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SINUMERIK 840D sl. Service - Functions. Manual (2018-2020) - page 6

Velocities, setpoint/actual value systems, closed-loop control

5.4 Setpoint/actual-value system

Note

Machine data index [ n ]

The machine data index [ n ] for encoder assignment has the following meaning:

• n = 0: First encoder assigned to the machine axis

• n = 1: Second encoder assigned to the machine axis

The assignment is made using machine data:

• MD30220 $MA_ENC_MODULE_NR[ n ]

• MD30230 $MA_ENC_INPUT_NR[ n ]

Further information

Commissioning Manual, CNC Commissioning: NC, PLC, drive; communication between NC and

drive > Drives: Assign axis

5.4.3

Adapting the motor/load ratios

Gear types

The following gear types are available for adapting the mechanical ratios:

Gear type

Activation

Adaptation

Installation location

Motor/load gear

Parameter set

Fixed configuration

Gear unit

Measuring gear encoder

Power On

Sensor-dependent

Sensor-side

Load intermediate gear unit

Warm restart

Load-dependent

Tool-side

Local position of gear unit / encoder

0RWRU VLGH HQFRGHU

/RDG VLGH HQFRGHU

7RRO VLGH HQFRGHU

(1&B,6B',5(&7

(1&B,6B',5(&7

(1&B,6B',5(&7

(1&B,6B',5(&7

(1&B,6B',5(&7

(1&B,6B',5(&7

0RWRU ORDG JHDU

0

7RRO

'5,9(B$;B5$7,2 B180(5$

1R RI ORDG UHY

'5,9(B$;B5$7,2 B'(120

1R RI WRRO UHY

'5,9(B$;B5$7,2B180(5$

1R RI PRWRU UHY

'5,9(B$;B5$7,2B'(120

1R RI ORDG UHY

Figure 5-2

Gear unit types and encoder locations

Axes and spindles

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Velocities, setpoint/actual value systems, closed-loop control

5.4 Setpoint/actual-value system

Motor/load gear

The motor/load gear supported by SINUMERIK is configured via the following machine data:

• MD31060 $MA_DRIVE_AX_RATIO_NUMERA (numerator load gear)

• MD31050 $MA_DRIVE_AX_RATIO_DENOM (denominator load gear)

The transmission ratio is obtained from the numerator/denominator ratio of both machine data.

The associated parameter sets are used automatically as default by the control system to

synchronize the position controller with the relevant transmission ratios.

Since a gear stage change is not always carried out automatically, and there are also several ways

to request a gear stage change, the position controller is not always incorporated via parameter

sets.

Note

For further information about the parameter sets for gear stage change, see Section "Spindles

(Page 377)".

Intermediate gear

Additional, configurable load intermediate gears are also supported by the control system:

• MD31066 $MA_DRIVE_AX_RATIO2_NUMERA (intermediate gear numerator)

• MD31064 $MA_DRIVE_AX_RATIO2_DENOM (intermediate gear denominator)

Power tools generally have their "own" intermediate gear. Such variable mechanics can be

configured by multiplying the active intermediate gear and the motor/load gear.

CAUTION

Different gear transmission ratios for switching

Unlike the motor/load gear, there is no parameter set for the intermediate gear and, therefore,

no way of controlling the time-synchronized switchover to the part program or PLC (NC/PLC

interface). Part machining during gear change is, therefore, ruled out. It remains the task of the

user to match the synchronization of the relevant changed machine data to the corresponding

mechanical switchover and activate it. On switchover during a motion, compensations cannot

be ruled out due to jumps in the scaling factors. These are not monitored for violation of the

maximum acceleration.

Encoder directly at the tool

Another connection option is possible for a "tool-side encoder" on the intermediate gear by

configuring the following machine data:

MD31044 $MA_ENC_IS_DIRECT2

Encoder not directly at the tool

The following supplementary conditions apply to a gear change of the intermediate gear in

position-control mode: The gear ratio to be changed is incorporated in a re-scaling of the

encoder information in this case.

Axes and spindles

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161

Velocities, setpoint/actual value systems, closed-loop control

5.4 Setpoint/actual-value system

In this case, the following applies to axes/spindles in positioning mode:

• A non-abrupt gear change is only possible at zero speed.

To do this, the tool-side position before and after a gear change are set equal for a change in

the ratio, since the mechanical position does not (or hardly) change during a gear stage

change.

Recommendation:

To avoid 21612 "Controller enable reset during motion", changeover should be carried out

"only at zero speed". It is still permissible and expedient to switch the axis or spindle to speed-

control or follow-up mode before or during a gear change.

Boundary conditions

If the encoder to be used for position control is connected directly at the tool, the gear stage

change only affects the physical quantities at the speed interface between the NC and the drive

of the motor/load gear. The internal parameter sets are not changed.

Reference point and machine reference

CAUTION

Loss of machine reference

The control cannot detect all situations that can lead to loss of the machine reference.

Therefore, it is the general responsibility of the commissioning engineer or user to initiate

explicit referencing of zero marker synchronization in such cases.

In the case of gear changes, it is not possible to make a statement about the effect of the

reference point or machine position reference on the encoder scaling. In such cases, the control

partially cancels the status "Axis referenced/synchronized".

If the machine reference has been lost, it must first be restored through an adjustment or

referencing of the lost machine reference.

See also

Homing (Page 31)

5.4.4

Speed setpoint output

Control direction and travel direction of the feed axes

You must determine the travel direction of the feed axis before starting work.

Control direction

Before the position control is started up, the speed controller and current controller of the drive

must be started up and optimized.

Traversing direction

Axes and spindles

162

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Velocities, setpoint/actual value systems, closed-loop control

5.4 Setpoint/actual-value system

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Q_VHW

0'

&75/287B/,0,7

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0$;B$;B9(/2

0D[ D[LV YHORFLW\

W

Figure 5-3

Maximum speed setpoint

However, due to control processes, the axes should not reach their maximum velocity

(MD32000 $MA_MAX_AX_VELO) at 100% of the speed setpoint, but at 80% to 95%.

In case of axes, whose maximum speed is attained at around 80% of the speed setpoint range,

the default value (80%) of the machine data:

MD32000 $MA_MAX_AX_VELO (maximum axis velocity)

can be adopted.

5.4.5

Machine data of the actual value system

Axis-specific machine data

To parameterize the actual value system, the following axis-specific machine data should be set:

Encoder and parameter set-independent machine da-

Meaning

ta: $MA_

MD30200 NUM_ENCS

Number of encoders

MD30300 IS_ROT_AX

Rotary axis / spindle

MD30310 ROT_IS_MODULO

Modulo conversion for rotary axis / spindle

MD30320 DISPLAY_IS_MODULO

360-degree modulo display for rotary axis or

spindle

MD30330 MODULO_RANGE

Size of the modulo range

MD30340 MODULO_RANGE_START

Start position of the modulo range

MD31030 $MA_LEADSCREW_PITCH

Leadscrew pitch

MD31064 $MA_DRIVE_AX_RATIO2_DENOM

Intermediate gear denominator

MD31066 $MA_DRIVE_AX_RATIO2_NUMERA

Intermediate gear numerator

MD32000 $MA_MAX_AX_VELO

Maximum axis velocity

Encoder-dependent machine data: $MA_

Meaning

MD30210 ENC_SEGMENT_NR[ n ]

Actual value assignment: Number of bus

segments

MD30220 ENC_MODULE_NR[ n ]

Actual value assignment: Drive number/

measuring circuit number

Axes and spindles

164

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Velocities, setpoint/actual value systems, closed-loop control

