POINT

The test operation mode cannot be used in the absolute position detection system. Use it after choosing "Incremental system" in parameter No. 1. The servo configuration software is required to perform positioning operation. Test operation cannot be performed if the servo-on (SON) signal is not turned OFF.

(1) Mode change

Call the display screen shown after power-on. Choose jog operation/motor-less operation in the following procedure. Using the "MODE" button, show the diagnostic screen.

When this screen appears, jog feed can be performed.

Press UP three times.

Press SET for morethan 2s.

Flickers in the test operation mode.

Press UP five times.

Press SET for more than 2s.

When this screen is displayed, motor-less operation can be performed.

4-58


(2) Jog operation

Jog operation can be performed when there is no command from the external command device.

(a) Operation Connect EMG-SG to start jog operation and connect VDD-COM to use the internal power supply. Hold down the "UP" or "DOWN" button to run the servo motor. Release it to stop. When using the servo configuration software, you can change the operation conditions. The initial conditions and setting ranges for operation are listed below:

Item Initial setting Setting range

Speed [r/min] 200 0 to instantaneous permissible speed Acceleration/deceleration time constant [ms] 1000 0 to 50000

How to use the buttons is explained below:

Button Description

"UP" Press to start CCW rotation. Release to stop.

"DOWN" Press to start CW rotation. Release to stop.

If the communication cable is disconnected during jog operation performed by using the servo configuration software, the servo motor will be decelerated to a stop.

(b) Status display You can confirm the servo status during jog operation. Pressing the "MODE" button in the jog operation-ready status calls the status display screen. With this screen being shown, perform jog operation with the "UP" or "DOWN" button. Every time you press the "MODE" button, the next status display screen appears, and on completion of a screen cycle, pressing that button returns to the jog operation-ready status screen. For full information of the status display, refer to Section 4.4.2. In the test operation mode, you cannot use the "UP" and "DOWN" buttons to change the status display screen from one to another.

(c) Termination of jog operation

To end the jog operation, switch power off once or press the "MODE" button to switch to the next screen and then hold down the "SET" button for 2 or more seconds.

4-59


(3) Positioning operation

POINT

The servo configuration software is required to perform positioning operation.

Positioning operation can be performed once when there is no command from the external command device.

(a) Operation Connect EMG-SG to start positioning operation and connect VDD-COM to use the internal power supply. Pressing the "Forward" or "Reverse" button on the servo configuration software starts the servo motor, which will then stop after moving the preset travel distance. You can change the operation conditions on the servo configuration software. The initial conditions and setting ranges for operation are listed below:

Item Initial setting Setting range

Travel distance [pulse] 10000 0 to 9999999 Speed [r/min] 200 0 to instantaneous permissible speed Acceleration/deceleration time constant [ms] 1000 0 to 50000

How to use the keys is explained below:

Key Description

"Forward" Press to start positioning operation CCW. "Reverse" Press to start positioning operation CW.

"Pause"

Press during operation to make a temporary stop. Pressing the "Pause" button again erases the remaining distance. To resume operation, press the button that was pressed to start the operation.

If the communication cable is disconnected during positioning operation, the servo motor will come to a sudden stop.

(b) Status display You can monitor the status display even during positioning operation.

4-60


(4) Motor-less operation

Without connecting the servomotor, you can provide output signals or monitor the status display as if the servo motor is running in response to external input signals. This operation can be used to check the sequence of a host programmable controller or the like. (a) Operation

After turning off the signal across SON-SG, choose motor-less operation. After that, perform external operation as in ordinary operation.

(b) Status display You can confirm the servo status during motor-less operation. Pressing the "MODE" button in the motor-less operation-ready status calls the status display screen. With this screen being shown, perform motor-less operation. Every time you press the "MODE" button, the next status display screen appears, and on completion of a screen cycle, pressing that button returns to the motor-less operation-ready status screen. For full information of the status display, refer to Section 4.3.8. In the test operation mode, you cannot use the "UP" and "DOWN" buttons to change the status display screen from one to another.

(c) Termination of motor-less operation To terminate the motor-less operation, switch power off.

4-61


4.3.14 The operation procedure in each operation mode (conclusion) (1) Position control mode

Please separate a machine from a servo motor, and connect with a machine after checking operating normally.

P o w e r o n (a) The Servo-On signal (SON) is turned off.

(b) After switches on power supply (NFB), displaying data that "C (return pulse accumulation)" is displayed after 2 seconds on a display part.

Please check that a servomotor operates using JOG operation in test operation mode. (Refer to section 4.3.13(1)) Parameter is set up according to the composition and specification of a machine. (Refer to section 4.3.8) * example

If a Servo on signal (SON) is turned on, it will be in the state which can be operated and a servo motor axis will lock. (Servo lock state) When not carrying out a Servo lock, it is not in the Servo on state. Please check an external sequence by diagnostic display. • If a pulse sequence is inputted from positioning, a servo motor will rotate.

Please check the rotation direction etc. in the beginning at a low speed. Please check an incoming signal, when you do not move in the direction to mean.

• Please check the rotation speed, the command pulse frequency, the rate of load of the servo motor by state display.

• If the check of a machine of operation finishes, automatic operation will be checked by the program of positioning controller.

• This Servo amplifier contains the real-time auto tuning function by model adaptive control. Execution of operation adjusts a gain automatically. The optimal tuning result can be obtained by the thing that suited the machine by parameter No.2 and to do for a response setup.

If the following operations are performed, operation will be interrupted and it will stop. (a) Servo on signal OFF ... Becoming base interception, a servomotor carries

out a free run stop. (b) A stroke end signal ....... The sudden stop of the servomotor is carried o

ut, and it carries out a Servo lock. It can operate to an opposite direction. (c) Alarm generating .....If alarm is generated, it will become base interception,

and the dynamic brake will operate and carry out the sudden stop of the servomotor.

(d) Emergency stop OFF (EMG) .... It becomes base interception, and dynamic brake operates and carries out the sudden stop of the servo motor. AL E6 occurs.

S t o p

Parameter Setting value content Automatic setup Servo amplifier : MR-J2S-40A Automatic setup Servo motor : HC-MFS43

No.0

0 3 0 0 Select the control mode: Position Selection of regenerative brake option: MR-RB12

No.1

0 0 0 2 Input signal filter : 3.555ms Electromagnetism brake interlock signal: -- it is not used Selection of position detection system --- Incremental system

No.2

0 1 0 1 Auto tuning response level setting: Low response Auto tuning selection.

No.3 2 No.4 1

Electronic gear (CMX/CDV ) : 2/1

P o w e r O n

Command pulse input

S e r v o O n

P a r a m e t e r s e t u p

T e s t o p e r a t i o n

MODE

SON ON

Servo on state

4-62


(2) Speed control mode Please separate a machine from a servomotor, and connect with a machine after checking operating normally.

P o w e r O n (a) The Servo-On signal (SON) is turned off. (b) After switches on the power supply (NFB), displaying data that "C (return

pulse accumulation)" is displayed after 2 seconds on a display part. Please check that a servomotor operates using JOG operation in test operation mode. (Refer to section 4.3.13(1)) Parameter is set up according to the composition and specification of machine. (Refer to section 4.3.8) • Example

If a Servo on signal (SON) is turned on, it will be in the state which can be operated and a servo motor axis will lock. (Servo lock state) When not carrying out a Servo lock, it is not in the Servo on state. Please check an external sequence by diagnostic display. • Servo motor rotation speed is chosen by speed selection 1 (SP1) and the

speed selection 2 (SP2). If forward rotation start (ST1) is turned on and the forward rotation(CCW) direction and inversion starting (ST2) will be turned ON, it will rotate in the inversion (CW) direction. Please set rotation speed as a low speed and check the rotation direction in the beginning. Please check an incoming signal, when you do not move in the direction to mean.

• Please check the servomotor rotation speed, the rate of load, etc. • If the check of a machine of operation finishes, automatic operation will b

e checked with the control device of a higher rank etc. • This Servo amplifier contains the real-time auto tuning function by model

adaptive control. Execution of operation adjusts a gain automatically. The optimal tuning result can be obtained by the thing that suited the machine by parameter No.2 and to do for a response setup.

If the following operations are performed, operation will be interrupted and it will stop. (a) Servo on signal OFF ... Becoming base interception, the servomotor carries

out a free run stop. (b) A stroke end signal ....... The sudden stop of the servomotor is carried o

ut, and it carries out a Servo lock. It can operate to an opposite direction. (c) Alarm generating ....If alarm is generated, it will become base interception,

and a dynamic brake will operate and carry out the sudden stop of the servomotor.

(d) Emergency stop OFF (EMG) .... It becomes base interception, and dynamic brake operates and carries out the sudden stop of the servo motor. The ALE6 occurs.

Parameter Setting value Contents Automatic setup Servo Amplifier ：MR-J2S-40A Automatic setup Servomotor ：HC-MFS43

No.0

0 0 0 2 Select the control mode : Speed Selection of regenerative brake option: no use

No.1

0 0 1 2 Input signal filter : 3.555ms Electromagnetism brake interlock signal: it is used

No.2

0 1 0 5 Auto tuning response level setting: Middle response Auto tuning selection: Auto tuning mode 1

No.8 1000 Internal speed command 1 : 1000r/min No.9 1500 Internal speed command 1 : 1500r/min

No.10 2000 Internal speed command 1 : 2000r/min No.11 1000 Acceleration time constant : 1s No.12 500 Deceleration time constant : 0.5s No.13 0 S-pattern acceleration/deceleration time constant: 0 S

S t o p

S t a r t

S e r v o O n

Parameter setup

Test operation

P o w e r O n

MODE

SON ON

Servo on state

4-63


(3) Torque control mode Please separate a machine from a servomotor, and connect with a machine after checking operating normally.

P o w e r O n

(a) The Servo-On signal (SON) is turned off. (b) After switches on power supply (NFB), displaying data that "C (return

pulse accumulation)" is displayed after 2 seconds on a display part. Please check that a servomotor operates using JOG operation in test operation mode. (Refer to section 4.3.13(1)) Parameter is set up according to the composition and specification of the machine. (Refer to section 4.3.8)

Example

If a Servo on signal (SON) is turned on, it will be in the state which can be operated and a servo motor axis will lock. (Servo lock state) When not carrying out a Servo lock, it is not in the Servo on state. Please check an external sequence by diagnostic display.

• Servo motor rotation speed is chosen by speed selection 1 (SP1) and the speed selection 2 (SP2). If forward rotation start (RS1) is turned on and the forward rotation (CCW) direction and inversion starting (RS2) will be turned ON, it will rotate in the inversion(CW) direction. Please set rotation speed as a low speed and check the rotation direction in the beginning. Please check an incoming signal, when you do not move in the direction to mean.

• Please check the servomotor rotation speed, the rate of load, etc. by state display.

• If the check of a machine of operation finishes, automatic operation will be checked with the control device of a higher rank etc.

If the following operations are performed, operation will be interrupted and it will stop. (a) Servo on signal OFF ... Becoming base interception, a servomotor carries

out a free run stop. (b)Alarm generating .....If alarm is generated, it will become base interception,

and a dynamic brake will operate and carry out the sudden stop of the servomotor.

(c) Emergency stop OFF (EMG) ....It becomes base interception, and dynamic brake operates and carries out the sudden stop of the servo motor. The AL E6 occurs.

(d) Simultaneous ON or the simultaneous off-servo motor of a forward rota-tion start (RS1) signal and an inversion selection (RS2) signal becomes a free run.

Parameter Setting value Contents Automatic setup Servo Amplifier : MR-J2S-40A Automatic setup Servomotor : HC-MFS43

No.0

0 0 0 4 Select the control mode : Torque Selection of regenerative brake option: no use.

No.1

0 0 0 2 Input signal filter : 3.555ms Electromagnetism brake interlock signal: it is used

No.8 1000 Internal speed command 1 : 1000r/min No.9 1500 Internal speed command 2 : 1500r/min No.10 2000 Internal speed command 3 : 2000r/min No.11 1000 Acceleration time constant : 1s No.12 500 Deceleration time constant : 0.5s No.13 0 S-pattern acceleration/deceleration time constant: 0 S No.14 2000 Torque command time constant : 2ｓ No.28 50 Internal torque limit 1 : Restrict to 50% of output.

S t o p

S t a r t

S e r v o O n

Parameter setup

Test operation

P o w e r O n

MODE

SON ON

Servo lock state

4-64


4.3.15 A function convenient for starting and diagnosis

Also besides the Section 4.3.9 "an external input-and-output signal check" and the section 4.3.13 "test operation", MR-J2S-A Servo amplifier rose and has arranged the function convenient to diagnose. The main item is listed below.

(1) Auto tuning .... According to the inertia moment of load, a Servo gain is adjusted

automatically. According to the conditions of a machine, the low, middle and high response can be chosen into quantity.

(2) VC automatic offset .... Offset of analog incoming signals, such as speed instructions, is rectified automatically.

(3) Reason display for a stop .... The factor is expressed with the segment of a display part when the motor has stopped. It is convenient for troubleshooting.

(4) DO forcible output .... The forcible output of the digital output signal of amplifier is carried out. Since the check of an external relay, a lamp, etc. is made to convenient.

(5) Machine simulation ..... Based on a machine analyzer's result, the simulation of the motion of a machine can be carried out on the screen of a personal computer.

(6) Gain search function .... A personal computer is automatic set gain that does not have an exaggerated shot for a short time is discovered while changing a gain.

(Note) Setup S/W is needed when performing a machine simulation and a gain search function.

4-65


Memo

4-66

5. MELSERVO – H PERFORMANCE AND FUNCTIONS

5.1 Basic Performance and Function As shown in the following figure, MR-H-N series Servo amplifier has come to be able to do all of connection with external apparatus, and a monitor from the front of amplifier, and can do those work easily also in the state of wearing in a board. As an input-and-output signal connected with an operation board, it is together put by a terminal stand and connectors CN1 and CN3 (only for monitor outputs). The converter unit is needed for 3 phase AC400V class mass type [ 30-55kW ].

C N

4

Servo Configuration Software

Personal Computor

+

Parameter Unit

Or

Programmable controller

Junction terminal Block MR-TB50

(note 2) Power supply3- phase AC, 200~230 V

No-fuse Breaker (NFB) or fuse

Magnetic contactor (MC)

Regenerative brake option Servo Amplifier

MR-H AN Analog Meter

To CN3

To CN4

To CN1 To CN2

(Note1)MR-HCN2

W V U

P

C

N

R

S

T

R1

S1

U

V

W

Ground

Servomotor

Note 1, Required when using the HC-MF, HA-FF OR HC-UF 3000 rpm servomotor 2. Depends on the servo amplifier capacity.

CHARGE

CN3

CN4

CN1 CN2

The parameterunit or Servo Configuration software is required for parameter setting

5-1


The composition of 3 phase AC400V class mass type [ 30-55kW ]

No-fuse Breaker (NFB)

Converter unit( MR-HP55KA4 )

Servo Amplifier

3 phase AC 380 – 460V

No-fuse Breaker (NFB)

Magnetic contactor

(MC)

Line noise Filter ( FR-BLF )

R S T

Servomotor HA-LF series

Regenerative breaker ( MR-RB -4 )

(note 2)

Power update DC Reactor( MR-DCL K-4 )

(Control circuit)

Servo configurationSoftware

Personal computer

＋

Parameter unit

OR

CN4

(MR-H AN4 )

( MR-HSCBL M )

(MR-J2HBUSM)

The parameter unit or Servo Configuration software is required For parameter setting.

Note 1. The converter unit that connect with Servo amplifier are standard accessories.