5.4 Setpoint/actual-value system

Encoder-dependent machine data: $MA_

Meaning

MD30230 ENC_INPUT_NR[ n ]

Actual value assignment: Input on drive

module/measuring circuit module

MD30240 ENC_TYPE[ n ]

Encoder type of the actual value acquisition

(actual position value)

MD30242 ENC_IS_INDEPENDENT[ n ]

Encoder is independent

MD30244 ENC_MEAS_TYPE[ n ]

Encoder measuring type

MD30250 ACT_POS_ABS[ n ]

Internal encoder position

MD30260 ABS_INC_RATIO[ n ]

Absolute encoder: Ratio between the abso-

lute resolution and the incremental resolu-

tion

MD30270 ENC_ABS_BUFFERING[ n ]

Absolute encoder: Traversing range exten-

sion

MD34090 $MA_REFP_MOVE_DIST_CORR[ n ]

Reference point offset

MD34320 $MA_ENC_INVERS[ n ]

Length measuring system is in the opposite

sense

n: Encoder index, with n = 0, 1, ... (1st encoder, 2nd encoder, ...)

Note

The "Activate machine data" can be activated either in the part program with the

command NEWCONF or via the user interface by pressing a softkey.

5.4.6

Actual-value resolution

5.4.6.1

Machine data of the actual value resolution

Depending where the measuring system (encoder) is mounted, the following measuring system

types should be taken into account:

• Load-side encoder: Direct measuring system (DM)

• Motor-side encoder: Indirect measuring system (IM)

Axes and spindles

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165

Velocities, setpoint/actual value systems, closed-loop control

5.4 Setpoint/actual-value system

Parameterizing the actual value resolution depending on the axis type (linear/rotary axis)

The control system calculates the actual value resolution based on the following machine data.

Machine data for calculating the actual value reso-

Linear axis

Linear axis

Rotary axis

lution

Linear scale /

Indirect

Direct

Indirect

Direct

direct measur-

measur-

measur-

measur-

measur-

ing system

ing sys-

ing sys-

ing sys-

ing sys-

tem

tem: Ma-

tem

tem: Ma-

chine/tool

chine/tool

MD30300 $MA_IS_ROT_AX

0

0

0

1

1

MD31000 $MA_ENC_IS_LINEAR[ n ]

1

0

0

0

0

MD31010 $MA_ENC_GRID_POINT_DIST[ n ]

Spacing

-

-

-

-

1)

MD34320 $MA_ENC_INVERS[ n ]

-

-

-

-

MD31020 $MA_ENC_RESOL[ n ]

-

Pulses/

Pulses/

Pulses/

Pulses/

rev

rev

rev

rev

MD31025 $MA_ENC_PULSE_MULT[ n ]

Encoder multipli-

cation

MD31030 $MA_LEADSCREW_PITCH

-

mm/rev.

mm/rev.

-

-

MD31040 $MA_ENC_IS_DIRECT[ n ]

- / 1

0

1

0

1

MD31044 $MA_ENC_IS_DIRECT2[ n ]

- / 1

0

1

0

1

2)

MD31050 $MA_DRIVE_AX_RATIO_DENOM[ n ]

-

Load

- / 1

Load

rev.

rev.

2)

MD31060 $MA_DRIVE_AX_RATIO_NUMERA[ n ]

-

Motor

- / 1

Motor

rev. if in-

rev.

feed

gear avail-

able

MD31070 $MA_DRIVE_ENC_RATIO_DENOM[ n ]

-

Encoder

Encoder

Encoder

Encoder

rev.

rev.

rev.

rev.

MD31080 $MA_DRIVE_ENC_RATIO_NUMERA[ n ]

-

Motor-

Motor

Motor

Load

side en-

rev.

rev.

rev.

coder ³⁾

-

Not relevant

1) For distance-coded measuring systems

2) These machine data are not required for encoder matching (path evaluation). However,

they must be entered correctly for the setpoint calculation! Otherwise the required servo

gain factor (K_V) will not be set. The load revolutions are entered into machine data

MD31050 $MA_DRIVE_AX_RATIO_DENOM and the motor revolutions in machine data

MD31060 $MA_DRIVE_AX_RATIO_NUMERA.

3) The encoder on the motor side is a built-in encoder and, therefore, does not have a

measuring gear unit.

The transmission ratio is always 1:1.

Axes and spindles

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Velocities, setpoint/actual value systems, closed-loop control

5.4 Setpoint/actual-value system

Machine data of the actual value resolution

The actual-value resolution results from the design of the machine, whether gearboxes are

available and their gear ratio, the leadscrew pitch for linear axes and the resolution of the

encoder being used. The following machine data must be set for this on the control system:

Encoder and parameter set-independent machine da-

Meaning

ta: $MA_

MD30300 IS_ROT_AX

Axis is a rotary axis / spindle

MD31010 ENC_GRID_POINT_DIST

Distance between reference marks of the lin-

ear scale

MD31030 LEADSCREW_PITCH

Leadscrew pitch

MD31064 DRIVE_AX_RATIO2_DENOM

Denominator of attached gearbox

MD31066 DRIVE_AX_RATIO2_NUMERA

Numerator of attached gearbox

Encoder-dependent machine data: $MA_

Meaning

MD31000 ENC_IS_LINEAR[ n ]

Measuring system is a linear scale

MD31020 ENC_RESOL[ n ]

Encoder pulses per revolution

MD31025 ENC_PULSE_MULT[ n ]

Encoder multiplication (high resolution)

MD31040 ENC_IS_DIRECT[ n ]

Direct or indirect measuring system

MD31044 ENC_IS_DIRECT2[ n ]

Encoders installed at the attached gearbox

MD31070 DRIVE_ENC_RATIO_DENOM[ n ]

Measuring gearbox denominator

MD31080 DRIVE_ENC_RATIO_NUMERA[ n ]

Measuring gearbox numerator

n: Encoder index, with n = 0, 1, ... (1st encoder, 2nd encoder, etc.)

Parameter-set-dependent machine data: $MA_

Meaning

MD31050 $MA_DRIVE_AX_RATIO_DENOM[ m ]

Denominator load gearbox

MD31060 $MA_DRIVE_AX_RATIO_NUMERA[ m ]

Numerator load gearbox

m: Parameter set index, with m = 0, 1, ... (1st parameter set, 2nd parameter set, etc.)

Parameterizing the computational resolution

The ratio of control-internal computational resolution to the actual-value resolution is an

indication of how exactly the values calculated by the control system can be implemented on the

machine.

Computational resolution: Linear axes

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,QWHUQDO LQFUHPHQWV PP

$FWXDO YDOXH UHVROXWLRQ

(QFRGHU LQFUHPHQWV PP

Axes and spindles

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167

Velocities, setpoint/actual value systems, closed-loop control

5.4 Setpoint/actual-value system

Computational resolution: Rotary axes

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$FWXDO YDOXH UHVROXWLRQ

(QFRGHU LQFUHPHQWV GHJUHH

Machine data

General machine data: $MN_

Meaning

MD10200 INT_INCR_PER_MM

Computational resolution for linear positions

MD10210 INT_INCR_PER_DEG

Computational resolution for angular posi-

tions

Recommended setting

The above components and settings that are responsible for the actual-value resolution, should

be selected so that the actual-value resolution is higher than the parameterized computational

resolution.

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ื

$FWXDO YDOXH UHVROXWLRQ

5.4.6.2

Example: Linear axis with linear scale

7DEOH

0'

,6B527B$;

/RDG

JHDUER[

%DOO VFUHZ

0

/LQHDU VFDOH

0'

(1&B,6B/,1($5

0'

(1&B*5,'B32,17B',67

OLQHDU HQFRGHU

0'

(1&B,19(56

RSSRVLWH GLUHFWLRQ

Figure 5-4

Linear axis with linear scale

The ratio of the internal increments to the encoder increments per mm is calculated as follows:

,QWHUQDO LQFUHPHQWV PP

(1&B*5,'B32,17B',67 >Q@

,17B,1&5B3(5B00

(QFRGHU LQFUHPHQWV PP

(1&B38/6(B08/7>Q@

Axes and spindles

168

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Velocities, setpoint/actual value systems, closed-loop control

5.4 Setpoint/actual-value system

5.4.6.3

Example: Linear axis with rotary encoder on motor

(1&B5(62/

0HDVXULQJ

/RDG

JHDUER[

JHDUER[_Q

Q_(QFRGHU

6SLQGOH

(

0

(1&B,6B/,1($5

(1&B,6B',5(&7

/($'6&5(:B3,7&+

,6B527B$;

'5,9(B$;B5$7,2B180(5$

1R RI PRWRU UHY

'5,9(B$;B5$7,2B'(120

1R RI ORDG UHY

'5,9(B(1&B5$7,2B180(5$

1R RI PRWRU UHY

'5,9(B(1&B5$7,2B'(120

1R RI HQFRGHU UHY

Figure 5-5

Linear axis with rotary encoder on motor

The ratio of the internal increments to the encoder increments per mm is calculated as follows:

,QWHUQDO LQFUHPHQWV PP

(QFRGHU LQFUHPHQWV PP

(1&B5(62/ >Q@

(1&B38/6(B08/7>Q@

'5,9(B(1&B5$7,2B180(5$ >Q@

'5,9(B(1&B5$7,2B'(120 >Q@

'5,9(B$;B5$7,2B'(120 >Q@

'5,9(B$;B5$7,2B180(5$ >Q@

/($'6&5(:B3,7&+

,17B,1&5B3(5B00

Example

Assumptions:

• Rotary encoder on the motor: 2048 pulses/revolution

• Internal pulse multiplication: 2048

• Gearbox, motor / ball screw: 5:1

• Leadscrew pitch: 10 mm/revolution

• Computational resolution: 10000 increments per mm

Machine data

Value

MD30300 $MA_IS_ROT_AX

0

MD31000 $MA_ENC_IS_LINEAR[0]

0

Axes and spindles

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Velocities, setpoint/actual value systems, closed-loop control

5.4 Setpoint/actual-value system

Machine data

Value

MD31040 $MA_ENC_IS_DIRECT[0]

0

MD31020 $MA_ENC_RESOL[0]

2048

MD31025 $MA_ENC_PULSE_MULT

2048

MD31030 $MA_LEADSCREW_PITCH

10

MD31080 $MA_DRIVE_ENC_RATIO_NUMERA[0]

1

MD31070 $MA_DRIVE_ENC_RATIO_DENOM[0]

1

MD31060 $MA_DRIVE_AX_RATIO_NUMERA[0]

5

MD31050 $MA_DRIVE_AX_RATIO_DENOM[0]

1

MD10210 $MN_INT_INCR_PER_DEG

10000

,QWHUQDO LQFUHPHQWV PP

PP

(QFRGHU LQFUHPHQWV PP

LQFU PP

An encoder increment corresponds to 0.004768 internal increments or 209.731543 encoder

increments correspond to an internal increment.

5.4.6.4

Example: Linear axis with rotary encoder on the machine

/RDG

0HDVXULQJ

(1&B5(62/

JHDUER[

JHDUER[_Q

Q_6SLQGOH

(QFRGHU

0

(

(1&B,6B/,1($5

,6B527B$;

/($'6&5(:B3,7&+

(1&B,6B',5(&7

'5,9(B$;B5$7,2B180(5$

1R RI VSLQGOH UHY

'5,9(B$;B5$7,2B'(120

1R RI HQFRGHU UHY

Figure 5-6

Linear axis with rotary encoder on the machine

The ratio of the internal increments to the encoder increments per mm is calculated as follows:

,QWHUQDO LQFUHPHQWV PP

(QFRGHU LQFUHPHQWV PP

(1&B5(62/ >Q@

(1&B38/6(B08/7>Q@

'5,9(B(1&B5$7,2B180(5$ >Q@

'5,9(B(1&B5$7,2B'(120 >Q@

/($'6&5(:B3,7&+

,17B,1&5B3(5B00

Axes and spindles

170

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Velocities, setpoint/actual value systems, closed-loop control

5.4 Setpoint/actual-value system

5.4.6.5

Example: Rotary axis with rotary encoder on motor

(1&B5(62/

0HDVXULQJ

/RDG

JHDUER[

JHDUER[

Q_(QFRGHU

Q_0RWRU

Q_0RWRU

Q_/RDG

(

0

/

5RWDU\ WDEOH

(1&B,6B/,1($5

(1&B,6B',5(&7

,6B527B$;

'5,9(B$;B5$7,2B180(5$

1R RI PRWRU UHY

'5,9(B$;B5$7,2B'(120

1R RI ORDG UHY

'5,9(B(1&B5$7,2B180(5$

1R RI PRWRU UHY

'5,9(B(1&B5$7,2B'(120

1R RI HQFRGHU UHY

Figure 5-7

Rotary axis with rotary encoder on motor

The ratio of the internal increments to the encoder increments per degree is calculated as

follows:

,QWHUQDO LQFUHPHQWV GHJUHH

GHJUHHV

(QFRGHU LQFUHPHQWV GHJUHH

(1&B5(62/ >Q@

(1&B38/6(B08/7>Q@

'5,9(B(1&B5$7,2B180(5$ >Q@

'5,9(B(1&B5$7,2B'(120 >Q@

'5,9(B$;B5$7,2B'(120 >Q@

'5,9(B$;B5$7,2B180(5$ >Q@

,17B,1&5B3(5B'(*

Example

Assumptions:

• Rotary encoder on the motor: 2048 pulses/revolution

• Internal pulse multiplication: 2048

• Gearbox, motor / rotary axis: 5:1

• Computational resolution: 1000 increments per degree

Machine data

Value

MD30300 $MA_IS_ROT_AX

1

MD31000 $MA_ENC_IS_LINEAR[0]

0

MD31040 $MA_ENC_IS_DIRECT[0]

0

MD31020 $MA_ENC_RESOL[0]

2048

MD31025 $MA_ENC_PULSE_MULT

2048

MD31080 $MA_DRIVE_ENC_RATIO_NUMERA[0]

1

Axes and spindles

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Velocities, setpoint/actual value systems, closed-loop control

5.4 Setpoint/actual-value system

Machine data

Value

MD31070 $MA_DRIVE_ENC_RATIO_DENOM[0]

1

MD31060 $MA_DRIVE_AX_RATIO_NUMERA[0]

5

MD31050 $MA_DRIVE_AX_RATIO_DENOM[0]

1

MD10210 $MN_INT_INCR_PER_DEG

1000

,QWHUQDO LQFUHPHQWV GHJUHH

GHJUHHV

(QFRGHU LQFUHPHQWV GHJUHH

LQF GHJUHH

An encoder increment corresponds to 0.017166 internal increments or 58.254689 encoder

increments correspond to an internal increment.