2. The above-mentioned example of connection is the case of MR-RB 136-4. In MR-RB 138-4, it is in three sets (parallel connection).

3. The converter unit is required for this system.

5-2


5.2 Parameter functions

A parameter is the function to prescribe the operation conditions of Servo that the section 4.3.7 that described beforehand, in the case of MR-H-N series, consists of a user parameter (No.00-No.19) and

an extended parameter (No.20-No.64).

(1) Parameter setting table

Position control

Speed control

Torque control

Remarks

The parameter surely set up or checked

before operation. 0, 1, 2, 0, 1, 2, 0, 1, 2, 1. There are parameters other

than the following and an item

which carries out a setting

check according to an operating

condition.

The parameter surely set up according to

machine specification and an operation

pattern.

4, 5

The parameter set up if needed. 21 9~ 14 15 2. After setting the parameter

The parameter set up while operating a

machine (adjustment). 20 20

No. 19 value, switch power

off, then on to make that

When a setting change of the extended

parameter is made

19 19 setting valid .

5-3


(2) The parameter surely set up or checked before operation If a setup is wrong, a motor will not move, or the parameter explained here becomes alarm. Please be sure to check before operation, and when you differ from an initial value, change the setup.

(a) No. 00 (M*MSR ; Motor series)

Used to choose the servo motor series.

Class. No. Code Name and Function Control

Mode

Initial

Value

Unit Setting

Range

1 *MSR Motor series Used to choose the servo motor series. When using the HC-MF,HA-FF, HC-SF, HC-RF, HC-UF series servomotor, this parameter need not be set since it is automatically judged by merely connecting the motor encoder and servo amplifier. At this time, this parameter is changed but may be used as it is.

P S T

_

0000 ~

0003 ~

0005

Bas

ic P

aram

eter

(b) No. 01 (MTY; Motor Type) The rating of the motor to operate is set up. The rated output and rated rotation speed of the motor are set up in four digits.

Classif

ication

No

.

Code Name and Function Control

Mode

Initial

Value

Unit Setting

Range

1 *MTY Motor series: Used to set the parameter(servomotor capacity) according to the motor used. The servomotor and servo amplifier to be set should be any of their combinations having the parameter in the table. When using the HC-MF,HA-FF, HC-SF, HC-RF, HC-UF series servomotor, this parameter need not be set since it is automatically judged by merely connecting the motor encoder and servo amplifier. At this time, this parameter is changed but may be used as it is.

Rated speed (Unit: 1000r/min)

Rated output (Unit: 100 W)

P S T

Setting Servomotor series

0000 HA -- SH

0001 HA -- LH

0002 HA -- UH

0003 HA -- FH

0005 HA -- MH

Servo amplifier MR-HN

Servomotor Capa.

(W)

10 20 40 60 100 200 350 500 700 11K 15K 22K

HA-MH053 50 053

HA-MH13 100 13

HA-UH152 1500 152

HA-UH222 2200 222

HA-UH352 3500 352

HA-UH452 4500 452

! Caution Servo amplifier and servomotor cannot be set up other than the combination in which the parameter setting value of a top table exists. It becomes the cause of a fire.

It ca

lls a

t a

left

tabl

e.

It ca

lls a

t a

left

tabl

e.

B

asic

Par

amet

er

5-4


(c) No. 02 (*STY; Servo Type) used to choose the control mode and the regenerative brake option.

Class. No. Code Name and Function Control mode

Initial value

Unit Setting range

2 *

STY

Servo type: Used to choose the control mode and regenerative brake option

Control mode selection 0. Position 1. Position and speed 2. Speed

3. Speed and torque 4. Torque 5. Torque and position Position : Pulse train Speed : The analog, internal 3 speed, and internal 7 speed. Torque : The analog.

Select the regenerative brake option. 0. Set 0 when the servo amplifier of less than 11kW capacity has

no external option or when the servo amplifier of 11kW or more uses the supplied regenerative brake resistor.

1. FR-RC, FR-BU brake unit 2. MR-RB013 3. MR-RB033 5. MR-RB32

6. MR-RB34 7. MR-RB54 8. MR-RB30 9. MR-RB50 B. MR-RB31 C. MR-RB51

E. When the servo amplifier is 11kW or more and the supplier regenerative brake resistor is cooled by a fan to improve its capacity.

0001 0000 ~

0E05h 0 0

Bas

ic P

aram

eter

With the following table, please select the regeneration option corresponding to each Servo amplifier, and set up a parameter.

Built-in External Regeneration option (W) (note 2)

Servo amplifier model

Brake( w )

Regenerative brake resistor

( W ) (Accessories)

MR- RB013

MR- RB033

MR- RB30

MR- RB31

MR- RB32

MR- RB34

(Note 1) MR-RB50

(Note 1) MR-RB51

(Note 1) MR-RB54

Special option ( W )

MR-H10AN, MR-H20AN - - 10 30 - - - - - - - -

MR-H40AN, MR-H60AN

50 - - - - - 300 - - - - -

MR-H100AN 80 - - - - - 300 - - - - -

MR-H200AN 80 - - - - - - 300 - - 500 -

MR-H350AN, MR-H500AN

130 - - - 300 - - - 500 - - -

MR-H700AN 170 - - - - 300 - - - 500 - -

MR-H11KAN - 500 - - - - - - - - - 800

MR-H15KAN, MR-H22KAN - 850 - - - - - - - - - 1300

Note 1.Please install a cooling fan; 2.It corresponds by change of parameter No.2, and resistor cooling fan installation.

5-5


(3) The parameter must be set up according to machine specification and an operation pattern If the parameter dealt with here is not setup correctly, the actual distance moved by the moving part will not be those specified by the values set. It is therefore essential to set these parameters in accordance with the specifications.

(a) No. 4, 5 (CMX, CDV; Electronic gear) required only at the time of position Servo.

The setting for Parameter No. 4 is the numerator of the ratio and No. 5 is its denominator.

Since the relation between machine specification and a ratio is indicated in detail refer to section 2.5.1.

Class No Code Name and Function Control

mode

Initial

value

Unit Setting

Range

4 CMX Command pulse magnification (numerator) : Set the multiplier for the command pulse input.

Command pulse input CMX Position command fc CDV

fc1 = fc 1 CMX

Note． < <50(set the value within this range) 50 CDV

For the setting, refer to Section 2.5.1 command pulse magnification can be switched with an external signal. (Refer to the parameter No.24)

P 1 1 ~

50000

5 CDV Electronic gear denominator.

P 1 1 ~

50000

CMX CDV

Bas

ic P

aram

eter

(4) The parameter set up if needed

(a) No. 9, 10, 11 (Internal speed command 1 – 3)

Used to set internal speed command. It is unnecessary when carrying out an analog setup from the outside.

Class No Code Name and function Control

mode

Initial

setting

Unit Setting

Range

9 SC1 Internal speed 1:

Used to set speed 1 of the internal speed command

S, T 100.0 r/min 0 ~ max. speed


Used to set speed 2 of the internal speed command S, T 500.0 r/min 0 ~

max. speed


Used to set speed 3 of the internal speed command

S, T 1000.0 r/min 0~ max. speed

Bas

ic P

aram

eter

5-6


(b) No. 12, No. 13 (STA, STB; Acceleration/deceleration time constant)

Acceleration time and slowdown time are set up according to an operation pattern. It is effective also to external analog instructions. Acceleration time until it reaches rated speed, or slowdown time until it stops from rated speed is set up to speed command (external and internal 3 speed).

Class No. Code Name and Function Control Mode Initial

value Unit

Setting Range

12 STA Acceleration time constant: This Parameter is used to set the acceleration time until the rated speed is reached from 0 rpm.

S 0 ms 0 ~ 50000

13 STB Deceleration time constant: This Parameter is used to set the deceleration time until the zero speed is reached from the rated speed.

S 0 ms 0 ~ 50000

Bas

ic p

aram

eter

If set command speed is lower than rated speed, acceleration/deceleration time will be shorter.

Time STB Setting value

0 r/min

Rated speed

Speed

STA Setting value

(c) STC; (Parameter No. 14; S-pattern acceleration/deceleration time constant)

Class No. Code Name and Function Control

Mode Initial

Value

Unit Setting

Range

14 STC S-pattern acceleration/deceleration time constant. Used to smooth the start/stop of the servomotor. When a constant is enlarged at the time of acceleration and

a slowdown, the time of a circle portion may stop suiting a setting value.

S 0 ms 0 ~ 5000

Bas

ic p

aram

eter

(d) No. 21 (* OP2; Function selection 3)

Pulse sequence input I/F at the time of position Servo operation is set up. Moreover, a low noise function is also chosen.

5-7



mode Initial

setting

Unit Setting

Range

21 *OP2 Function selection 3:

Used to select the option function.

Low acoustic noise mode selection

0: non-low acoustic noise

3: low acoustic noise

Note: By choosing the low acoustic noise mode,

electromagnetic sound generated by the

servomotor can be reduced by about 20dB

Command pulse input form

0: forward, reverse rotation pulse train

1: signed pulse train

2: A/B- phase pulse

Command pulse logic selection

0: Positive logic

1: Negative logic

0000 ms 0000 ~ 0123h

Extension Parameter

0

5-8


(5) The parameter set up while operating a machine (adjustment)

(a) No. 20 (Function selection 2) Used to select automatic restart after instantaneous power failure and servo lock in the auto tuning/speed control mode.

Class No. Code Name and Function Control Mode Initial

Value Unit

Setting Range

20 OP1 Function selection 2: Used to choose automatic restart after instantaneous power failure and

servo lock in the auto tuning/speed control mode.

Auto tuning selection 0: auto tuning selected for use of interpolation axis

control, etc, in position control (valid) 1: auto tuning for ordinary operation(valid) 2: No auto tuning (Invalid)

Auto-restart after instantaneous power failure ( speed control Mode) Restart can be made without an alarm (AL 10) stop when power is restored after instantaneous power failure. 0: Invalid 1: valid

Response setting (When auto tuning is valid) Optimum response can be selected according to the rigidity of the machine. As the machine has higher rigidity, faster response can be set to improve tracking performance in response to a command and to reduce setting time.

Note) When changing the value, always increase the setting from lower to higher response levels while simultaneously checking the vibration and setting of servo motor and machine immediately before a stop and during a stop. Speed control servo lock selection. 0: Valid 1: Invalid

Note) When the function is made valid, the servomotor shaft attempts to

return to the original position if it is turned by external force.

When this function is invalid, counterforce matching the external

force is produce but the shaft does not return to the original position.

P, S 0001 0000 ~ 1C12

0

Ex

tens

ion

Para

met

er

Machine Description Guideline of position setting time

Type Set value

Response Guide of corres

ponding rigidity

GDL2/GDM2

Guideline of load inertia(GDL2/GDM2

= within 5 times)

Initial 0 Low Low to high 1 ~ 5 times －

Ordinary

1 2 3 4 5

Low

Middle

High

Low rigidity

~ Medium rigidity

~ High rigidity

50 ~ 300ms

10 ~ 70ms

10 ~ 30ms

Large friction

8 9 A B C

Low

Middle

High

Low rigidity

~ Medium rigidity

~ High rigidity

70 ~ 400ms

10 ~ 100ms

10 ~ 50ms

1 ~ 10 times

5-9


(6) The Parameter you are recommended to set under some operating conditions (a) No. 19 (*BLK; Parameter block)

Used to restrict the reference and write ranges of parameters. By executing a parameter block operation after completing adjustment, the system can be protected against incorrect operations. Only the basic parameter (No. 00 to No. 19) can be written in the factory-set condition. Parameter No. 19 has to be set in order to set expansion parameters.


mode Initial

setting

Unit Setting

Range

19 *BLK

Parameter write disable

Used to limit parameter write.

0000 0000 ~

000E

Basic Param

eter

Setting Referred Parameter Written Parameter

0000 Basic parameter Basic parameter

000A Parameter No.19 Parameter No.19

000C Basic parameter +

expansion parameter

Basic parameter

000E Basic parameter +

expansion parameter

Basic parameter +

expansion parameter

<Reference> Parameter package initialization Doing this work changes all parameters to an initial value. Since it becomes impossible to return to the parameter before operation, it is necessary to carry out after cautions enough. 1) pr.19 are set as "ABCD." 2) turn off power supply and on again 3) pr.85 are set as "0001." 4) If OFF/ON the power supply, package conversion of pr.0-pr.79 (basic and extended

parameter) will be carried out at the initial value (Table 5.1). 5) pr.19 are returned to the original value "0000." Cautions: Since pr.0-pr.3 is initialized, please re-set it as the motor and Servo type that surely correspond.

5-10


(7) Converter unit Parameter of MR-HP55kA4

No. Code Name and Function Initial

setting

Unit Setting

Range

0 *STY Control mode and regeneration option selection Control mode and a regeneration option are chosen. 0 0 0 Selection of a regeneration option 0: It is not used. 1: MR-RB136-4 2: MR-RB128-4 (3 No.s)

0000 0000h

~

0002h

1 *MCC Machine maker setup 0000

2 *D01 Machine maker setup 0000

3 MOD Machine maker setup 0001

4 *DMD State display selection

The state display displayed at the time of a power supply turn on is chosen.

0 0 0 The converter unit at the time of a power supply up The state display of a display part 0: Bus voltage（initial value） 1: The rate of effective load 2: The rate of peak load 3: The rate of regeneration load

0000 0000h

~

0003h

5 *ACL Alarm history clearance

An alarm history clearance is chosen.

0 0 0

Alarm history clearance 0: Invalid (it does not clear) 1: Valid (it clears)

When an alarm history clearance is confirmed, it is rear to clear about an alarm history next time at the time of a power supply turned on. It automatically invalid after an alarm history clearance if it is set to (0)

6 Spare

7 Spare

8 Spare

9 *BLK For a machine maker setup 0000

* . It becomes effective by power supply OFF->ON after parameter setting change.

5-11


5.3 Display and Diagnosis Functions

5.3.1 MR—PRU01A Parameter Unit This unit has an LCD (13 characters X 4 lines) used for condition display and alarm diagnosis. It can be used to set data, perform test operation, set parameters, monitor the operating status, and display alarm definition.

(1) MR—PRU01A Structure

Operation Key : Help mode select key.

Used to set the monitor or parameter in a list.

: SHIFT Key Used to make the typing of the corresponding shift character valid.Used to switch the screen.Example: use to alternate between the current alarm and the concurrent alarm.

: Cancel Key Used to return to the previous screen.

: Scroll Keys Used to scroll the screen

Hold down the key for more than 1 second to increase the scroll speed. Used to move the cursor on the screen.

HELP

SHIFT

CAN

: Forward rotation start key. Used to start forward rotation in the test run mode

- / Reserve rotation start key Used to enter the –(negative) sign Used to start reverse rotation in the test run mode

: Stop/ reset Key Used to stop the test run temporarily.

Used to reset an alarm or clear data entered.

FWD

REV

--

STOP

RESET

: Definition Key Used to define the parameter data after it is entered

Used to choose the necessary operation on the corresponding function menu screen.

Definition Key

: Numerals (0 to F) Used to enter the set value of the parameter. To type F, Press the [F/9] after pressing the [SHIFT] key.

: Decimal point

F 9 0

1STEP .

Numeral key

: Monitoring mode select key. Used to change the screen display to the monitoring mode.

: Alarm/diagnostics mode select key. Used to change the screen display to the alarm/diagnostic mode.

: Parameter mode select key. Used to change the screen display to the parameter mode.

: Test mode select key. Used to change the screen mode to the test mode.