5.4.6.6

Example: Rotary axis with rotary encoder on the machine

/RDG

5RWDU\

0HDVXULQJ

WDEOH

(1&B5(62/

JHDUER[

JHDUER[_Q

Q_/RDG

(QFRGHU

0

/

(

(1&B,6B/,1($5

,6B527B$;

(1&B,6B',5(&7

'5,9(B(1&B5$7,2B180(5$

1R RI PRWRU UHY

'5,9(B(1&B5$7,2B'(120

1R RI HQFRGHU UHY

Figure 5-8

Rotary axis with rotary encoder on the machine

The ratio of the internal increments to the encoder increments per degree is calculated as

follows:

,QWHUQDO LQFUHPHQWV GHJUHH

GHJUHHV

(QFRGHU LQFUHPHQWV GHJUHH

(1&B5(62/ >Q@

(1&B38/6(B08/7>Q@

'5,9(B(1&B5$7,2B180(5$ >Q@

'5,9(B(1&B5$7,2B'(120 >Q@

,17B,1&5B3(5B'(*

Axes and spindles

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Velocities, setpoint/actual value systems, closed-loop control

5.5 Closed-loop control

5.4.6.7

Example: Intermediate gear with encoder on the tool

(1&B5(62/

0HDVXULQJ

/RDG

,QWHUPHGLDWH

JHDUER[

JHDUER[

JHDUER[

Q_(QFRGHU

Q_0RWRU

Q_0RWRU

Q_7RRO

(

0

7RRO

(1&B,6B',5(&7

(1&B,6B',5(&7

(1&B,6B',5(&7

(1&B,6B',5(&7

(1&B,6B',5(&7

(1&B,6B',5(&7

'5,9(B$;B5$7,2 B180(5$

1R RI ORDG UHY

'5,9(B$;B5$7,2 B'(120

1R RI VSLQGOH UHY

'5,9(B$;B5$7,2B180(5$

1R RI PRWRU UHY

'5,9(B$;B5$7,2B'(120

1R RI VSLQGOH UHY

'5,9(B(1&B5$7,2B180(5$

1R RI PRWRU UHY

'5,9(B(1&B5$7,2B'(120

1R RI HQFRGHU UHY

Figure 5-9

Intermediate gear with encoder directly on the rotating tool

The ratio of the internal increments to the encoder increments per degree is calculated as

follows:

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5.5

Closed-loop control

5.5.1

Position control of axes/spindles

The closed-loop control of an axis consists of the current and speed control loop of the drive plus

a higher-level position control loop in the NC.

The basic structure of an axis/spindle position control is illustrated below:

Axes and spindles

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173

Velocities, setpoint/actual value systems, closed-loop control

5.5 Closed-loop control

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$MA_DYN_MATCH_TIME

MD32895

$MA_DESVAL_DELAY_TIME

MD32200

$MA_POSCTRL_GAIN

x

Position setpoint

v

Velocity setpoint

x_act

Position actual value

n_act

Speed actual value

n_set

Speed setpoint

Fine interpolation

Using the fine interpolator (FIPO), the contour precision can be further increased by reducing the

staircase effect in the speed setpoint. You can set three different types of fine interpolation:

MD33000 $MA_FIPO_TYPE = <FIPO mode>

<FIPO mode>

Meaning

1

Differential fine interpolation with mean value generation (smoothing) over an IPO

cycle

2

Cubic fine interpolation

3

Cubic fine interpolation optimized for use with the pre-control for the highest contour

precision

Servo gain factor (K_V)

In order that few contour deviations occur in the continuous-path mode, a high servo gain factor

(K_V) is necessary:

MD32200 $MA_POSCTRL_GAIN[n]

However, if the servo gain factor (K_V) is too high, instability, overshoot and possibly

impermissible high loads on the machine will result.

The maximum permissible servo gain factor (K_V) depends on the following:

• Design and dynamics of the drive

(rise time, acceleration and braking capacity)

• Machine quality

(elasticity, oscillation damping)

• Position control cycle or speed control cycle for active DSC

Axes and spindles

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Velocities, setpoint/actual value systems, closed-loop control

5.5 Closed-loop control

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Jerk limiting

For information on the jerk limitation, see Section "Acceleration and jerk (Page 79)".

Dynamic response adaptation

Axes that interpolate with one another, but with different servo gain factors (K_V) can be set to the

same following error using the dynamic adaptation function. This allows an optimum contour

accuracy to be achieved without loss of control quality by reducing the servo gain factors (K_V) to

the dynamically weakest axis.

The function is activated via:

MD32900 $MA_DYN_MATCH_ENABLE = 1 (dynamic response adaptation)

The dynamic response adaptation is realized by entering a new equivalent time constant. It is

calculated from the difference in the equivalent time constant of the dynamically weakest axis

and the axis to be adapted:

MD32910 $MA_DYN_MATCH_TIME [n] = <difference in the equivalent time constant>

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Axes and spindles

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Velocities, setpoint/actual value systems, closed-loop control

5.5 Closed-loop control

Example of a dynamic response adaptation of three axes without speed feedforward

control

The equivalent time constant of the position control loop is:

Axis 1:

30 ms

Axis 2:

20 ms

Axis 3:

24 ms

With an equivalent time constant of 30 ms, axis 1 is the dynamically weakest axis.

This results in the following new equivalent time constants for the axes:

Axis 1:

MD32910 $MA_DYN_MATCH_TIME = 0 ms

Axis 2:

MD32910 $MA_DYN_MATCH_TIME = 30 ms - 20 ms = 10 ms

Axis 3:

MD32910 $MA_DYN_MATCH_TIME = 30 ms - 24 ms = 6 ms

Approximation formulas for the equivalent time constant of the position control loop of an axis

The equivalent time constant T_equiv of the position control loop of an axis is approximately

calculated depending on the type of feedforward control:

• Without feedforward control:

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Note

If dynamic response adaptation is realized for a geometry axis, then all other geometry axes

must be set to the same dynamic response.

Axes and spindles

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5.5 Closed-loop control

Function

Position control of an axis/spindle with switchable position setpoint filter circuit:

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$MA_AX_JERK_TIME

MD32910

$MA_DYN_MATCH_TIME

MD32895

$MA_DESVAL_DELAY_TIME

MD32200

$MA_POSCTRL_GAIN

x

Position setpoint

v

Velocity setpoint

x_act

Position actual value

n_act

Speed actual value

n_set

Speed setpoint

Selection and/or preassignment of filter types for every filter circuit

The switchable position setpoint filter circuits are activated by entering a two-digit value in

machine data MD32402 $MA_AX_JERK_MODE (filter type for axial jerk limiting). This allows two

alternative jerk filters to be selected.

Axes and spindles

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5.5 Closed-loop control

Parameter assignment

Two filter types must be selected to be able to switch between the two filter circuits from the part

program:

• The jerk filter type of the first filter circuit is selected in the "Ones position" of machine data

MD32402 AX_JERK_MODE, and the associated filter settings are set in index 0 of the machine

data to parameterize the filter.

• The jerk filter type of the second filter circuit is selected in the "Tens position" of machine data

MD32402 AX_JERK_MODE, and the associated filter settings are set in index 1 of the machine

data to parameterize the filter.