MONI- TOR

ALM/ DGN

PARAM DATA MITSUBISHI MELSERVO-PRU01A

MONI-TOR

ALM/DGN

PARAMDATA TEST

HELP SHIFT CAN

Test Run Key

FWD

REV

－

STOPRESET

D7 E

8 F

9 A

4 B

5 C

6

1 2 3

0 1STEP

・

Mode Key—Used to switch between modes display

~

Display—Liquid crystal screen(13 characters by 4 digits)Interactive parameter setting Help function, troubleshooting guidance Monitoring

TEST

5-12


(2) Operation of the MR—PRU01A

SERVO Initializing --Servo being initialized

COMMUNICATION Initializing

--Being initialized by communication.

CONTROL POSITION --Control mode display

(for about 3 seconds)

Position Position/Speed

SpeedSpeed/torque Torque

Torque/position

1 Speed F/B 0. 0 r/ min

MONI- TOR Monitoring mode

1 1st AL--No Alarm

ALM/ DGN Alarm diagnostic mode

<TEST mode> : On test 0 → Finish 1 Jog feed

TEST Test mode

1 → Speed F/B 2 Ref. Speed 3 Droop 4 Ref. pulse

HELP Screen 1 → ALARM2 Not Rot3 ALM Hist.4 I/O Sig.

HELP Screen

<PARAM mode>Pr. Read : No. Pr. List : Help Copy: SFT + 3

PARAMDATA Parameter mode

<PARAM HELP>→ List All

List Chg

HELP Screen

00 MTR Ser. 0003

0 ~100 B

0Parameter No. 0 Call screen

→ JAPANESE ENGLISH

MONITOR ALM/DIAG. PARAMETER TEST MODE

Characters displayed on the screen are switched between English and Japanese.

Japanese-English select screen

→ Monitor AlM/DIAG ParameterTest Mode

Press the HELP key to move to the HELP screen in the mode indicated by the cursor

HOME screen

CAN

HELP screen

HELP

CAN

CAN

: POSITIO : POSITION/SPEED : SPEED : SPEED/TORQUE : TORQUE : TORQUE/POSITION

(3) Function

There is a function in monitor mode, alarm mode, parameter mode, and test operation mode in a parameter unit.

Please refer to the manual for the specification handling description about the contents of each function, and the flow of operation.

5-13


5.3.2 Monitor (1) The monitor by parameter unit MR-PRU01A

Name Status Display Indication

Range

Unit Description Positi

on

Spee

d

Torq

ue

Feedback pulse

value

Pulse F/B

-999999

~999999

Pulse

Feedback pulse from the servomotor encoder are counted and displayed. When the value exceeds 9999999, it starts with 0. Press “reset” to reset the value to 0

O

O

-

Servomotor Speed Speed F/B -4600.0

~4600.0 r/min

The speed of the servomotor is displayed. Reverse rotation is indicated by “-“. O O O

Command Speed Ref. Speed -4600.0

~4600.0 r/min

Command speed input to the servo amplifier is shown. For the internal speed command, the value set in the selected parameter is display.

O O O

Droop Pulse Value Droop -999999

~999999 Pulse

The pulse value of the deviation counted is displayed. Reverse rotation pulse value is indicated by “—“. O - -

Command Pulse

Value

Ref. Pulse

-999999

~999999

Pulse

Position command input pulses are counted and displayed. Since the value displayed is not yet multiplied by the electronic gear, it may not match the indication of the feedback pulse value. When the value exceeds 9999999, it starts with 0. Press “reset” to reset the value to 0

O

-

-

Command Pulse

frequency

Ref. freq

-400~400

Kpps

Position command input pulse frequency is displayed. The value displayed is not yet multiplied by the electronic gear. Reverse rotation pulse value is indicated by “—“

O

-

-

Speed Command

Voltage

Ref SPDV -10.00~

+10.00

Volt

(1) For Position or torque control mode, the Analog speed limited (VC) voltage is displayed.

(2) For speed control mode, the Analog speed command (VC) voltage is displayed.

-

O

O

Reverse rotation

analog torque

command voltage

- TQ LMTV 0.00~

-10.00

Volt

Reverse rotation analog torque command(TLAP) voltage is displayed. Indication range: 0.00 to -8.00 V

O

O

O

Reverse rotation

analog torque

command voltage

+TQ LMTV 0.00~

10.00 Volt Forward rotation analog torque command. O O -

Regenerative load

factor

Reg. load

0~100

%

The percentage of regenerative power to the permissible regenerative value is displayed.

O

O

O

Effective load

factor

Effc. Load 0~300 % Continuous effective load torque is displayed. The effective value is displayed relative to the rated torque of 100%.

O O O

Peak load factor Peak load 0~300 % Max. generated torque is displayed. The peak value in the past 15seconds is displayed relative to the rated torque of 100%.

O O O

Within one

revolution position

1 cycle Pos 0~16383 Pulse The position within one revolution is displayed in terms of encoder pulse.

O O O

A B S counter ABS count 0~65535 rev Moving distance from the home position in the absolute position detection system is displayed in the counter value of the absolute position encoder.

O O O

Machine speed Mach. SPD 0~999.00 m/min Speed multiplied by the machine speed conversion

constant is displayed. O O

O

Bus voltage P/N Volt 0~ 400 Volt The voltage (across P-N) of the main circuit converter is

displayed.

O O O

5-14


(2) The monitor in the main part of Servo amplifier The monitor (Table 5.3) of an operation state is based on a parameter unit, and also it can be seen by 4-figure LED of the Servo amplifier. The rotary switch (0-C) of a main part performed selection of the contents of a monitor, and it has been independent of the contents of selection by MR-PRU01A.

Table 5.3 The setup of the contents of the monitor and the rotary switch

Rotary switch(CS1)

Status Display

Setting Position Control Speed Control Torque Control

0


1

2

3

4

5

6

7

8

9

A

B

C

Fr

Cr

E

P

PA

F

Up

Un

Ld

JA

Jb

Cy

Pn

Servomotor speed

Command speed

Droop pulse value

Command pulse value

Command pulse frequency

------- Reverse rotation torque limit voltage

Forward rotation torque limit voltage

Regenerative load factor

Effective load factor

Peak load factor Within one revolution position

Bus voltage

Servomotor speed

Command speed

-------

-------

-------

Speed command voltage Reverse rotation torque limit voltage Forward rotation torque limit voltage




Bus voltage

Servomotor speed

-------

-------

-------

-------

Torque command voltage Reverse rotation torque limit voltage Forward rotation torque limit voltage




Bus voltage

Code

5-15


5.4 The setup and operation

5.4.1 Hard Ware setup (1) The setup of rotary switch(CS1)

Please be sure to check never turn the power on with the rotary switch of amplifier unites set at D, E, F. Since it will become a display error. The contents of a L.E.D. monitor of the front of amplifier (refer to Table 5.3) are chosen in the position of a scale 0 - C.

(2) Wearing of a battery When you use a motor with a position detection machine absolutely, please equip amplifier with an exclusive option (MR-BAT) for memory preservation.

5.4.2 Turned on Power Please switch on a power supply in the same check and same procedure as the case of MR-J2S (Refer to section 4.3.5).

5.4.3 Parameter setup Initial setting of the parameter value according to the conditions of operation is carried out after power supply on. Since there is a parameter stated by the section 5.2, please set up based on design specification. Please be sure to check about the parameter stated especially by section 5.2 (3) and (4).

5-16


(1) The outline of the parameter setup

When setting up an extended parameter (No.20 or subsequent ones), a parameter block (No.19) needs to be reset.

Please perform the parameter block after a setting end for the parameter rewriting rate prevention by incorrect operation.

There are some which a power supply once and become effective in a parameter after a setup. Please be based on power supply OFF->ON after a setup.

(2) Release of the parameter block The range of a parameter that can be setup is limited to the basic parameter (No.00-No.19) at the time of factory shipments. Please reset the parameter block, when you make a setting change of the extended parameter. Release of a parameter block is based on a setup of parameter No.19.

Setting value Parameter can be reference Parameter can be write

0000 (Initial setting) Basic parameter Basic parameter

000A Parameter block No.19 Parameter block No.19

000C Basic parameter + extended parameter Basic parameter

000E Basic parameter + extended parameter Basic parameter + extended parameter

(d) Power supply OFF- On

(a) Release of a parameter block

(b) Parameter setup

(c) Parameter block

Start

5-17


(3) The Setting operation of a parameter Setup of a parameter and read-out are performed using parameter unit MR-PRU01A of exclusive use. For any parameter whose symbol is preceded by *, set the parameter value and switch power off once, then switch it on again to make that parameter setting valid.

[the operation procedure and contents] [Key operation] [Screen display]

(a) The parameter mode

of MR-PRU01A is

chosen.

<Setting mode> Pr. No. ０ Read:

Key is pressed

Key in is carried out.

Key is pressed

key in is carried out.

Key is pressed.

Key in is carried out.

P A R A M

0

1

3

０ Motor series 3 Power-off then ON Pr Read: No.

0 motor series 0 0 ~5

<Parameter mode> Pr Read : No. Pr List : Help Copy : SFT + 3

(All the data of a repetition and a parameter list is set up) (Main Power Supply OFF)

(b) The key in of

parameter No. to

set up is carried

out.

(c) The key in of

the setting data is

carried out.

(d) The key in of fol-

lowing parameter

No is carried out. <Setting mode>

Pr. No. 1 Read

(Main Power Supply On)

5-18


5.4.4 Input-and-output signal check The monitor of the ON/OFF state of the input-and-output signal of the connector CN1 for control signals can be carried out using parameter unit MR-PRU01A. Please check the connection state of the switches of operation board before putting in operation instructions.

(An operation procedure and contents) (Key operation) (Screen display)

(a) The alarm and diagnostic mode of MR-PRU01A are chosen.

(Third screen)

DI D I 1 D I 2

D I 3 D I 4

E M G

DI SON TL

PC RES

LSP LSN

CR DIO

(Second screen)

4 DIO Signal : On : Off Read ：

Key is pressed

Key is pressed 3 times.

Key is pressed

(First screen)

ALM/DGN

∇

1 1st Alarm No Alarm

(b) The DIO diagnostic function is called.

(c) The ON/OFF state

is checked on a DIO diagnostic screen.

∇ Key is pressed

∇ Key is pressed D O RD PF

ZSP TLC

ALM OP

Note 1. “ ” of a screen expresses ON state and “” expresses an OFF state.

2. The number of DIO signals and a name change with Servo loop form.

5-19


Memo

5-20

6. SELECTION

6.1 Provisional selection of motor capacity

The rough guidelines for selecting the capacity of AC Servo that is appropriate for a given mechanical drive system is as follows: (1) The Guideline relating to the stability of a control loop

Moment of load inertia (JL) ≤ Moment of motor rotor inertia (Jm) X recommendation load inertia moment ratio

(2) The allowance for load torque Load torque (TL) ≤ motor rated torque(TM) x (0.5-0.8)

6.1.1 Load inertia moment (JL) The term “load inertia moment” means of the moment of inertia of the mechanical locking

element which is connected to the motor output shaft and that of the drive system beyond the coupling; both act as loads on the motor. The moment of inertia of magnetic brake of the motor and that of the reduction gears should also be included. The unit which should be used to express the moment of load inertia.

In addition, by AC servo system, the unit of the load inertia moment JL uses [kg.cm2], and the formula used to calculate the moment of load inertia is given in Table 6.1.

6.1.2 Load torque TL A thrust, friction power, imbalanced torque, etc. which work in the movable part of the

machine used as the load of a motor are said. In addition, the unit of the load torque TL uses [N-m], and shows the formula of load torque

in Table 6.2.

Note The Symbols of a formula are based on Appendices 1.

6-1

6. SELECTION

6.1.3 Formulae to calculate load inertia moment and load torque (1) Formulae used to calculate load inertia moment

The formulae used to calculate moment of inertia in typical cases are presented in Table 6.1

Table 6.1 Calculation of Load inertia moment

TYPE Mechanism Formula

1. Cylinder

π•ρ•L W ＪL＝ • (D1 – D2 ) = • (D1 + D2 ) ………( 6 –1) 32 8

JL :Moment of load inertia [•cm2 ] ρ :Density of material [／cm3] L :Length of cylinder [cm] D 1 :Outside diameter of cylinder [cm] D 2 :inside diameter of cylinder [cm] Ｗ :Mass of cylinder [kg]

Reference: Density of material: steel --------7.8 •10- 3 [kg/cm3] Aluminum --------2.7 •10 – 3 [ /cm3 ] Copper ----------8.96 •10 – 3 [ /cm3 ]

2.Prism

a 2＋ b 2

J＝Ｗ • ＋ R 2 ------------- (6-2) 3

a, b, R : see the diagram in the left. [cm]

3. A

n ob

ject

mov

ing

alon

g th

e lin

er

axis

4. A

susp

ende

d ob

ject

5.C

onve

rted

mom

ent

of l

oad

iner

tia

appl

ied

to th

e m

otor

shaf

t.

2

2 4 4

Axis of rotation

)(

Axis of rotation

V 2 1 V 2 ∆ S 2JL = W・ =W• • = W • -(6-3) 600 ω 2πn 10 2 π

J L : Converted moment of load inertia applied to the Motor shaft [ •cm2 ]

V : Speed of moving object [mm/min] N : Motor rotation speed [r/min]

Z 1 ∆ S = P B • Z 1, Z 2 : No. of teeth of gears. Z 2

W J L = • D 2 + J p (6 – 4) 4

JP : Moment of inertia of pulley [ •cm2 ]

D : Diameter of pulley [ ]

Ｎ 2 2

J L = J 11 + ( J 21 + J22 + J A )・ ( ) Ｎ 1

N 3 2

+ ( J 31 + J B ) • (--------) ---------( 6-5)

( ))(
Load A
Load B

N 1

J A , J B : Converted moment of load A,B 〔・cm2〕

J11 ~ J 31 : Moment of inertia of gears [ •cm2 ]

N 1 ~ N 3 : Rotational speed of shafts [ｒ / min]

6-2

6. SELECTION

(2) Formulae used to calculate load torque

The formulae used to calculate load torque in typical cases are presented in Table 6.2

Table 6.2 Calculation of Load Torque

Type Mechanism Formula

Line

r mot

ion

F V F • ∆ S T L = * = - ---------(6-6) 2 X10 3 π η N 2 X 10 3 π η

F : Axis force of machine moving along linear axis [ N] η : Efficiency of drive system

The force required to move the table as illustrated in the diagram To the left is calculated using the following formula.

F = F c + µ ( W • g + F c ) -------------------(6 – 7) Fc : Thrust applied to the movable part ( N) F G : Table guide way clamping force ( N ) µ : Friction coefficient V : Speed of object moving along liner axis [mm / min ] N : Motor rotational speed ( r /min) W : Mass of object. [ kg] g : Gravitational acceleration [ 9.8 m /s 2 ] ∆ S : Object feed distance per motor revolution (mm)

Rot

atio

n

Z

T1 1

L = • • T L O + T F ( 6 - 8) Z 2 η

TL o : Load torque applied to the shaft (N• m)

T L : Converted friction load torque applied to the motor

shaft (N• m)

T F : movable friction torque (N • m)

Ver

tical

mot

ion

For upward motion

T L = T U + T F ------------------------------- (6 –9 )

For upward motion

T L = - η 2 • T U + T F ------------------------------------------(6 - 10)

T U : Imbalance (N•m)

T F : movable friction torque (N•m)

( W - W )•g V (W 1 2 T = • =

1 – W 2)•g •∆S U

2 X 10 3 πη N 2X 10 3π η ----------- (6-11)

µ • ( W + W ) • g • ∆S 1 2

( )

Motor

Load

Mass of count-

T = ------------------------------- (6 - 12) F 2 X10 3 π η

W1 : Mass of load [kg ]

W2 : Mass of counterweight [kg]

η : Efficiency of drive system

µ : Friction coefficient (on sheave)

6-3

6. SELECTION

6.2 Reduction Ratio To make the most of the servomotor’s performance, it is important to draw power from the servomotor in the most efficient way and to keep the servo system, including the machine, operating stably and at high responsibility. An important factor in achieving this is the reduction ratio of the mechanism between the servomotor and the machine. The conditions necessary for selecting the reduction ratio correctly are discussed below. (1) Select the reduction ratio so that the motor runs at the rated rotational speed when the

machine is operating at the fastest speed. This allows you to utilize the motor output (power) most efficiently.

(a) The max. output(rated output) of a servomotor is obtained when it runs at the rated rotational speed.

(b) The converted load torque and converted moment of load inertia applied to the motor shaft of the machine become smaller as the selected reduction ratio is increased. In other words, the load on the motor is smallest when the reduction ratio is selected so that the motor runs at the rated rotational speed.

(2) Select the reduction ratio and motor capacity so that moment of load inertia ratio will be 5 to 10 . This ensures good servo system responsibility while maintaining stable operation.

Moment of load inertia ratio m

Converted load applied to the motor shaft J L M = Motor JM < (5 to 10 )

The smaller the moment ratio of load inertia is, the greater the possibility of increasing the responsibility of the servo system. For systems with a high incidence of starting and stopping, select as small a ratio (m < 2) as permitted.

(3) To ensure high positioning accuracy, the feed distance (∆l0) per pulse should be as small as possible.

The following is a rough guideline for the relationship between machine accuracy (∆ε) and feed distance per pulse (∆l0). (∆l0) < ∆ε X [ (1/5) to (1/10) ] Note: For the relationship between ∆l0 and the reduction ratio, refer to section 2.5.1. MEMO

1. The power during acceleration will be smallest when m=1. This is achieved by setting the reduction as 1/n = (√ Jm / JL). This reduction ratio is generally called the optimum reduction ratio.

2. When spur gears and pulleys are used to reduce motor speeds, if the diameter of the driven pulley is enlarged to increase the reduction ratio, the moment of load inertia may become large due to speed reduction.

6.3 Operation Patterns and Required Motor Torque

6-4

6. SELECTION

An operation pattern is usually assessed by dividing a cycle into accelerating time, Tpsa; fixed speed operation time, tc; decelerating time, Tpsd; setting time, ts, and stop time ts

The energy necessary for accelerating an object which has a load inertia moment(JL) is called the acceleration torque, Ta, and that necessary for deceleration is called the deceleration torque, Td.

During the period from the start of deceleration in the fixed speed operation state to the settling time, ts, the friction torque, ＴL, acts in the same manner as it does during fixed speed operation.

6.3.1 Acceleration torque (Ta)

The formula used to calculate the acceleration torque Ta is formulae (6-17)

(JL + JM) • No - Ta= • ( 1- ε ) (N•m) ---------------------- (6-17)

T PSAT p

9.55 X10 4 •Tpsa

Formulae (6-18) is also used to calculate the approximate acceleration torque Ta.

(Jl + JM) • No Ta= (N•m) ------------------------------------------(6-18) 9.55X10 4 • Tpsa

6.3.2 Deceleration torque (Td)

The formulae used to calculate the deceleration torque(Td) is formulae (6－20).

(JL + JM) • No - Td = • (1- ε ) (N•m) (6-20)

T PsaT p

9.55X104 • Tpsd

Formulae (6-21) is also used to calculate the approximate deceleration torque(Td).

(JL +JM) • No Td = (N • m) ----------------------------------------------- (6-21) 9.55 X104 • Tpsd

If Tpsa = Tpsd, the acceleration torque and the deceleration torque have the same value; Ta = - (Td )

6-5

6. SELECTION

6.3.3 Driving pattern

The discussion above can be summarized as follows: (a) The motor torque required for fixed speed operation is the converted load torque applied to motor shaft, TL . (b) The converted load torque applied to the motor shaft, TL, may have a negative value under certain conditions if the

motor is used for up/down motion; (c) The motor torque necessary for acceleration and deceleration are:

Motor torque necessary for acceleration Tma = Load torque TL + Acceleration torque Ta Motor torque necessary for deceleration Tmd = Load torque TL - deceleration torque Td

(d) The condition Tmd = TL – Td > 0 indicates a power deceleration state in which the motor decelerates while supplying energy to the machine;

(e) The condition Tmd = TL – Td < 0 indicates the regenerative braking(the regenerative mode) in which the motor decelerates while applying a braking force to the machine. In this mode, regenerative power flows from motor to amplifier.

(f) Fig. 6.1 shows the deceleration pattern and torque pattern.

Power mode

Regenerative mode

The acceleration/ deceleration torque follows the pattern illustrated in (a) in the diagram to the left due to lag in the control system. However, to simply calculation, Ta and Td in (b) may be used.

Acceleration/deceleration torque

Required Motor torque

Acceleration/deceleration torque

Load torque

Motor speed

Pulse frequency

Motor speed

Input pulse frequency (PPS)

(Remark)

ｔst Stop time [s] ｔf 1 operation cycle [s]

ｔｆ

ｔ０

ｔＣ

Fig. 6.1 Driving Pattern and Torque Pattern at Each Interval

6-6

6. SELECTION

6.3.4 Determining motor capacity

Whether a specific motor may be used for the required application should be determined by

assessing if it can produce the required motor torque shown in Fig. 6.1. In addition to the torque,

the temperature rise of the motor and heat capacity of the regenerative brake must also be

assessed in the case of motors subjected to frequent use.

The motor provisionally selected may be used if it satisfies the following three conditions.

(1) Motor torque required for acceleration Tma in Fig. 4.1

Tma = TL + Ta < Max. motor torque Tma ---------------------------------(6-23)

(2) Motor torque required for deceleration Tmd

Tmd = TL – Ta < Max. motor torque Tmax -------------------------------(6-24)

(3) Continuous effective torque Trms

Trms < Motor rated torque Tm --------------------------------------------(6-25)

The load torque at which the temperature rise of a motor operated intermittently is equal to its

temperature rise when operated continuously is called the continuous effective load

torque, Trms. Therefore, if Trms < Tm, it indicates that the motor maybe used without heat

generation problems.

In the case shown in fig. 6. 1, the continuous effective load torque, Trms, may be calculated

by using the following formula.

Trms = √ Tma • Tpsa + TL • (tc + ts) + Tmd • Tpsd

tf

6-7

6. SELECTION

If any one of the conditions (1), ( 2) and (3) indicated above is not satisfied. Review the conditions at the machine, the operation, motor capacity, etc. and evaluated the selection motor again using the procedure. If all of the conditions(1), (2), (3)indicated above are satisfied, the provisionally selected motor can be used for the required application using the planned speed pattern and cycle time without encountering problems relating to torque or temperature rise. If negative torque is generated in the torque pattern, the performance of the regenerative brake of servo amplifier must be examined.

6-8

6. SELECTION

6 - 9

6.4 Example of Capacity Selection Procedure (1) Table feed

Shaft

Servomotor Coupling

System configuration figure

Table mass Load mass Load resistance power force of a table guidance side Slowdown ratio (NL/NM) Slowdown machine inertia moment Coupling inertia moment Output axis conversion inertia moment Ball screw lead Ball screw diameter Ball screw length Drive part efficiency Friction coefficient Rapid-traverse speed Positioning length / time Positioning time 1 cycle time

WT : W L : FC : FG : 1/n : JG : JC: JO: PB: DB: LB: η: µ: VO: L: To: ｔ f :

kg kg N N kg• cm 2

kg• cm 2

kg• cm 2

mm mm mm/ min mm S S

200.0 50.0 0.01 0.01 1/1 0.20 2.00 0.10 10.00 20.00 1500.00 0.90 0.10 20000.00 400.00 1.50 2.00

Mechanical

ITEM

REMARKCALCULATION The load inertia moment can be computed by machine makers. However, with the system illustrated above, the moment of load inertia can be calculated as indicated below. Note when computing a load inertia moment, the value must be converted into the moment applied to the motor shaft . ① Ball screw

JB LB DB= × × × × ⎛⎝⎜

⎞⎠⎟

132

0 007810 10

4

π . ＝ 13 2

3 1 4 1 6 0 0 0 7 8 1 5 0 01 0

2 01 0

4× × × × ⎛

⎝⎜⎞⎠⎟

. .

[k 2]

Calculation

The calculation of movements per motor rotation (the motor to which the slowdown machine is 1 1

nm= )

∆s PBn nm

= × ×1 1＝＝ [mm/rev]

Motor rotation speed calculation

N VS

0 0=∆

＝＝ [r/min]

<Reference>: Since operation is impossible when calculated NO surpasses the motor maximum rotation speed, it is necessary to make the highest machine speed VO small, or to enlarge amount of sending ∆S per motor rotation.

The positioning time of machine side specification and positioning speed (the highest machine speed) are asked for acceleration and deceleration time of servomotor. Generally, a motor is straight line acceleration anddeceleration , and since acceleration and deceleration time are set up equally, it asks for an operation pattern by thepremise also by this example. (The position loop gain Kp is taken as the initial value 35 of MR-J2S.) The acceleration and deceleration time is found in the following ways from a front figure. Stop setting time calculation

tsKp

= ×3 1 ＝＝ [s]

The acceleration and deceleration time calculation

Tsa Tsd t LV

ts= = − × +⎛⎝⎜

⎞⎠⎟

=00

60

＝ [s]

0.214

1.5－(400/20000 X60＋0.086)

ITEM

1. Calculation of Load data

2. Motor Rotation Speed at Time of Highest Machine Speed

3. Operation Pattern

3 X 1/35 0.086

20000/10.0 2000

10.0 10X１X１

REMARK

6. SELECTION

6 - 10

HC-MFS73 MR-J2S-70A

0.433

10.471 0＋0＋6.333＋ 0.2＋2＋0.1＋1.838 X(1)2 X12

6.333

1.838

＞ＴＬ＝ 0.433 Ｔｔｙｐ＝ 2.4

ＪＭ＝ 0.6 ＪＬ／30 ＝ 0.349 ＞

( . . ). .

.10 471 0 6 20009 55 10000 0 214

0 433+ ×× ×

+

1.516 7.2

− + ×× ×

+( . . ). .

.10 471 0 6 20009 55 10000 0 214

0 433

－0.650 7.2

6. SELECTION

6 - 11

CALCULATION Calculate the continuous effective load torque from the driving pattern and the required motor torque, calculated above. The calculated continuous effective load torque must not exceed the rated torque of the provisionally selected motor. Continuation effective load torque

( )Tr ms

Tma Tsa TL t Tsa Tsd ts TMd Tsdtf

=× + × − − − + ×2 2 20

＝

＝ [N.m] ＜Motor Rated torque Type

Determine if the regenerative brake option is necessary, on the basis of the brake duty. Acceleration energy Ea N TMa Tsa= × × ×01047 0

2.

＝＝ [Ｊ]

Deceleration energy Ed N TMd Tsd= × × ×01047 02

.

＝＝ [Ｊ]

Working energy ( )Ef N TL to Tsa Tsd ts− −= × × × −01047 0.＝＝ [Ｊ]

Absolute value of the negative energy sum total ＝＝ [Ｊ]

Regenerative: Pr =× − × −ηm Em Wa t Ec

tf＝

＝ [Ｗ]

Regeneration brake option unused Regeneration brake option used

The result selected from the above examination is as follows. Servomotor

Servo amplifier Regeneration option

Motor rotational speed corresponding to the maximum machine speed ： 2000 (ｒ／ｍｉｎ) Acceleration/ deceleration time ： 0.214 (ｓ) Motor torque required for acceleration ： 1.516 (Ｎ・ｍ) Motor torque required for deceleration ： -0.650 (Ｎ・ｍ) Continuous effective load torque ： 0.619 (Ｎ・ｍ)

The regeneration brake more than regeneration power is used. Model name

Unused

0.1047 X2000/2X1.516X0.214 33.967

0.1047X2000/2X(-0.650)X0.214 -14.564

89.401 0.1047X2000X0.433X0.986

14.564 ｜-14.564｜

Built-in regeneration power 20 [Ｗ] ＜－3.1744

HC-MFS73

MR-J2S-70A

1516 0 214 0 433 15 0 214 0 214 0 086 0 650 0 2142

2 2 2. . . ( . . . . ) ( . ) .× + × − − − + − ×

REMARK ITEM

8. Calculation of

continuous effective load torque

9. Evaluation of

whether the regenerative brake option should be used or not

10.Result of

selection

2.4 0.619

＜ unused 、＞：used

( / ) . .80 100 14 5 0 0 214 18

2× −64× −

6. SELECTION

6 - 12

(2)Lift applications

coupling

Motor Shaft

System configuration figure

Table mass Load mass Counter weight mass Load resistance power Force of the table guidance side Slowdown ratio（ＮＬ／ＮＭ） Slowdown machine inertia moment Coupling inertia moment Other output conversion inertia moment Ball screw lead Ball screw diameter Ball screw length Drive part efficiency Friction coefficient Rapid-traverse speed Positioning length / time Positioning time 1 cycle time

ＷＴ：ＷＬ：ＷＣ：Ｆｃ：ＦＧ：１／ｎ：ＪＧ：ＪＣ：Ｊ０：ＰＢ：ＤＢ：ＬＢ： η： μ：Ｖ０：Ｌ：ｔ０：ｔｆ：

ｋｇｋｇｋｇＮＮｋｇ・ｃｍ２ｋｇ・ｃｍ２ｋｇ・ｃｍ２ｍｍｍｍｍｍｍｍ／ｍｉｎｍｍｓｓ

８０．００５０．００１００．０００．０１０．０１１／2 ０．２０２．０００．１０１０．００２０．００１５００．０００．９００．１０ 1００００．００４００．００２．６０６．００

Mechanical Specification

ITEM

1. Calculation of Load Data

2. Motor rotation speed at time of highest machine speed

3. operation Pattern

CALCULATION

The calculation of movements per motor rotation ( the slowdown machine 1 1nm

= )

∆s PBn nm

= × ×1 1＝＝ [mm/rev]

Motor rotation speed calculation

N VS

0 0=∆

＝＝ [r/min]

＜Note＞：Since operation is impossible when calculated NO surpasses the motor maximum rotation speed, it is necessary to make the highest machine speed VO small, or to enlarge amount of sending ∆S per motor rotation.

The positioning time of machine side specification and positioning speed (the highest machine speed) are askedfor acceleration and deceleration time of servomotor. Generally, a motor is straight line acceleration anddeceleration , and since acceleration and deceleration time are set up equally, it asks for an operation pattern by thepremise also by this example. (The position loop gain Kp is taken as the initial value 35 of MR-J2S.)

The acceleration and deceleration time is found in the following ways from a front figure.

Setting time calculation

tsKp

= ×3 1 ＝＝ [s]

The acceleration and deceleration time calculation

Tsa Tsd t LV

ts= = − × +⎛⎝⎜

⎞⎠⎟

00

60 ＝

＝ [s]

0.114

2.6－(400/10000X60＋0.086)

3X1/35 0.086

10000/5.0 2000

5 10X0.5X１

REMARK

6. SELECTION

CALCULATION The load inertia moment can be computed by machine makers. However, with the system illustrated above, the moment of load inertia can be calculated as indicated below. Note when computing a load inertia moment, the value must be converted into the moment applied to the motor shaft .