• The following machine data has two indices:

- MD32402 AX_JERK_FIR_FREQ

- MD32408 AX_JERK_FIR_ORDER

- MD32409 AX_JERK_FIR_WINDOW

- MD32410 AX_JERK_TIME

- MD32411 AX_JERK_TIME_ADD

- MD32412 AX_JERK_FREQ

- MD32414 AX_JERK_DAMP

Constraints

Filter circuits can only be parameterized if the following conditions are satisfied:

• MD33000 $MA_FIPO_TYPE = 1 or 3

• MD32220 $MA_POSCTRL_INTEGR_ENABLE = 0

• MD32930 $MA_POSCTRL_OUT_FILTER_ENABLE = 0

• MD32610 $MA_VELO_FFW_WEIGHT = 1.0

• MD32620 $MA_FFW_MODE = 0, 3 or 4

Commissioning

Two filter types are selected to preset the filter types for the filter circuits. To switch over the

parameterized filter circuits, you use the system variable $AA_DESVAL_FILTERS_SELECT[<axis>].

The following system variables are available for querying the status of the filter circuits:

System variable

Meaning

$VA_DESVAL_FILTERS_ACTIVE

Currently active filter circuit

$VA_DESVAL_FILTERS_DELTA_POS

Current difference in position between the filter circuits

This is needed in order to be able to determine a suitable switchover point. Suit-

able switchover points are motions with a constant velocity (acceleration = 0) or

when an axis is at a standstill in which the position difference is small. If a switch-

over is made while an axis is accelerating, then an acceleration step (jump) can

occur, which under certain circumstances can trigger the contour monitoring

function. The switchover is made immediately when requested.

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Velocities, setpoint/actual value systems, closed-loop control

5.5 Closed-loop control

System variable

Meaning

$VA_DESVAL_FILTERS_DELAY_1

Effective delay time of the first circuit

$VA_DESVAL_FILTERS_DELAY_2

Effective delay time of the second circuit

Example

Two switchover position setpoint filter circuits are parameterized with the following attributes

using MD32402 $MA_AX_JERK_MODE = 25:

• With a value of 5, a position setpoint filter, filter type 5 = FIR lowpass is parameterized in the

first position setpoint filter circuit.

• With a value of 20, a position setpoint filter, filter type 2 = moving average calculation

parameterized in the second position setpoint filter circuit.

• MD32895 $MA_DESVAL_DELAY_TIME is used to synchronize the total delay times of the two

filter circuits to one another.

See also

Jerk filter (position setpoint filter, axis-specific) (Page 106)

5.5.3

Parameter sets of the position controller

Six parameter sets per machine axis are available to quickly adapt the position control to the

changed machine properties during operation, e.g. a gear change of the spindle, or to adjust the

dynamic response to another axis, e.g. during tapping.

Machine data

A parameter set comprises the following machine data:

Number

Identifier $MA_

Meaning

31050

DRIVE_AX_RATIO_DENOM

Denominator load gearbox

31060

DRIVE_AX_RATIO_NUMERA

Numerator load gearbox

32200

POSCTRL_GAIN

Servo gain factor (K_V)

32452

BACKLASH_FACTOR

Backlash compensation

32610

VELO_FFW_WEIGHT

Feedforward control factor

36012

STOP_LIMIT_FACTOR

Exact stop coarse/fine factor and zero speed

32800

EQUIV_CURRCTRL_TIME

Equivalent time constant, current control loop for feed-

forward control

32810

EQUIV_SPEEDCTRL_TIME

Equivalent time constant, speed control loop for feed

forward control

32910

DYN_MATCH_TIME

Time constant for dynamic response adaptation

36200

AX_VELO_LIMIT

Threshold value for velocity monitoring

Axes and spindles

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5.6 Optimization of the control

Tapping, thread cutting

For tapping or thread cutting, the following applies with regard to the parameter sets of axes:

• For machine axes that are not involved in tapping or thread cutting, parameter set 1 (index

= 0) is active. The other parameter sets do not have to be taken into account.

• For machine axes that are involved in tapping or thread cutting, the same parameter set

number as that of the current gear stage of the spindle is active.

All parameter sets correspond to the gear stages and must therefore be parameterized.

The current parameter set is displayed on the user interface at:

Operating Area "Diagnostics" > "Service axis"

Parameter sets during gear stage change

Each gear stage of a spindle is assigned a separate parameter set. The gear stage is selected via

the following NC/PLC interface signal:

DB31, ... DBX16.0 - 2 = <actual gear stage>

Actual gear stage

DB31, ... DBX16.0 - 2

Parameter set

1st gear stage

000

2

(Index=1)

1st gear stage

001

2

(Index=1)

2nd gear stage

010

3

(Index=2)

3rd gear stage

011

4

(Index=3)

4th gear stage

100

5

(Index=4)

5th gear stage

101

6

(Index=5)

110

111

For further information on gear stages for spindles, see Section "Spindles (Page 377)".

5.6

Optimization of the control

5.6.1

Position controller, position setpoint filter: Balancing filter

Function

With feedforward control active, the position setpoint is sent through a so-called balancing

filter before it reaches the controller itself. It is thus possible to control the speed setpoint to

100% in advance, without resulting in overshoots when positioning.

Activation

The feedforward control variant is selected and so also the filter activated using the axis-specific

machine data:

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Velocities, setpoint/actual value systems, closed-loop control

5.6 Optimization of the control

MD32620 $MA_FFW_MODE (feedforward control mode)

Value

Meaning

3

Speed precontrol

4

Combined torque/speed precontrol

Activating and deactivating via the part program

Part programs can be used to activate and deactivate the feedforward control for all axes, using

commands FFWON and FFWOF.

If the feedforward control of the individual axes should not be influenced by FFWON/FFWOF, the

setting in the following machine data must be changed for these axes:

MD32630 $MA_FFW_ACTIVATION_MODE (activate feedforward control from program)

Parameterization

Recommended setting for recommissioning

If recommissioning, or if default values have been loaded (switch position 1 on commissioning

switch and POWER ON), the following machine data default values apply:

• MD32620 $MA_FFW_MODE = 3

• MD32610 $MA_VELO_FFW_WEIGHT (feedforward control factor for the velocity

feedforward control) = 1

The balancing time for the speed feedforward control then just has to be adjusted in the

following machine data:

MD32810 $MA_EQUIV_SPEEDCTRL_TIME (equivalent time constant speed control loop for

feedforward control)

Setting the equivalent time constant of the speed control loop (MD32810)

We recommend that the axis be allowed to move in and out in "AUTOMATIC" mode with a part

program and that travel-in to the target position, i.e. the actual position value of the active

measuring system, be monitored with the servo trace.

The initial value for setting is the time constant of the speed control loop. This can be read from

the reference frequency characteristic of the speed control loop. In the frequent case of a PI

controller with speed setpoint smoothing, an approximate equivalent time can be read from

drive machine data p1414, p1415, p1416 and p1421.

This start value (e.g. 1.5 ms) is now entered:

MD32810 $MA_EQUIV_SPEEDCTRL_TIME = 0.0015

The axis then travels forward and backward and the operator monitors a greatly-magnified

characteristic of the actual position value at the target position.

Axes and spindles

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5.6 Optimization of the control

The following rules apply to making manual fine adjustments:

Monitoring

Measure

Effect

Overshoot

Increase MD32810

The position controller responds more slowly.

⇒ The tendency to overshoot decreases.

Problem: The contour error (deviation from the program-

med contour) increases at curves.

Excessively slow

Reduce MD32810

The position controller responds faster.

approach

⇒ The contour error at curves decreases.

Problem: The tendency to overshoot increases.

Note

The effects are similar to modification of the position controller gain (MD32200

$MA_POSCTRL_GAIN). They can be observed on the user interface in the operating section

"Diagnostics" > "Axis service" using the computed K_V value.