① Ball screw

6 - 13

JB LB DB= × × × × ⎛⎝⎜

⎞⎠⎟

132

0 007810 10

4

π .

( )

＝

＝ [kg・cm2]

② The straight-line motion object

JF WT WL WC S= + + ××

⎛⎝⎜

⎞⎠⎟

∆10 2

2

π＝

＝ [kg・cm2]

③ Motor shaft conversion load inertia moment (the motor which the slowdown machine is not attached, JMG=0

JL JMG JMB JF JG JC J JB= + + + + + + × ⎛⎜ ⎞⎟

⎧⎨⎪ ⎫

⎬⎪ × ⎛⎜ ⎞

⎟0 1 12 2

( )

n nm⎝ ⎠⎩⎪ ⎭⎪ ⎝ ⎠

= = [kg・cm2]

<note>：Since all the objects moved when a motor rotates are applicable, an inertia moment needs to take all them into

consideration.. The load inertia moment can be computed by machine makers. However, with the system illustrated above, the moment of load inertia can be calculated as indicated below. Note when computing a load inertia moment, the value must be converted into the moment applied to the motor shaft . (Gravity acceleration g= 9.8)

Imbalanced torque

TUFc WT WL WC g S=

+ + − ×× ∆

( )

1000 2π＝

＝ [N.m]

Friction torque

TFWT WL WC g FG S=

× + + × +µ ∆

( )

×π1000 2

＝

＝ [N.m]

TLuTU TF

=+η

＝＝ [N.m]

the motor shaft conversion load torque at the time of descent. ・（－ＴＵ＋ＴＦ）＞０

TLd TU TF− +=η

( )TLd TU TF= − + ×

＝＝ [N.m]

・（－ＴＵ＋ＴＦ）＜０

η ＝＝ [N.m]

Once the load torque and a load inertia moment can be found, it is possible to select an approximate motor capacity., as the standard of provisional selection.

① The motor rated torque Ttyp should be more than load torque. (A margin is usually given to about 50 - 80% of the rated torque Ttyp.)

② The load inertia moment of the motor itself, Jm, must be at least 1/10(HC-KFS) of Jl ; ③ The motor of a perpendicu ts with a safety top brake. lar axis selec

Provisional selection motor、 a servo nd amplifier

ＪＭ＝ 0.42

REMARK

(－0.234＋0.179)X0.9 －0.05

CALCULATION

Now the load torque, the load inertia moment, and the operation pattern of motor have been obtained. The next step is to assess whether the torque required for accelerating and deceleration by the provisionally selected motor is less than the max. torque of this motor. If the torque required for acceleration/deceleration exceeds the max. torque of the motor, the motor cannot follow the pattern within the acceleration/deceleration time calculated in the preceding step, and a servo error will result. Acceleration torque at the time of rise

( )JL JM N+ ×⎧ ⎫0

HC-KFS43B MR-J2S-40A

Ｔｔｙｐ＝ 0.64 ＴＬｕ＝ 0.459

REMARKITEM

4. Calculation of Load Inertia Moment

5. Calculation of Load Torque

6. Provisional selection of a motor

0 01 50 100 9 81000

52 31416

. (80 ) ..

+ + − ××

×

0.234

01 80 50 100. (× + + 9 8 0 011000

52 3146

) . ..

× +×

×

0.179

0.459 0 234 0179. .+

0 9.

ITEM

＞

ＴＬｄ＝－0.05 ＞Ｔｔｙｐ＝ 0.64

＞ＪＬ／15 ＝ 0.2837

0＋0.040＋1.456＋ 0.2＋2＋0.1＋1.838x(0.5)2x12 4.256

1.456

( ) ..

80 50 100 5 010 2 3 1416

2+ + ×

× ×⎛⎝⎜

⎞⎠⎟

1.838

1 0 0078 150010

2010

4× × ⎛

⎝⎜⎞⎠⎟

. .32

3 1416× ×

6. SELECTION

6 - 14

－0.909

)05.0(114.01000055.92000)420.0256.4(

−+⎭⎬⎫

⎩⎨⎧

×××+

−

)05.0(114.01000055.92000)420.0256.4(

−+⎭⎬⎫

⎩⎨⎧

×××+

1.9

0.809

1.9 －0.400

459.0114.01000055.92000)420.0256.4(

+⎭⎬⎫

⎩⎨⎧

×××+

−

( . . ). .

.4 266 0 670 20009 55 10000 0114

0 459+ ×× ×

⎧⎨⎩

⎫⎬⎭

+

1.9

1.9

1.366

2.6－0.114－0.114－0.086

2.286

tc to Tsa Tsd ts= − − −

Trmst

TMau TMad Tsa TMdu TMdd Tsd TLu TLd tc TU tf t tsf

= )+ × + + × + + × + × − × + ×( ) ( ) ( ) (2 2 2 2 2 2 2 2 0 2

0.393 0.64

6

)086.026.226(2

234.0286.2)2

)05.0(2

459.0(114.0)2

)909.0(2

)400.0((114.0)2

809.02

366.1( ×+×−×+×−++×−+−+×+

6. SELECTION

6 - 15

CALAULATION Determine if the regenerative brake option is necessary, on the basis of the brake duty. Acceleration energy at the time of rise

Eau N TMau Tsa= × × ×010472

0. ＝

＝ [Ｊ]

Deceleration energy at the time of rise

Edu N TMdu Tsd×= × ×010472

0. ＝

＝ [Ｊ]

working energy at the time of rise Efu N TLu tc= × × ×01047 0. ＝＝ [Ｊ]

Acceleration energy at the time of descent Ead N TMad Tsa= × × ×0 1047

20. ＝

＝ [Ｊ]

Deceleration energy at the time of descent Edd N TMdd Tsd×= × ×01047

20. ＝

＝ [Ｊ]

working energy at the time of descent Efd N TLd tc= × × ×01047 0. ＝＝ [Ｊ]

The absolute value of the negative energy sum total Ｅｍ＝｜（Ｅａｕ，Ｅｄｕ，Ｅｆｕ，Ｅａｄ，Ｅｄｄ，Ｅｆd Sum total｜

＝＝ [Ｊ]

Regenerative:

Pr = × − × −ηm Em Wa t Ectf

＝

＝ [Ｗ]

Regeneration brake option unused Regeneration brake option used

15.731

114.0)400.0(20002

1047.0 ×−××

－4.774

219.718 0.1047X2000X0.459X2.286

114.0809.1047.0 020002

×××

9.656

114.0)909.0(20002

1047.0 ×−××

－10.850

0.1047X2000X(-0.05)X2.286 －23.934

｜(－4.774)＋(－10.850)＋(－23.934)｜ 39.558

69514.20558.39)100/70( −×−×

Built-in regeneration power 10 [Ｗ]

< 3.115

114.0318.120002

1047.0 ×××

＜unused 、＞：use

The regeneration brake more than regeneration power is used. Model name

ITEM

10. Evaluation of whether the regenerative brake option should be used or not

REMARK

6. SELECTION

6 - 16

CALAULATION The result selected from the above examination is as follows.

Servomotor

Servo amplifier

Regeneration option

Motor rotational speed corresponding to the maximum machine speed ： 2000 (ｒ／ｍｉｎ) Acceleration time ： 0.114 ［ｓ］

Motor torque required for acceleration at the time of rise ： 1.318 ［Ｎ・ｍ］

Motor torque required for deceleration at the time of rise ： 0.809 [Ｎ・ｍ]

Motor torque required for acceleration at the time of descent ： -0.400 ［Ｎ・ｍ］

Motor torque required for deceleration at the time of descent ： -0.909 [Ｎ・ｍ]

Continuous effective load torque ： 0.393 ［Ｎ・ｍ］

HC-KFS23B

MR-J2S-20A

unused

ITEM

11.Result of selection

REMARK

7. The Measure Against Noise, Leak Current, Harmonics

7.1 The measure against a noise

Servo amplifier is controlling the servomotor by switching rectification and the direct-current power supply of

about 300 V that carried out flat and smooth for a commercial power supply. Therefore, Servo amplifier may serve

as a noise generation source to peripheral equipment, and may generate the trouble of a noise with the amount of -

proof [noise] of Servo amplifier, the cloth line affair of the power line between servomotors, the grounding method,

and Servo peripheral equipment.

The signal line of that on which the noise generated from Servo amplifier is radiated from the electric wire

connected to the main part of Servo amplifier, and a Servo amplifier main circuit (ON and output), and the

peripheral equipment close to the main circuit electric wire -- electromagnetism -- it can divide roughly into a target,

the thing to guide in static electric, and the thing transmitted in power supply circuit.

Servo amplifier

Generating noise

Noise transmitted in

the air

Noise radiated directly

from Servo amplifier

Noise radiated from the

power supply cable

Noise radiated from the

motor connection cable Electromagnetism

induction Noise

Static electric induction

Noise

----Route (4), (5)

----Route (6)

The Noise transmitted

through electric channels

Noise transmitted through

power supply cable

Noise from the grounding

cable due to leak current.

---- Route (1)

----Route (2)

----Route (3)

----Route (7)

----Route (8)

Telephone

Sensor power supply

Servomotor Sensor

Servo Amp. Instrument Receiver

7-1

7. The measure against a noise, leak current, harmonics

Noise propagation Measure

(1) (2) (3)

Feeble signals, such as a measuring instrument, a receiver, and a sensor, are treated, and since

apparatus may incorrect-operate by air propagation of a noise when it is influenced of a noise, and it is

contained in the same board as Servo amplifier, or the apparatus which is easy to operate, and its signal

cable approach and are wired, it is necessary to take the following measures.

(1) The apparatus which is easy to be influenced is separated from Servo amplifier as much as

possible, and is installed.

(2) From the input-and-output cable of Servo amplifier, the signal cable which is easy to be

influenced is detached as much as possible, and is patterned.

(3) Wiring is avoided in parallel routing and the bunch of a signal cable and a power line (Servo

amplifier input-and-output cable).

(4) If a cable noise filter and an input can insert a radio noise filter in an input-and-output cable, the

radiation noise from an electric wire can be controlled.

(5) It is still more effective, if the shield cable is used for the signal cable or the power cable or it

puts into a respectively individual metal duct.

(4) (5) (6)

When parallel routing of the signal cable is carried out or it is bundled by the power cable together

with the power cable, it electromagnetism induction. Since a noise may spread and incorrect-operate

on a signal line by the noise and the static electricity induction noise.

It is necessary to take the following measures.

(1) The apparatus that is easy to be influenced is separated from Servo amplifier as much as

possible, and is installed.

(2) From the input-and-output cable of Servo amplifier, the signal cable that is easy to be influenced

is detached as much as possible.

(3) Wiring is avoided in parallel route and the bunch of a signal cable and a power cable (Servo

amplifier input-and-output cable).

(4) It is still more effective, if the shield cable is used for a signal cable or the power cable or it puts

into a respectively individual metal duct.

(5) A data line filter is attached in the signal cable.

(7)

The case where the power supply of peripheral equipment is connected with the power supply of the

same system as Servo amplifier since apparatus may incorrect-operate from the noise in which the

generated noise flows backwards the power supply cable, it is necessary to take the following

measures:

(1) A radio noise filter (FR-BIF) is installed in the power cable(input-and-output cable) of Servo

amplifier.

(2) A radio noise filter (FR-BLF, FR-BSF01) is installed in the power cable of Servo amplifier.

(3) A data cable filter is attached in the power supply cable of peripheral equipment.

7-2


(8)

When wiring of peripheral equipment is having the closed loop circuit constituted by wiring Servo

amplifier, it leaks from the grounding cable of Servo amplifier, current flows in, and apparatus may

incorrect-operate.

When such, if the grounding cable of apparatus is removed, there is a case where it stops incorrect-

operating.

7.2 Leak current

To AC Servo, the chopper current of the harmonics by which PWM control was carried out flows. It leaks and current becomes

large compared with the motor containing a part for harmonics operated with a commercial power supply.

A short circuit breaker should select a lower formula to reference, and a Servo amplifier, servomotor etc. should ground

certainly.

Moreover, please the route distance of the electric wire of input and output be short as much as possible to reduce leak current,

detach as much as possible between the grounds, and carry out electrical route (about 30cm).

Rated sensitivity current >=10X(lg1＋lgn＋lga＋ＫX(lg2＋lgm)) (mA)

K: The constant in consideration of a part for harmonics

Short circuit breaker

Type Elegance of

our

company

Harmonics and a serge

correspondence article

NV - SF

NV - CF 1

Common article

NV - CA

NV - CS

NV - SS

3

Wire length

Servo amplifier

7-3


Ig1 ：Leak current of the circuit from a short circuit breaker to a Servo amplifier input terminal (It asks from

Fig. 7.1.)

Ig2 ：Leak current of the circuit from a Servo amplifier output terminal to the servo motor (It asks from

Fig. 7.1.)

Ign ：Leak current at the time of connecting an input side filter etc. (In FR-BIF, it is 4.4mA per piece.)

Iga ：Leak current of Servo amplifier (It asks from Table 7.2.)

Igm ：Leak current of a servomotor (it asks from Table 7.1)

Leak current of a servo motor (it asks from Table 7.1)

Fig. 7.2 Example of leak current per km

at the time of carrying out metal wiring

of CV cable (Ig1, Ig2)

Table 7.1 Servo motor’s

eak current (Igm) l

Servo motor output (kW)

Leak current(mA)

0.05 ~0.5 0.1

0.6 ~0.1 0.1

1.2 ~2.2 0.2

3, 3.5 0.3

Table 7.2 Servo amplifier’s leak

urrent (Iga) c

Servo Amplifier

capacity (kW)

Leak current (mA)

0.1 ~ 0.6 0.1

0.7 ~ 3.5 0.15

Leakage current

Cable size

7-4


7.3 Harmonics

7.3.1 A basic wave and harmonics It is defined as the thing with the frequency of the integral multiple of a basic wave (generally power supply

frequency), and it is distorted and what compounded one basic wave and two or more harmonics is called

harmonics with the wave. (Refer to Fig. 7.3)

Although the distortion wave is generally included to the harmonics (kHz-MHz) of a harmonics domain, it differs

in character with the problem of the harmonics domain which the 40-50th (-3kHz) usually deal with it as harmonics

of a power distribution system, and generally presents a random aspect. For example, problems with a personal

computer, such as an electric wave obstacle and a noise (refer to section 7.1), are local problems stuck to apparatus

hard, and the influence and a correspondence means differ from the harmonics for an electric power network. It is

necessary to clarify this first.

∞ I = Io + Σ In •sin (2πfnt + ϕn)-------------------------- (7.1) n=1

n = 1, 2, 3……….

f = Basic frequency

Merger wave

3 times harmonics

2 times harmonics

Basic Wave

Fig. 7.2 Basic wave and harmonics Fig. 7.3 Distortion wave

7-5


Table 7.3 The harmonics and noise as following

ITEM Harmonics Noise

Frequency Usually, the 40-50th 3kHz or less Harmonics (several 10 kHz-MHz order)

Environment Depended on track and power supply impedance

Depended on space, distance, a routing course

Quantity grasp Theoretical calculation is possible. They are generating and quantity grasp difficulty at random.

The amount of generating

It is proportional to load capacity mostly.

It is based on a current rate of change (size like high-speed switching).

The amount of -proof of damage apparatus

It writes clearly by the standard for every apparatus.

It changes with a maker's apparatus specifications.

The example of a measure

A reactor (L) is attached. Distance (l) is extended.

7.3.2 The characteristic of a rectification circuit and generating harmonics As a generation source of harmonics, there are a rectifier, an exchange electric power adjustment machine, etc. The converter

part of general-purpose Servo consists of the rectifier circuit, and has generated many harmonics.

As shown in Table 7.4, there are two kinds of things in a rectifier circuit with the main circuit system, and most 3 phase bridge

systems are adopted in general-purpose Servo.

Table 7.4 Rectifier circuit system and harmonics

Circuit name Basic circuit diagram Harmonics degree Harmonics content

Single bridge

N = 4k + 1

K = 1, 2……

Kn X 1/n

3 phase Bridge

N = 6k + 1

K = 1, 2 ……

Kn X 1/n

Kn: The coefficient decided by the control delay angle, the running style overlap angle, etc.

7.3.3 The measure against harmonics The Ministry of International Trade and Industry enacted the harmonics control measure guideline about the

measure against harmonics control in September, 94.

The Servo amplifier of 4.0 or less kW becomes the object product of "household electric appliances and a general-purpose

article harmonics control measure guideline." In accordance with these guidelines, the gradual regulation level was decided in

Japan Electrical Manufacturers' Association.

Since this regulation level is suited, the Servo amplifier 4.0kW or less installed on and after January 1,

97 needs to connect a power improvement reactor (FR-BAL).

7-6

8. Maintenance and Inspection

8.1 Maintenance and Inspection

Although AC Servo amplifier is stillness apparatus constituted focusing on the semiconductor element, in order to

prevent beforehand the trouble generated from the influence of use environment, such as temperature, humidity,

and vibration, secular change of use parts, a life, etc., it is necessary to perform everyday check.

8.1.1 Notes at the maintenance and inspection Please carry out after checking with a tester etc. that the voltage between main circuit terminal P-N is 0V waiting

and after that until a charge lamp puts out the light, since a flat and smooth capacitor is in a high-voltage state for a

while after intercepting a power supply, when checking the inside of AC Servo amplifier.

8.1.2 Item of inspection

1 Daily inspection Basically, it checks for no following abnormalities during operation.

(1) Does the motor move as the setting?

(2) Is it normal by the environment of the installation place?

(3) Is it normal for the cooling system?

(4) Aren't there unusual vibration and unusual sound?

(5) Aren't there unusual overheating and discoloration?

It is usually with a tester during operation, and the input voltage of AC Servo is checked.

2 Scheduled inspection The part which cannot be checked unless it stops operation, and the part which requires a scheduled

inspection are checked.

(1) Is it normal for a cooling system? .... Cleaning of an air filter etc.

(2) It increases with a check with a bundle and fastens. .... Under the influence of vibration,

temperature change, etc., since connector, such as a screw and a bolt, may loosen, it often carries

out after a check.

(3) Aren't corrosion and breakage in the conduct and an insulator?

(4) Measurement of insulation resistance

(5) The check and exchange of the cooling fan, the smooth capacitor, and the relay.

8-1


8-2

Table 8.1 Daily check and scheduled inspection

Check item

Check matter

Dai-

ly

Per-

iod

The check method

Judgment standard

Meter

Circumference

environment

Circumference

temperature, humidity, dirt,

etc. are checked.

X A thermometer,

a hygrometer, a

recorder

Who

le u

nit

Preservation

environment

Circumference

temperature, humidity, dirt,

etc. are checked.

X It measures with

temperature, a hygrometer,

etc.

(1) motor: -- below -10 degrees

C - +70 degree-C(there needs to

be no freeze) RH [ 90%] (there

needs to be no dew

condensation) amplifier: --

below -20 degrees C - +65

degree-C(there needs to be no

freeze) 90%RH (there needs to

be no dew condensation)

A thermometer,

a hygrometer, a

recorder

Entire Equipment Aren't there unusual

vibration and unusual

sound?

X It is based on viewing and

hearing.

If normal. -

Power supply

voltage

The main circuit voltage is

normal.

X Voltage measurement

between phase to phase of

the Servo amplifier terminal

stands R, S, and T

Standard specification is referred

to.

Multi-meter

Whole unit (1) Isn't there any slack of

Connector?

(2) After overheating into

each portion, is there

nothing?

(3) Cleaning

X

X

(1) Carry out an increase

bundle.

(2) It is based on viewing.

There are no abnormalities in (1)

and (2).

Mai

n ci

rcui

t Connection

conduct

Wire or cable

(1) Isn't there any

distortion in conduct?

(2) Isn't there any tear of

electric wire covering?

X (1) (2) It is based on

viewing.

There are no abnormalities in (1)

and (2).

Terminal stand Isn't it damaged? X It is based on viewing.

Are normal.

Flat and smooth

capacitor

(1) Isn't there any liquid

leak?

(2) Has not (safety valve)

come out or doesn't a

swelling have it?

X

(1) and (2) is based on

viewing.

(1)(2). There are no

abnormalities

Capacity meter


8-3

swelling have it?

(3) Measurement of static

electricity capacity

X (3) Measure with a capacity

measuring instrument.

(3) 85% or more of rated

capacity

Mai

n ci

rcui

t

Relay (1) Isn't there any Beeper

sound at the time of

operation?

(2) The check of the time

of a timer of operation

(3) Isn't there that any in a

point of contact?

X

X

X

(1) It is based on a feeling of

listening

(2) Time from a power

supply ON to relay suction


(1) Are normal.

(2) Operate in 0.1 - 0.15

seconds.

(3) Are normal.

Multi-meter

Resistor

(1) Isn't there any Wire of

a resistor insulator?

(2) The check of

disconnection existence

X

X

(1) It is based on

viewing. Cement

resistance and

winding form

resistance

(2)

Remove connection

of one side and they

are measurement

cement resistance

and winding form

resistance with a

tester.

(1) Are normal.

(2) It is less than 10% of error

of display resistance.


Check Item

Check matter

Daily

Period

Check method

Judgment standard

Meter

Con

trol c

ircui

t and

pro

tect

ion

circ

uit To check of

operation

(1) By Servo simple

substance (no-load)

operation, it is the check of

balance of each phase of

output voltage.

(2) Sequence protection

operation is performed and

there are no abnormalities

in protection / display

circuit.

X

X

(1) Measure the Servo

amplifier output terminals U

and V and the voltage

between W phase.

(2) Short-circuit the

protection circuit output of

Servo amplifier in imitation.

(1) The voltage balance between

phase to phase is less than

[ 4V ].

(2) Abnormalities operate on a

sequence.

Rectified type

voltmeter

Coo

ling

syst

em Cooling fan (1) Aren't there unusual


sound?

(2) Isn't there any slack

of a connection part?

X

X

(1) It turns by hand in the

state of no power supply.

(2) Carry out an increase

bundle.

(1) Rotate smoothly.

(2) Are normal.

Dis

play

Display Aren't there a charge

lamp and a piece of a 7

segment Light Emitting

Diode display?

X The lamp and display

machine of the amplifier

face of a board are shown.

Lighting is checked.

Serv

omot

or Whole unit (1) Aren't there unusual


sound?

(2) Isn't there any nasty

smell?

X

X

(1) It is based on a feeling

of listening, a physical

feeling, and viewing.

(2) The nasty smell check

by overheating, damage,

etc.

There are no abnormalities in

(1) and (2).

Encoder Aren't there unusual


sound?

X It is based on a feeling of

listening, and a physical

feeling.

Are normal.

Cooling fan (1) Aren't there unusual


sound?

(2) Have not the foreign

substance, etc. adhered?

X (1) It turns by hand in the

state of no power supply.


(1) Rotate smoothly.

(2) Are normal.

Bearing Aren't there unusual


sound?

X It is based on a feeling of

listening, and a physical

feeling.

Are normal.

8-4


8.1.3 Parts exchanged

The following parts have secular degradation on mechanical wear or physical properties, and since the

performance fall of a unit and failure may be affected, while performing a scheduled inspection for preventive

maintenance, it is necessary to carry out periodical exchange.

(1) Flat and smooth capacitor : As for a flat and smooth capacitor, the characteristic deteriorates under the

influence of ripple current etc. Although greatly influenced by

circumference temperature and the operating condition, the life of a

capacitor will turn into a life in ten years, when continuation operation is

carried out on the air-conditioned usual environmental conditions.

(2) Relays : Poor contact occurs in the point-of-contact wear by opening-and-closing

current. Although influenced by power supply capacity, it becomes a life

by the 100,000 hours of accumulation opening and closing (opening-and-

closing life).

(3) Servo amplifier cooling fan : It is 10,000 - 35,000 hours from a cooling fan's bearing life. Therefore, in

continuation operation, it is necessary to usually exchange it the whole

fan, using the 2 - 3 year as a standard. Moreover, when unusual sound

and unusual vibration are discovered at the time of check, it is necessary

to exchange.

(4) Servo motor bearing : Please exchange 20,000 - 30,000 hours for a standard by rated speed and

rated load operation. Since it is influenced by the operation situation,

when unusual sound and unusual vibration are discovered, exchange is

required at the time of check.

(5) Servo motor oil seal, V ring: Exchange is needed by making 5000Hr(s) into a standard at rated speed.

Exchange is needed, when an oil leak etc. is discovered at the time of

check, since it was influenced by operation conditions.

(6) Battery : It will become a life from a manufacture day in five years.

8-5


8-6

Table 8.2 Standard exchange years of parts

Parts Standard exchange time Remark

Flat and smooth capacitor 10 Years

Servo amplifier Relay -

Cooling Fan 10,000 ~30,000hours (2~3 Years)

Bearing 20,000 -- 30,000 hours

Servo motor Encoder 20,000 -- 30,000 hours

Oil seal, V Ring 5000 hours

Battery It is for five years from a manufacture day.


8.1.4 Troubleshooting

If alarm is generated, a failure signal (ALM) will be turned off that displayed alarm on a display part.

A servo motor stops. Please remove the cause of alarm according to which kind of Alarm . A

generating factor can be referred to if the setup software of an option is used. Only in the case of

MR-J2S, an alarm code is outputted. In MR-H, use of a parameter unit can refer a generating factor.

(Note2)Alarm Code Alarm deactivation

Display CN1B 19

CN1A 18

CN1A 19

Name Power OFF→

ON

Press “set” on current Alarm screen

Alarm reset (RES) signal

AL.10 0 1 0 Undervoltage o o o AL.12 0 0 0 Memory error1 o AL.13 0 0 0 Clock error o AL.15 0 0 0 Memory error 2 o AL.16 1 1 0 Encoder error 1 o AL.17 0 0 0 Board error 2 o AL.19 0 0 0 Memory error 3 o AL.1A 1 1 0 Motor combination error o AL.20 1 1 0 Encoder error 2 o AL.24 1 0 0 Motor output ground fault o AL.25 1 1 0 Absolute position erase o AL.30 0 0 1 Regenerative error o o o

AL.31 1 0 1 overspeed o o o

AL.32 1 0 0 overcurrent o o o

AL.33 0 0 1 overvoltage o AL.35 1 0 1 Command pulse frequency error o o o

AL.37 0 0 0 Parameter error o AL.45 0 1 1 Main circuit device overheat o o o

AL.46 0 1 1 Servomotor overheat o o o

AL.50 0 1 1 Overload 1 (note1) o (note1) o (note1) o

AL.51 0 1 1 Overload 2 (note1) o (note1) o (note1) o

AL.52 1 0 1 Error excessive o o o

AL.8A 0 0 0 Series communication time-out o o o

AL.8E 0 0 0 Series communication error o o o

8.8.8.8.8. 0 0 0 Watchdog o AL.92 Open battery cable warning

AL.96 Home position setting warning

AL.9F Battery warning

AL.E0 Regenerative warning

AL.E1 Overload warning

AL.E3 Absolute position counter

warning

AL.E5 ABS time-out warning

AL.E6 Servo emergency stop

AL.E9 Main circuit off warning

AL.EA

ABS servo-on warning

Removing the cause of occurrence deactivates the alarm automatically.

Note 1. Deactivate the alarm about 30 minutes of cooling time after removing the cause of occurrence. 2. If the value of a parameter 49 is set to "01", an alarm code can be outputted at the time of alarm generating. 0:

It becomes an OFF 1:ON signal.

8-7


Dis- play Name Defination Cause Action

1. Power supply voltage is low.

2. There was an instant power failure for 15ms or more.

3. Shortage of Power supply capacity caused the power supply voltage to drop at start,

etc. 4. It turned on within 5s after the power

supply OFF.

Review the power supply. AL.10 Undervoltage Power supply voltage dropped. MR-J2S-A:160V or less

5. Faulty parts in the servo Amplifier

Alarm(AL. 10) occurs if power is switched on after N1A,CN1B and CN3 connectors are disconnected

Checking Method

Change the servo amplifier

AL.12 Memoty error1 RAM, Memory fault

AL.13 Clock error Print board fault

AL.15 Memory error2 EEP-ROM fault

Faulty parts in the servo amplifier

Alarm(any of AL12,13 and 15) occurs if power is switched on after CN1A,CN1B and CN3 all connectors are disconnected.

Check Method

Change the servo amplifier.

1. CN2 connector disconnected. Connect correctly

2. Encoder fault Changed the servo motor.

3. Encoder cable faulty (Wire breakage or shorted)

AL.16 Encoder error1 Communication error occurred between encoder and servo amplifier

4. The combination of Servo amplifier and a servo motor is different.

Cable repair or exchange.

Note

At the time of alarm generating, please re-operate after removing a cause and securing safety. It becomes the cause of an injury.

When the following alarm is generated, please carry out alarm release repeatedly by control circuit power supply OFF->ON, and do not resume operation. It becomes the cause of failure of Servo amplifier, a servomotor, and a regeneration option. Please resume operation after setting the cooling time for about 30 minutes at the same time it removes the cause of generating.

* Regenerative error(AL.30) * Overload １ (AL.50) * Overload ２ (AL.51)

Wa rning

8-8


Display Name Definition Cause Action

AL.17 Board error 2 CPU/parts fault AL.19 Memory error 3 ROM memory fault

Faulty parts in the servo amplifier Checking method

Alarm (AL.17 or AL.19) occurs i f power is switched on after CN1A,CN1B and CN3 connectors aredisconnected.


AL.1A Motor combination error

Wrong combination of servo anplifier and servo motor.

Wrong combination of servo amplifier and servomotor connected.

Use correct combination.

1. Encoder connector (CN2) disconnected. Connect correctly. AL.20 Encoder error 2 Communication error occurred between encoder and servo amplifier.

2. Encoder cable faulty (Wire breakage or shorted)

Repair or change the cable.

1. Power input wires and servo motor output wires are in contact at main circuit terminal block (TE1).

Connect correctly.

2. Sheathes of servo motor power cables deteriorated, resulting in ground fault.

Change the cable.

AL.24 Main circuit error Ground fault occurred at the servo motor outputs (U,V and W phases) of the servo amplififer.

3. Main circuit of servo amplifier failed. Checking method

AL.24 occurs i f the servo isswitched on after disconnect ingthe U, V, W power cables fromthe servo ampli fier .


1. Reduced voltage of super capacitor in encoder

After leaving the alarm occurring for a few minutes, switch power off, then on again. Always make home position setting again.

2. Battery voltage low

Absolute position data in error

3. Battery cable or battery is faulty. Change battery. Always make home position setting again.

AL.25 Absolute position erase

Power was switched on for the first time in the absolute position detection system.

4. Super capacitor of the absolute position encoder is not charged

After leaving the alarm occurring for a few minutes, switch power off, then on again. Always make home position setting again.

1. Wrong setting of parameter No. 0 Set correctly. 2. Built-in regenerative brake resistor or

regenerative brake option is not connected.