MD32810 fine adjustment

Therefore, MD32810 should be assigned as small a value as possible, with the overshoot setting

the limit during positioning. Furthermore, the initial value is only modified slightly during fine

adjustment, typically by adding or deducting 0.25 ms.

For example, if the initial value is 1.5 ms, the optimum value calculated manually is usually

within the range 1.25 ms to 1.75 ms.

In the case of axes equipped with direct measuring systems (load encoders) and strong

elasticity, you may possibly accept small overshoots of some micrometers. These can be reduced

with the help of the position setpoint filter for dynamic response adaptation (MD32910

$MA_DYN_MATCH_TIME) and for jerk (MD32410 $MA_AX_JERK_TIME), which also reduces the

axis speed.

Identical axis data within an interpolation group

All the axes within an interpolation group should have identical settings in the following data:

• MD32200 $MA_POSCTRL_GAIN (adapted using MD32910)

• MD32620 $MA_FFW_MODE

• MD32610 $MA_VELO_FFW_WEIGHT

• MD32810 $MA_EQUIV_SPEEDCTRL_TIME (or MD32800 $MA_EQUIV_CURRCTRL_TIME)

(dependent on the mechanical system and drive)

• MD32400 $MA_AX_JERK_ENABLE

• MD32402 $MA_AX_JERK_MODE

• MD32410 $MA_AX_JERK_TIME

The servo gain display (K_V) of the user interface in operating section "Diagnostics" > "Axis service"

is used for checking.

Non-identical axis data within an interpolation group

If identical values are not possible for the above data, the following machine data can be used

to make an adjustment:

Axes and spindles

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Velocities, setpoint/actual value systems, closed-loop control

5.6 Optimization of the control

MD32910 $MA_DYN_MATCH_TIME (time constant of dynamic response adaptation)

This allows the same servo gain value (K_V) to be displayed.

Different servo gain display values (K_V) usually point to the following:

• The gear ratios do not match in one or several axes.

• The feedforward control setting data does not match.

Setting the equivalent time constant of the current control loop (MD32800)

The activation of the torque feedforward control filter is performed with:

MD32620 $MA_FFW_MODE = 4

The same rules and recommendations apply to setting the time constant of the current control

loop MD32800 $MA_EQUIV_CURRCTRL_TIME as to the speed feedforward control.

Limitation to stiff machines

Experience has shown that this expenditure is only worthwhile in the case of very stiff machines,

and requires appropriate experience. The elasticities of the machine are often excited due to the

injection of the torque so strongly that the existing vibrations neutralize the gain in contour

accuracy.

In this case, it would be worth trying the function "Dynamic Stiffness Control" (DSC) as an

alternative:

MD32640 $MA_STIFFNESS_CONTROL_ENABLE = 1

Note

The following conditions apply to use of DSC:

• In the NC, no actual value inversion (MD32110 $MA_ENC_FEEDBACK_POL = -1) must be

parameterized. Actual-value inversion in the drive (SINAMICS parameter p0410) is

permissible.

• The function must be activated for all axes that are in an interpolation relationship (path

motion or coupling) (MD32640 = 1).

• If one of the axes is parameterized as a simulated axis (MD30130 $MA_CTRLOUT_TYPE = 0,

MD30240 $MA_ENC_TYPE = 0), DSC cannot be applied. In this case, the function must be

deactivated for all axes that are in an interpolation relationship (MD32640 = 0).

CAUTION

Exception error condition

An exception error condition may occur if p1192 is set for a non-existing measuring system and

DSC is activated!

For service situations in which an additional measuring system has to be disabled and DSC is

active, it must be assured that p1192 is also adapted.

Axes and spindles

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5.6 Optimization of the control

Control response with POWER ON, RESET, REPOS, etc.

In the case of POWER ON and RESET, as well as with "Enable machine data", the setting data of

the feedforward control is read in again (see the appropriate values of the relevant machine

data).

Mode change, block search and REPOS have no influence on the feedforward control.

5.6.2

Position controller, position setpoint filter: Phase filter

Function

The axis-specific phase filter setpoint (dead time / delay) implements a pure phase shifter with

which the setpoint phase response can be influenced. Together with the axis-specific jerk filter

setpoint (MD32402_$MA_AX_JERK_MODE[<axis>] = 2; see Function Manual "Axes and

Spindles", Section "Jerk filter") it is possible to adapt the amplitude response and the phase

response independently of one another to the dynamically weakest of several axes, which

should proceed along a programmed path together.

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① Position controller cycle clock: 2 ms

② Time constant of the axis-specific phase filter setpoint: 19.2 ms

Figure 5-10

Effect of the axis-specific phase filter setpoint

Parameterization: Time constant

The time constant for the axis-specific phase filter setpoint can be set in the range:

(0 to 64) * position controller cycle clock (MD10061 $MN_POSCTRL_CYCLE_TIME)

The value of the time constants must be entered in seconds [s] in the machine data:

MD32895 $MA_DESVAL_DELAY_TIME[<axis>]

Example: Position controller cycle clock: 2 ms ⇒ adjustable time constant: 0.0 to 0.128 s

Note

The time constant of the phase filter setpoint delays the axis response characteristics for tapping,

retractions, and exact stops / block changes, etc. It is therefore recommended to set the time

constant as low as possible.

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Velocities, setpoint/actual value systems, closed-loop control

5.6 Optimization of the control

Standard setting is 0. In this case, the injection of positional deviation is inactive.

Note

The weighting factor MD32950 $MA_POSCTRL_DAMPING can be set on the basis of step

responses, for example.

If the control approaches the stability limit (vibration inclination increases), the parameter is too

large or the value has the incorrect sign.

5.6.4

Position control with proportional-plus-integral-action controller

Function

As standard, the core of the position controller is a P controller. It is possible to switch-in an

integral component for special applications (such as an electronic gear). The resulting

proportional-plus-integral-action controller then corrects the error between setpoint and actual

positions down to zero in a finite, settable time period when the appropriate machine data is set

accordingly.

CAUTION

Overshootings of the actual position for activated PI controller

In this instance, you must decide whether this effect is admissible for the application in

question. Knowledge of the control technology and measurements with servo trace are an

absolute prerequisite for using the function. If the appropriate machine data is incorrectly set,

then machines could be damaged due to instability.

Procedure

1. First optimize the position control loop as a proportional-action controller using the tools

described in the previous subsections.

2. Increase the tolerances of the following machine data while measurements are being taken

to determine the quality of the position control with proportional-plus-integral-action

controller:

- MD36020 $MA_POSITIONING_TIME

- MD36030 $MA_STANDSTILL_POS_TOL

- MD36040 $MA_STANDSTILL_DELAY_TIME

- MD36400 $MA_CONTOUR_TOL

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5.7 Data lists

Example

Setting result after several iterative processes for _KR and T_n.

Machine data settings:

• MD32220 $MA_POSCTRL_INTEGR_ENABLE = 1

• MD32210 $MA_POSCTRL_INTEGR_TIME = 0.003

• MD32200 $MA_POSCTRL_GAIN[1] = 5.0

Parameter set selection 0

Each of the following quantities - following error, actual velocity, actual position, and position

setpoint - has been recorded by servo trace. When traversing in JOG mode, the characteristic of

the individual data shown in the following figure was then drawn.

Graphic1 <Tr.1: Axis X1, Tr.2: Axis X1>

Tr.1: Following error

Marker X:

Tr.2: Actual velocity

Graphic2 <Tr.3: Axis X1, Tr.4: Axis X1>

Tr.3: Actual position measuring syst. 1

Marker X:

Tr.4: Position setpoint

5.7

Data lists

5.7.1

Machine data

5.7.1.1

Displaying machine data

Number

Identifier: $MM_

Description

9004

DISPLAY_RESOLUTION

Display resolution

9010

SPIND_DISPLAY_RESOLUTION

Display resolution for spindles

9011

DISPLAY_RESOLUTION_INCH

Display resolution for INCH system of measurement

Axes and spindles

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Velocities, setpoint/actual value systems, closed-loop control

5.7 Data lists

5.7.1.2

NC-specific machine data

Number

Identifier: $MN_

Description

10000

AXCONF_MACHAX_NAME_TAB

Machine axis name

10050

SYSCLOCK_CYCLE_TIME

System basic cycle

10070

IPO_SYSCLOCK_TIME_RATIO

Factor for interpolator cycle

10060

POSCTRL_SYSCLOCK_TIME_RATIO

Factor for position-control cycle

10200

INT_INCR_PER_MM

Computational resolution for linear positions

10210

INT_INCR_PER_DEG

Computational resolution for angular positions

10220

SCALING_USER_DEF_MASK

Activation of scaling factors

10230

SCALING_FACTORS_USER_DEF

Scaling factors of physical quantities

10240

SCALING_SYSTEM_IS_METRIC

Basic system metric

10250

SCALING_VALUE_INCH

Conversion factor for switchover to

inch system

10260

CONVERT_SCALING_SYSTEM

Basic system switchover active

10270

POS_TAB_SCALING_SYSTEM

Measuring system of position tables

10290

CC_TDA_PARAM_UNIT

Physical units of the tool data for CC

10292

CC_TOA_PARAM_UNIT

Physical units of the tool edge data for CC

13050

DRIVE_LOGIC_ADDRESS

Logical drive addresses

13060

DRIVE_TELEGRAM_TYPE

Standard message frame type for PROFIBUS DP

13070

DRIVE_FUNCTION_MASK

DP function used

13080

DRIVE_TYPE_DP

Drive type PROFIBUS DP

5.7.1.3

Channelspecific machine data

Number

Identifier: $MC_

Description

20150

GCODE_RESET_VALUES

Initial setting of the G groups

5.7.1.4

Axis/spindlespecific machine data

Number

Identifier: $MA_

Description

30110

CTRLOUT_MODULE_NR

Setpoint assignment: Drive number

30120

CTRLOUT_NR

Setpoint assignment: Setpoint output on drive module

30130

CTRLOUT_TYPE

Output type of setpoint

30200

NUM_ENCS

Number of encoders

30220

ENC_MODULE_NR

Actual value assignment: Drive module number

30230

ENC_INPUT_NR

Actual value assignment: Input on the drive module

30240

ENC_TYPE

Type of actual value acquisition (actual position value)

30242

ENC_IS_INDEPENDENT

Encoder is independent

30300

IS_ROT_AX

Rotary axis

31000

ENC_IS_LINEAR

Direct measuring system (linear scale)

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Velocities, setpoint/actual value systems, closed-loop control

5.7 Data lists

Number

Identifier: $MA_

Description

31010

ENC_GRID_POINT_DIST

Distance between reference marks on linear scales

31020

ENC_RESOL

Encoder pulses per revolution

31030

LEADSCREW_PITCH

Leadscrew pitch

31040

ENC_IS_DIRECT

Encoder is connected directly to the machine

31044

ENC_IS_DIRECT2

Encoder on intermediate gear

31050

DRIVE_AX_RATIO_DENOM

Denominator load gearbox

31060

DRIVE_AX_RATIO_NUMERA

Load gear numerator

31064

DRIVE_AX_RATIO2_DENOM

Intermediate gear denominator

31066

DRIVE_AX_RATIO2_NUMERA

Intermediate gear numerator

31070

DRIVE_ENC_RATIO_DENOM

Measuring gear denominator

31080

DRIVE_ENC_RATIO_NUMERA

Measuring gear numerator

31090

JOG_INCR_WEIGHT

Weighting of increment for INC/handwheel

31200

SCALING_FACTOR_G70_G71

Factor for converting values when G70/G71 is active

32000

MAX_AX_VELO

Maximum axis velocity

32100

AX_MOTION_DIR

Travel direction

32110

ENC_FEEDBACK_POL

Sign actual value (feedback polarity)

32200

POSCTRL_GAIN

Servo gain factor (K_V)

32210

POSCTRL_INTEGR_TIME

Integrator time position controller

32220

POSCTRL_INTEGR_ENABLE

Activation of integral component of position controller

32250

RATED_OUTVAL

Rated output voltage

32260

RATED_VELO

Rated motor speed

32400

AX_JERK_ENABLE

Axial jerk limitation

32402

AX_JERK_MODE

Filter type for axial jerk limitation

32407

AX_JERK_FIR_FREQ

Corner frequency axial jerk filter, type 5

32408

AX_JERK_FIR_ORDER

Filter order, axial jerk filter, type 5

32409

AX_JERK_FIR_WINDOW

Window type, axial jerk filter, type 5

32410

AX_JERK_TIME

Time constant for the axial jerk filter

32411

AX_JERK_TIME_ADD

Time constant for the second axial jerk filter, type 4

32412

AX_JERK_FREQ

Blocking frequency of the axial jerk filter

32414

AX_JERK_DAMP

Damping, axial jerk filter

32450

BACKLASH

Backlash

32500

FRICT_COMP_ENABLE

Friction compensation active

32610

VELO_FFW_WEIGHT

Feedforward control factor for speed feedforward con-

trol

32620

FFW_MODE

Feedforward control mode

32630

FFW_ACTIVATION_MODE

Activate feedforward control from program

32650

AX_INERTIA

Moment of inertia for torque feedforward control

32652

AX_MASS

Axis mass for torque precontrol

32711

CEC_SCALING_SYSTEM_METRIC

System of units for sag compensation

32800

EQUIV_CURRCTRL_TIME

Equivalent time constant current control loop for feed-

forward control

Axes and spindles

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Velocities, setpoint/actual value systems, closed-loop control

5.7 Data lists

Number

Identifier: $MA_

Description

32810

EQUIV_SPEEDCTRL_TIME

Equivalent time constant speed control loop for feed-

forward control

32890

DESVAL_DELAY_ENABLE

Axial position setpoint phase filter

32895

DESVAL_DELAY_TIME

Time constant for the axial phase position setpoint

phase filter

32900

DYN_MATCH_ENABLE

Dynamics matching

32910

DYN_MATCH_TIME [n]

Time constant for dynamic response adaptation

32930

POSCTRL_OUT_FILTER_ENABLE

Activation of low-pass filter at position controller output

32950

POSCTRL_DAMPING

Damping of the speed control loop

33000

FIPO_TYPE

Fine interpolator type

34320

ENC_INVERS[n]

Length measuring system is inverse

35100

SPIND_VELO_LIMIT

Maximum spindle speed

36200

AX_VELO_LIMIT [n]

Threshold value for velocity monitoring

36210

CTRLOUT_LIMIT[n]

Maximum speed setpoint

36400

AX_JERK_ENABLE

Axis-specific jerk limitation

36410

AX_JERK_TIME

Time constant for the axis-specific jerk filter

36500

ENC_CHANGE_TOL

Max. tolerance for position actual-value switchover

36510

ENC_DIFF_TOL

Measuring system synchronism tolerance

36700

ENC_COMP_ENABLE[n]

Interpolatory compensation

5.7.2

System variables

Identifier

Meaning

Access

$AA_DESVAL_FILTERS_SELECT

System variable that controls the switchover between the filter cir-

r/w

cuits.