Connect correctly

3. High-duty operation or continuous regenerative operation caused the permissible regenerative power of the regenerative brake option to be exceeded.

Checking methodCal l the status display and checkthe regenerat ive load rat io.

1. Reduce the frequency of positioning. 2. Use the regenerative brake option of larger

capacity. 3. Reduce the load.

4. Power supply voltage is abnormal. MR-J2S- A:260V or more MR-J2S- A1:135V or more

Review power supply

Permissible regenerative power of the built-in regenerative brake resistor or regenerative brake option is exceeded.

5. Built-in regenerative brake resistor or regenerative brake option faulty.

Change servo amplifier or regenerative brake option.

AL.30 Regenerative alarm

Regenerative transistor fault

6. Regenerative transistor faulty. Checking method

1) The regenerat ive brake opt ion has overheated abnormally.2) The alarm occurs even after removal of the bui l t -in regenerat ive brake resistor or regenerat ive brake opt ion.


8-9



1. Input command pulse frequency exceeded the permissible instantaneous speed frequency.

Set command pulses correctly.

2. Small acceleration/deceleration time constant caused overshoot to be large.

Increase acceleration/deceleration time constant.

3. Servo system is instable to cause overshoot.

1. Re-set servo gain to proper value. 2. If servo gain cannot be set to proper value:

1) Reduce load inertia moment ratio; or 2) Reexamine acceleration/

deceleration time constant. 4. Electronic gear ratio is large

(parameters No. 3, 4) Set correctly.

AL.31 Overspeed Speed has exceeded the instantaneous permissible speed.

5. Encoder faulty. Change the servomotor. 1. Short occurred in servo amplifier output

phases U, V and W. Correct the wiring. AL.32 Overcurrent Current that flew is

higher than the permissible current of the servo amplifier.

2. Transistor (IPM) of the servo amplifier faulty.

Checking methodAlarm (AL.32) occurs if power isswitched on after U,V and Ware disconnected.


3. Ground fault occurred in servo amplifier output phases U, V and W.

Correct the wiring.

4. External noise caused the overcurrent detection circuit to misoperate.

Take noise suppression measures.

1. Lead of built-in regenerative brake resistor or regenerative brake option is open or disconnected.

1. Change lead. 2. Connect correctly.

2. Regenerative transistor faulty. Change servo amplifier 3. Wire breakage of built-in regenerative

brake resistor or regenerative brake option

1. For wire breakage of built-in regenerative brake resistor, change servo amplifier.

2. For wire breakage of regenerative brake option, change regenerative brake option.

4. Capacity of built-in regenerative brake resistor or regenerative brake option is insufficient.

Add regenerative brake option or increase capacity.

AL.33 Overvoltage Converter bus voltage exceeded 400V.

5. Power supply voltage high. Review the power supply.

8-10



1. Pulse frequency of the command pulse is too high.

Change the command pulse frequency to a proper value.

2. Noise entered command pulses. Take action against noise.

AL.35 Command pulse frequency error

Input pulse frequency of the command pulse is too high.

3. Command device failure Change the command device. 1. Servo amplifier fault caused the

parameter setting to be rewritten. Change the servo amplifier. AL.37 Parameter error Parameter setting is

wrong. 2. Regenerative brake option not used with

servo amplifier was selected in parameter No.0.

Set parameter No.0 correctly.

1. Servo amplifier faulty. Change the servo amplifier. 2. The power supply was turned on and off

continuously by overloaded status. The drive method is reviewed.

AL.45 Main circuit device overheat

Main circuit device overheat

3. Air cooling fan of servo amplifier stops. 1. Exchange the cooling fan or the servo amplifier.2. Reduce ambient temperature.

1. Ambient temperature of servo motor is over 40 .

Review environment so that ambient temperature is 0 to 40 .

2. Servo motor is overloaded. 1. Reduce load. 2. Review operation pattern. 3. Use servo motor that provides larger output.

AL.46 Servo motor overheat

Servo motor temperature rise actuated the thermal protector.

3. Thermal protector in encoder is faulty. Change servo motor. 1. Servo amplifier is used in excess

of its continuous output current. 1. Reduce load. 2. Review operation pattern. 3. Use servo motor that provides larger output.

2. Servo system is instable and hunting. 1. Repeat acceleration/ deceleration to execute auto tuning.

2. Change auto tuning response setting. 3. Set auto tuning to OFF and make gain

adjustment manually. 3. Machine struck something. 1. Review operation pattern.

2. Install limit switches. 4. Wrong connection of servo motor. Servo

amplifier's output terminals U, V, W do not match servo motor's input terminals U, V, W.

Connect correctly.

AL.50 Overload 1 Load exceeded overload protection characteristic of servo amplifier. Load ratio 300%:

2.5s or more Load ratio 200%:

100s or more

5. Encoder faulty. Checking method

When the servo motor shaft isrotated slowly with the servo off,the cumulat ive feedback pulsesshould vary in propor t ion to therotary angle. I f the indicat ion skips or returns midway, the encoder is faulty.

Change the servomotor.

8-11



1. Machine struck something. 1. Review operation pattern. 2. Install limit switches.

2. Wrong connection of servomotor. Servo amplifier's output terminals U, V, W do not match servo motor's input terminals U, V, W.

Connect correctly.

3. Servo system is instable and hunting. 1. Repeat acceleration/deceleration to execute auto tuning.

2. Change auto tuning response setting. 3. Set auto tuning to OFF and make gain

adjustment manually.

AL.51

Overload 2 Machine collision or the like caused max. output current to flow successively for several seconds. Servo motor locked:

1s or more

4. Encoder faulty. Checking method

When the servo motor shaft isrotated slowly with the servo off,the cumulat ive feedback pulsesshould vary in propor t ion to therotary angle. I f the indicat ion skips or returns midway, the encoder is faulty.

Change the servomotor.

1. Acceleration/deceleration time constant is too small.

Increase the acceleration/deceleration time constant.

2. Torque limit value (parameter No.28) is too small.

Increase the torque limit value.

3. Motor cannot be started due to torque shortage caused by power supply voltage drop.

1. Review the power supply capacity. 2. Use servomotor which provides larger output.

4. Position control gain 1 (parameter No.6) value is small.

Increase set value and adjust to ensure proper operation.

5. Servo motor shaft was rotated by external force.

1. When torque is limited, increase the limit value.

2. Reduce load. 3. Use servomotor that provides larger output.

6. Machine struck something. 1. Review operation pattern. 2. Install limit switches.

7. Encoder faulty Change the servomotor.

AL.52 Error excessive The droop pulse value of the deviation counter exceeded the encoder resolution 10 [pulse].

8. Wrong connection of servomotor. Servo amplifier's output terminals U, V, W do not match servo motor's input terminals U, V, W.

Connect correctly.

1. Communication cable breakage. Repair or change communication cable 2. Communication cycle longer than

parameter No. 56 setting. Set correct value in parameter.

AL.8A Serial communication time-out error

RS-232C or RS-422 communication stopped for longer than the time set in parameter No.56. 3. Wrong protocol. Correct protocol.

1. Communication cable fault (Open cable or short circuit)

Repair or change the cable. AL.8E Serial communication error

Serial communication error occurred between servo amplifier and communication device (e.g. personal computer).

2. Communication device (e.g. personal computer) faulty

Change the communication device (e.g. personal computer).

8-12



88888 Watchdog CPU, parts faulty Fault of parts in servo amplifier Checking method

Alarm (88888) occurs i f poweris switched on after CN1A, CN1Band CN3 connectors aredisconnected.

Change servo amplifier.

8.1.5 Remedies for warnings


1. Battery cable is open. Repair cable or changed. AL.92 Open battery cable warning

Absolute position detection system battery voltage is low. 2. Battery voltage dropped to 2.8V or less. Change battery.

1. Droop pulses remaining are greater than the in-position range setting.

Remove the cause of droop pulse occurrence

2. Command pulse entered after clearing of droop pulses.

Do not enter command pulse after clearing of droop pulses.

AL.96 Home position setting warning

Home position setting could not be made.

3. Creep speed high. Reduce creep speed. AL.9F Battery warning Voltage of battery for

absolute position detection system reduced.

Battery voltage fell to 3.2V or less. Change the battery.

AL.E0 Excessive regenerative warning

There is a possibility that regenerative power may exceed permissible regenerative power of built-in regenerative brake resistor or regenerative brake option.

Regenerative power increased to 85% or more of permissible regenerative power of built-in regenerative brake resistor or regenerative brake option.

Checking methodCall the status display and checkregenerat ive load rat io.

1. Reduce frequency of positioning. 2. Change regenerative brake option

for the one with larger capacity. 3. Reduce load.

AL.E1 Overload warning There is a possibility that overload alarm 1 or 2 may occur.

Load increased to 85% or more of overload alarm 1 or 2 occurrence level.

Cause, checking methodRefer to AL.50,51.

Refer to AL.50, AL.51.

1. Noise entered the encoder. Take noise suppression measures. AL.E3 Absolute position counter warning

Absolute position encoder pulses faulty. 2. Encoder faulty. Change servo motor.

1. PC lader program wrong. Contact the program. AL.E5 ABS time-out warning

2. ST2 TLC signal mis-wiring Connect properly.

AL.E6 Servo emergency stop warning

EMG-SG are open. External emergency stop was made valid. (EMG-SG opened.)

Ensure safety and deactivate emergency stop.

8-13

AL.E9 Main circuit off warning

Servo was switched on with main circuit power off.

Switch on main circuit power.

1. PC ladder program wrong. 1. Correct the program. AL.EA ABS servo-on warning

Servo-on signal (SON) turned on more than 1s after servo amplifier had entered absolute position data transfer mode.

2. SON signal mis-wiring. 2. Connect properly.


8.1.6 The cause investigation method at the time of position gap generating Position Servo

8-14

In the above figure, “A” is the output pulse counter and “B” is the command pulse accumulation, “C” is the return pulse accumulation display, and “d” is the machine stop position are the check parts at the time of position gap generating. Moreover, the figure shows a position gap reason. For example, the noise having ridden on wiring of positioning equipment and Servo amplifier, and having carried out the mistake count of the pulse is shown. The next relation is materialized in the normal state where a position gap is not carried out.

(1) Q= P(Output counter = Servo amplifier instruction pulse accumulation of positioning equipment)

CMX (Parameter No.3) (2) P • CDX (Parameter No. 4)

= C (Command pulse accumulation x electronic gear = return accumulation)

(3) C •Δλ= (machine position = Amount of per pulse movements x return accumulation)

The position gap is checked in order of the following. (1) If Q ≠ P

The mistake count of noise riding and the pulse was carried out at wiring of the pulse sequence signal

of positioning equipment and Servo amplifier. (Reason A )

CMX

(2) If P • ≠ C

A outputPulse counter

Q

Electronic gear (Parameter No. 3, 4)

P

B Command pulse accumulation

C

C Return pulse accumulation

CMXCDV

Encoder

Ｍ

L Servomotor

D Servo on (SON)stroke and (LSP-LSN) an input

D Machine stop position (Ｍ)

A

B

C

Machine

CDV

A Servo On signal (SON), right running and an inversion stroke, and the signal (LSP-LSN) were

turned off during operation. Or the clear signal (CR) was turned on. (Reason D)

(3) If C •Δλ ≠ M

The noise rode on wiring of the Encoder cable, and the mistake count of the pulse was carried out. Or


8-15

the mechanical slide was produced between the servomotor and the machine.

Appendices

Appendix 1 Symbols for the specifications T a

T d

T M a

T M d

T L

T u

T F

T lo

Trms

T m

T max

J L

J LO

J m

N r

N o

N

V o

V

P B

Z1

Z 2

: Acceleration time

: Deceleration torque

: Motor torque required for acceleration

: Motor torque required for acceleration

: Converted torque of inertia applied to the motor shaft

: Imbalance torque

: Torque of load friction

: Torque of load on load shaft

: Converted continuous effective load torque applied to the motor shaft

: Rated motor torque

: Max. motor torque

: Converted moment of load inertia applied to the motor shaft

: Converted moment of load inertia applied to the load shaft

: Moment of rotor inertia of the motor

: Rated motor rotational speed

: Motor rotational speed at the Max. machine speed

: Motor rotational speed

: Max. machine speed

: Machine speed

: Lead of ball screw

: No. of gear teeth on the motor shaft

: No. of gear teeth on the load shaft

[N•m]

[N•m]

[N•m]

[N•m]

[N•m]

[N•m]

[N•m]

[N•m]

[N•m]

[N•m]

[N•m]

[kg•cm 2]

[kg•cm2]

[kg•cm2]

[r/min]

[r/min]

[r/min]

[mm/min]

[mm/min]

[mm]

P I

F CI

F c

fo

Tpsa

Tpsd

K p

T P

∆λ o

∆λ c

λ

P

T f

t o

t st

tc

ts

m

ε

∆ ε

∆S

: No. of feedback pulses

: Electronic gear output pulse frequency

: Electronic gear input pulse frequency

: Input pulse frequency at the max. machine speed

: Acceleration time of command pulse frequency

: Deceleration time of command pulse frequency

: Position loop gain

: Position loop time constant (T P = 1 / K P )

: Feed distance per output pulse of electronic gear

: Feed distance per input pulse of electronic gear

: Feed distance per operation

: No. of input command pulses

: One operation cycle

: Position time

: Stop time

: Rated operation time

: Setting time

: Inertia ratio (m = J L / J M )

: No. of deviation counter pulses

: Positioning accuracy

: Feed distance per motor revolution

Example: Ball screw

[pulse/rev]

[pps]

[pps]

[pps]

[s]

[s]

[s- 1]

[s]

[mm/pulse]

[mm/pulse]

[mm]

[pulse]

[s]

[s]

[s]

[s]

[s]

[pulse]

[mm]

[mm]

Z1 Reduction ratio 1/n＝

Z2 Speed decrease if 1/n < 1; Speed increase if 1/n > 1.

If direct connection ∆S = P B

If reduction ratio is 1/n ∆S = P B • (1/n)

Note 1. If the moment of inertia is expressed as G D 2, the relationship with J is GD 2 = 4X J.

2. 1kg •m2 = 10000kg • cm2

3. For the purposes of the specifications in the table above, “input” and “output” are defined in relation

to the servo amplifier. If input and output were defined in relation to the positioning controller, some

of the specifications above would have to be redefined. Two examples are given below:

Electronic gear input pulse frequency f c → Command output pulse frequency

Feed distance per input pulse of electronic gear ∆λ c → Feed distance per command per output pulse

(least command unit)

APP-1

APPENDICES

Appendix 2 Types of Drive System

(1) Classification of motion direction There are varieties of drive systems driven by an AC servomotor, and the system best fitting the intended purpose (required accuracy, feed accuracy in motion, travel distance, type of machine operation, etc.) can be selected. In order to examine the relationship between the mechanical system and the servomotor, the direction of machine motion is considered first. The command unit for linear motion is mm; for rotary motion, either the angle or the number of the servomotor must be assessed carefully since torque with a negative value is generated during operation.

Classification of Motion Direction

Horizontal Direction Vertical Direction

* The drive method most widely adopted for table feed of various machines, and transfer system, using a ball screw, rack and pinion, belt, etc.

* The drive method adopted for vertical motion in transfer systems and vertical motion axis of robot, etc. As shown in the illustration, a counterweight for balancing the load is often used. A motor equipped with a magnetic brake is also used to prevent the load from falling in the case of power failure.

SM

B

W Magnetic brake

Reduction gear Servo Motor

Counterweight

Chain

Ball screw

Encoder Servo Motor Reduction gear

Ball screw Table

Li

near

Mot

ion

The drive method adopted for rotary axes such as those of index table.

Generally, the rotational speed of the load axis(table rotating axis) is small and motor speed is reduced by gears or pulleys.

Worm gear

Bevel gears Example 1: Connection by gear

Servomotor

Servomotor

Example 2: Connection by belt

Timing belt

R

otar

y M

otio

n

APP-2

APPENDICES

(2) Example of drive methods For position control using a position loop, the basic element is the machine feed distance per pulse. To calculate this distance, it is necessary to determine the machine feed distance (symbol: ∆S, unit: mm) per motor revolution. The general configurations of the drive systems used for linear motion applications, shown in (1), are illustrated below, accompanied by details of basic formulae.

Classification of drive Methods Features and Basic Formula

* The typical drive method adopted for

accurate positioning in a relatively short

motion distance

Positioning accuracy and motion speed

are influenced by the ball screw lead; if

the ball screw lead is made smaller,

accuracy becomes higher and motion

speed becomes slower. (with the same

servomotor).

[ Basic formula]

Feed distance per motor revolution.

∆S (mm) = P B(mm)• (1/n)

If the coupling is directly connected without

using the reducer:

∆ S = P B

* The drive method adopted for positioning

over relatively long distance.

* Usually, the pinion is fixes and the rack

moves. In some applications, the rack is

fixed and the pinion side(including the

motor) moves.

[ Basic Formula ]

∆ S (mm) = P L (mm)• Z • (1/n)

or

∆S = PCΦ • π • (1/n)

Object to be driven

Lead of ball screw (symbol: Pb) Reduction ratio (1/n)

(1

) Bal

l scr

ew

Reduction ratio (1/n)

PC

Symbols for pinion

Module (Symbol: m)

Number of teeth (symbol: Z)

Rack pitch (symbol: PL)

Rack

Rac

k

Pini

on

Teeth are machine in fixed pitches on straight bar.

Gear with teeth machined in fixed pitches on its circumference.

Pinion

(2

) Rac

k an

d pi

nion

APP-3

APPENDICES

Classification of Drive Methods Features and Basic Formulas

* The drive method widely adopted for

various applications from large-sized

transfer systems to precision machines.

* In contrast to the situation with the V-

belts and flat belts often used for belt

drive systems, the teeth in the pulley and

those in the timing belt engage with each

other to ensure positive drive and there is

no error due to slip. However, with some

types of belt materials, deterioration in

accuracy is caused by aging, such as wear,

and careful maintenance is necessary. The

belt pitch is specified in “inch” system

dimensions. Therefore, if control is

executed in the “mm” system, fractions

are generated when setting the relationship

between the command pulse and the feed

distance.

[ Basic Formula ]

∆S (mm) = PT (mm)• Z • (1/n)

* The drive method generally adopted for

large-sized transfer systems.

* This method is suitable for feeding an

object at high-speed over a long distance.

* The chain pitch is specified in “inch”

system dimensions, as with the timing

belt. This means that some care is

required when setting the feed distance.

Another factor to be taken into

consideration is the initial elongation of

the chain that affects positioning

accuracy.

[ Basic Formula]

∆ S(mm) = Pc (mm)• Z • (1/n)

Belt pitch (Symbol: PT)

Reduction ratio (1/n) Number of pulley teeth (Symbol: Z)

Teeth on pulley

Timing pulley

Timing pulleyTiming belt

Timing Belt Enga

gem

ent b

etw

een

pulle

y an

d be

lt

(3

) Tim

ing

belt

No. of sprocket teeth (symbol: Z)


Chain pitch (symbol: PC)

Chain

(4

) Cha

in

APP-4

APPENDICES

Classification of Drive Methods Features and Basic Formula

* The drive method in which workplaces

are fed by the friction force generation

force generated when a roll is rotated.

* This method is widely adopted for fixed-

pitch feed(the roll feeder for presses is a

typical example), and also for feeding film

sheet and paper(draw-control, cutters, etc.)

* To improve the positioning accuracy, it is

necessary to eliminate slip between the roll

and the material as well as to machine the

roll precisely to achieve a true circle.

* Since π is an irrational No. fractions

are inevitable when the command

pulse are converted into feed distance.

Compensation is therefore necessary.

[ Basic formula]

∆S (mm) = π • D(mm) • (1/n)

* The drive method used to drive a

cart with the servomotor mounted in

the cart as the drive power source

* The method of driving the wheels with

a servomotor, illustrated to the left, is

the one generally adopted. Careful

consideration is required to eliminate

slip between the rail and the wheels.

* The rack and pinion mechanism is

also used to drive carts. While the rack

is fixed, the pinion moves along the

rack.

[ Basic Formula] ( for the mechanism

illustrated to the left)

∆ S (mm) = π • D (mm) • (1/n)

Feed roll

Diameter of feed roll (Symbol : D)


Workplace (material)

(5

) Rol

l fee

d

Cart

Cart drive mechanism

Drive wheels (right and left)

Diameter of drive wheel (symbol: D)

Gear reduction (1/n)

(6

) Driv

ing

cart

APP-5

APPENDICES

APPENDIX3. EXAMPLE APPLICATIONS

Several example applications using an AC servomotor are described below.

(1) X - Y Table a. A MELSEC-A series

programmable controller is used to run a program that executes high-speed and accurate positioning of the X-Y table driven by an AC servomotor.

* Devices used Servomotor: HC-KFS Servo amplifier: MR-J2S 2-axis positioning module AD75

(2) Transfer System (Vertical transfer)

Transfer and positioning of a lifter are controlled by the program of the FX-1 GM positioning module.

The servomotor equipped with an magnetic brake is used to prevent the load from falling in the event of a power failure.

* Devices used Servomotor(With brake): HC-SFS-B Servo Amplifier: MR-J2S Regeneration option: MR-RB Position Module: FX-10GM

AD75TAD75 HC-KFS

MR-J2S

Pulse train

HC-KFS

Lifter

HC-SFS-B

Pulse train

FX-10GM

MR-J2S Regeneration option

APP-6

APPENDICES

(3) Synchronous feed (coating line) The sensor is used to detect the

position of products and the encoder is used to control synchronous feed. After feeding a fixed distance, the mechanism returns to the home position and waits for the arrival of the next product.

Encoder for synchronous feed control

Positioning controller A171SH

MR-J2S-B HC-SFS

Sensor

* Devices used Servomotor: HC-SFS Servo Amplifier: MR-J2S-B Motion controller: A171SH Encoder for synchronous feed control.

Digital switches

MR-H-AC

Servomotor

Press

Roll feeder

(4) Press roll feeder

By driving the feed roll with an AC servomotor, a fixed length of material is supplied to the machine.

The material is supplied while the ram is moving up; the ram moves done to press the material after positioning of the supplied material has finished.

The feed distance is input from an external digital switch and transmitted to the servo amplifier.

* Devices used Servomotor: HC-SF Servo amplifier: MR-H-CAN(with built-in 1-axis positioning control function)

APP-7

APPENDICES

(5) Torque control (tension control) By combining a digital

servo system in the torque control mode with a tension sensor and tension control module, the tension is controlled during winding of sheet material.

Torque sensor

LX-TCServo amplifier

MR-H-AN

LA-10AT-SET

Tension control module

Input ofTorquecommand

* Devices used Servomotor: HC-SF Servo amplifier: MR-HAN Tension sensor: LX-TC Tension control module: LA-10AT-SET

APP-8

APPENDICES

APPR-9

Appendix 4 Positioning Controllers Performance Comparison

Controller positioning unit type Unit kind FX-1PG FX-1GM

FX-10GM FX-20GM AD75P1

A1SD75P1 AD75P2

A1SD75P2 AD75P3

A1SD75P3 The network CPU Positioning unit Servo amplifier

Syst

em c

onfig

urat

ion

Servomotor

(note) (1)The solid show the line bus connection. (2)Adashed line shows a pulse sequence.

C-C LINK(MNET/MINI) CPU

MNET( II), MNET/B(MNET/10)

I/F

spec

ifi-

catio

n

A positioning unit amplifier

A pulse sequence or bus connection

Pulse train Pulse train Pulse train Pulse train

Pulse train Pulse train

Instruction language (used language) *

Language + ladder Special language+ladder Data table system + ladder

Encoder specification INC/ABS System INC/ABS INC/ABS INC/ABS

The program for ABS communication is INC/(ABS), however it is necessity and difficulty at the time of ABS use.

The maximum controllable number of axes

One axis One axis Two axes One axis Two axes 3 axes

Output pulse frequency 100KPPS 100KPPS 200KPPS

(100KPPS) Differential system 400KPPS

Open collector system 200KPPS Pattern control function * * Linear/circular * Linear/circular

The main control functions Position/speed Position/speed Position/speedPosition/speed (position and speed )

change constant The number of control axes

small-scale axial control

small-scale axial control

For 2 axis control

For 1 axis control

For 2 axis control

For 3 axis control

Sequence Function (No.s of I/O)(Memory capacity)

All positioning

data is a ladder and

an object for small-scale I/O systems.

All positioning

data is a ladder and

an object for small-scale I/O systems.

I/O mark are an

object with I/O=8 /

eight points for small-

scale.

ACPU can be chosen arbitrarily. Position data is a data table system. (Even 100 point / axis is possible for the time of 600 point / axis, and a CPU write-in system)

SerContr

vo ol

function

For easy positioning

For easy positioning

two axes , more

function

1 axis

The straight line, circle assistant speed / position

control

The point and elated point of model selection of a positioning unit / controller group

Cost Performance Others

It is small and is a cheap system. It is used in combination with CPU.

It is small cheap system. Use is possible even when it is independent.

It is small cheap system. Use is possible even when it is independent.

Small (one 32 slot occupancy) and cheap. It is a FROM/TO command between CPUand position unit. Between positioning unitServo amplifier, they are a pulse sequenceand those with cable length restrictions. an electronic gear, both AD75P and Servoamplifier uses is possible electronic key position data -- a flash ROM --storing (battery -- unnecessary) AD75P andServo position data -- a flash ROM -- bothstoring (battery -- unnecessary) backup use ispossible

The Servo amplifier series group *

MR-J2-Jr MR-J2-A

MR-J2S-A MR-H-AN

In addition, all pulse sequence I/F systems can be used.

MR-J2-Jr MR-J2-A

MR-J2S-A MR-H-AN

In addition, all pulse sequence I/F systems can be used.

Perip

hera

l eq

uipm

ent

The programming tool for positioning, and a S/W package

* FX-PCS/WIN

* FX-PCS -KIT/98

* E-20TP * FX-PCF-KIT-GM/98

(DOS/V, PC98 personal computer) SW*NX-AD75P SW*IVD-AD75P

APPENDICES

APPR-10

AD75M1

A1SD75M1 AD75M2

A1SD75M2 AD75M3

A1SD75M3 AD778M

A1SD778M A171SH

CPU A172SH

CPU A173UH

CPU A273UH

CPU

MR-J2C

MR-H

ACN

MNET(Ⅱ)、MNET/B(MNET/10) CPU

Bus connection Bus connection

Bus connection --

Data table system + ladder Special

language ladder

Special language + ladder (NC language SV43 station)

Point table system /Point-of-contact input

INC/ABS ABS only

INC/ABS INC/ABS

1 axis 2 axes 3 axes 8 axes 4 axes 8 axes 32 axes 32 axes 1 axis 1 axis

High-speed serial communication system

High-speed serial

communication system

High-speed serial communication system --

* straight/ circle line straight/ circle

straight/ circle line *

A position / speed / position, and speed change

A position / speed /

position, and speed change

position/speed/-- a position, and speed change / position flattery control / cam Position Position

For 1 axiscontrol

For 2 axes control

For 3 axes control

For max 8 axes control




For max 32 axes control For 1 axis

control For 1 axiscontrol

ACPU can be chosen arbitrarily. Position data is a data table system. (600 point / axis, even 100 point / axis is possible for the time of a CPU write-in system) (It is the program needlessness for communication also at the time of ABS use)

Combination is arbitrarily possible for ACPU.

They are I/O=512 point 14K step 0.25microsecond / step by A2SH.

A2SH-S1 about I/O=1024 point 30K step 0.25microsecond / step

A3U about I/O=2048 point 60K step 0.15microsecond / step

A3U about I/O=2048 point 60K step 0.15microsecond / step

All positioning data is built-in point table systems. For small-scale I/O systems.

For 1 axis control

A straight line, circle assistant control speed / position control, others

4 axis straight line 2 axis circle

4 axis straight lines, 2 axis circle assistant control speed / position, uniform control, position flattery control For easy

positioning For easy

positioningIt is a FROM/TO command between small (one 32 slot occupancy), cheapness, wiring easy CPU unit. A SSCNET bus and all the axial Servo-on signals Y15 are required between positioning unit and Servo amplifier. Infinite length positioning of ABS specification is impossible. The electronic gear in Servo amplifier cannot be used (pear). Electronic gear magnification is applied at the time of hand PA use. All parameter setup is performed from theAD75 side.

Motion language use. SSCNET bus connection ABS infinitelength positioning is possible.

(1) A motion language, NC language use (SV43) (2) SV13/SV22/SV43/SV51 Selection is possible. (3) It is a SSCNET system between controller and

Servo amplifier. (4) ABS infinite length positioning is possible.

It is small and is a cheap system. It is used independently.

It is small and is a cheap system. It is usedindependently.

MR-J2-B MR-J2S-B

MR-H-BN (full closed control is also possible)

<Terminus resistance important point>

same as left

same as left

MR-J2C MR-HACN

(DOS/V, PC98 personal computer) SW*NX-AD75P SW*IVD-AD75P

(DOS/V) SW0SRX- SV13ADL (Exclusive S/W)

(DOS/V, PC98 personal computer) (MS-DOS) OS : SW*SRX-SV13/SW*NX-SV13 : SW*SRX-GSV13/22 : SW*NX-GSV13/22 : SW**-CAMP

Main operation part of a general-purpose personal computer

General-purpose personal computer parameter unit

APPENDICES

<Special mention matter> 1. The Servo amplifier dealing with CC-Link serves as a MR-H-TN type. The number of

Servo amplifier connection becomes 21 sets in one master unit at the time of a maximum of 42 sets (at the time of one-game occupancy), and two-game occupancy.

2. FR-A500 series equips with built-in option FR-A5NC. The number of connection is a maximum of 42 sets (the number of connection changes with a remote device office and local broadcasting stations) at one master unit.

3. As for FR-E500 series, FR-E520-0.1 KN-FR-E520-7.5KN differs from a model name. 3. The basic base of A273UHCPU cannot be equipped with the special unit for sequencer A series.

4. the point of various system selections – (a) sequence function; (b) Servo function; (c) selection is required by the number of control axes; (d) cost performance; (e) programming nature; (f) system scale, extendibility, etc.

5. There is also the SFC (motion side) system Windows-NT version. In A171SH, correspondence is impossible.

6. The drive of MR-J2-A, Vector INV, the vector INV of the other company, etc. is also possible at use of an actuator I/F unit (analog output), and torque controls, such as tension control, are also possible.

7. Full Closed Loop Control is Possible to MR-H-AN and MR-H-BN at Option Built-in (Amplifier is Special).

8. Carry out from a positioning unit side altogether also including a Servo amplifier side parameter at the time of AD75M (A1SD75M) use. Therefore, it is easier for a program to use software-AD75P. Especially the parameter of fixation etc. recommends soft use.

APPR-11

servo motor

Documents

positioning accuracy

ac servo motor

types of positioning

performance of ac servo

definition of servo

positioning method

structure of ac servo

function of servo amplifier