$VA_DESVAL_FILTERS_ACTIVE

System variable in which the currently active filter circuit is located.

r

$VA_DESVAL_FILTERS_DELTA_POS

System variable that provides the position difference between the

r

two filter circuits.

$VA_DESVAL_FILTERS_DELAY_1

System variable that provides the effective delay time between the

r

1st or 2nd filter circuit.

$VA_DESVAL_FILTERS_DELAY_2

r

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Feedrates

6.2 Path feedrate F

Program code

Comment

Setting data

Revolutional feedrate in JOG mode

The behavior of an axis in terms of its revolutional feedrate relative to the master spindle of the

channel to which the axis is currently assigned in JOG mode depends on the settings in the NC-

specific setting data:

SD41100 $SN_JOG_REV_IS_ACTIVE, Bit <x>

Bit

Value

Meaning

0

0

The behavior depends on further setting data, depending on the function of the axis:

• Axis / spindle: SD43300 $SA_ASSIGN_FEED_PER_REV_SOURCE

• Geometry axis on which a frame with rotation acts: SD42600

$SC_JOG_FEED_PER_REV_SOURCE

• Orientation axis: SD42600 $SC_JOG_FEED_PER_REV_SOURCE

1

The axis is traversed with the revolutional feedrate.

Boundary condition

Traversing is performed without the revolutional feedrate if the following applies:

• Axis / spindle: The master spindle is stationary AND SD43300 $SA_AS-

SIGN_FEED_PER_REV_SOURCE == -3

• Geometry axis on which a frame with rotation acts: The master spindle is

stationary AND SD42600 $SC_JOG_FEED_PER_REV_SOURCE == -3

• Orientation axis: The master spindle is stationary AND SD42600

$SC_JOG_FEED_PER_REV_SOURCE == -3

1

0

In rapid traverse, traversing is performed with the revolutional feedrate.

1

In rapid traverse, traversing is performed without the revolutional feedrate.

2 ¹⁾

0

In handwheel jogging, traversing is performed with the revolutional feedrate.

1

In handwheel jogging, traversing is performed without the revolutional feedrate.

3 ¹⁾

0

In DRF handwheel traversing, traversing is performed with the revolutional fee-

drate.

1

In DRF handwheel traversing, traversing is performed without the revolutional

feedrate.

1) The function is active in addition to the setting in bit 1.

NC/PLC interface signals

• Revolutional feedrate active (channel-specific)

The interface signal indicates that axes are traversed with revolutional feedrate in the

channel:

- AUTOMATIC mode: Path or synchronized axes

- JOG mode: Geometry axes

DB31, ... DBX62.2 == 1 (revolutional feedrate active)

• Revolutional feedrate active (axis-specific)

The interface signal indicates that the axis is traversed with revolutional feedrate:

DB31, ... DBX33.2 == 1 (revolutional feedrate active)

Axes and spindles

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Feedrates

6.2 Path feedrate F

When the thread length l

G

, pitch change F and initial pitch k_a are known, the pitch increase at the

end of block k_e can be determined as follows by modifying the formula:

• For G34 (increasing pitch):

N

)

NH

D

O*

• For G35 (decreasing pitch):

)

NH

N D

O*

Note

If the formula results in a negative root expression, the thread cannot be machined!

In this case, the NC signals alarm 10605 or alarm 22275.

Application

The G34 and G35 functions can be used to produce self-shearing threads.

Example

Thread cutting G33 with decreasing thread pitch G35

Program code

Comment

N1608 M3 S10

; Spindle speed

N1609 G0 G64 Z40 X216

; Approach starting point

N1610 G33 Z0 K100 SF=R14

; Thread with constant pitch 100 mm/rev

N1611 G35 Z-220 K100 F17.045455

; Thread pitch decrease 17.045455 mm/rev2

; Thread pitch at end of block 50 mm/rev

N1612 G33 Z-240 K50

; Traverse thread block without jerk

N1613 G0 X218

N1614 G0 Z40

N1616 M17

Monitoring during the block preparation

Any pitch changes that would overload the thread axis when G34 is active or would result in an

axis standstill when G35 is active, are detected in advance during block preparation. Alarm

10604 "Thread pitch increase too high" or 10605 "Thread pitch decrease too high" is signaled.

During thread cutting, certain practical applications require a correction of the spindle speed. In

this case, the operator will base his correction on the permissible velocity of the thread axis.

To do this, it is possible to suppress the output of alarms 10604 and 10605 as follows:

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211

Feedrates

6.2 Path feedrate F

MD11410 $MN_SUPPRESS_ALARM_MASK bit 10 = 1

Block preparation is then continued normally.

Monitoring during the execution

The following situations are monitored cyclically when the thread is machined (interpolation):

• Exceeding of maximum velocity of thread axis

• Reaching of axis standstill with G35

The following alarm is signaled when the monitoring function responds:

• Alarm 22269 "Maximum velocity of thread axis reached" or

• Alarm 22275 "Zero velocity of thread axis reached"

6.2.4.3

Acceleration behavior of the axis for G33, G34 and G35

The acceleration behavior of the feed axis when thread cutting/tapping with G33, G34 or G35

can be set via the channel-specific setting data:

SD42010 $SC_THREAD_RAMP_DISP[<n>] = <Value>

<n>

Meaning

<Value>

Meaning

0

Acceleration behavior at the

< 0

The acceleration of the thread axis when run-

thread run-in:

ning-in the thread is as programmed

(Default: -1)

in BRISK/SOFT

= 0

The acceleration of the thread axis when run-

ning-in the thread is sudden (step function)

(≙ BRISK).

> 0

The maximum thread run-in distance is speci-

fied.

Specifying the maximum run-in thread path

can also be specified via address DITS also in

the part program (see "Programmed run-in

and run-out path for G33, G34 and G35 (DITS,

DITE) (Page 213)"). When a block is inserted in

the main run, the programmed run-in path is

transferred into the setting data.

Note

Too short a distance can result in the axis be-

ing overloaded when accelerating.

Axes and spindles

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Feedrates

6.2 Path feedrate F

<n>

Meaning

<Value>

Meaning

1

Acceleration behavior at

< 0

The braking of the thread axis when running-

thread run-out:

ou the thread is as programmed in BRISK/

(Default: -1)

SOFT

= 0

The braking of the thread axis when running-

out the thread is sudden (step function)

(≙ BRISK).

> 0

The maximum thread run-out distance is

specified.

Specifying the maximum run-out thread path

can also be specified via address DITE also in

the part program (see "Programmed run-in

and run-out path for G33, G34 and G35 (DITS,

DITE) (Page 213)"). When a block is inserted in

the main run, the programmed run-out path

is transferred into the setting data.

Note

Too short a distance can result in an acceler-

ation overload of the axis.

2

Acceleration behavior for

= -1 (default)

Permits smoothing corners between two

thread transitions within a

thread blocks in order to maintain dynamic

thread chain

response limits.

Rounding using smoothing is not carried out

if the dynamic performance of the machine

allows a hard transition, e.g. as a result of the

effectiveness of the overload factor for axial

velocity step/jumps (MD32310

$MA_MAX_ACCEL_OVL_FACTOR).

= 0

Corners between two thread blocks are exe-

cuted precisely without rounding - the axes

follow the control loop commands.

> 0

Reserved

6.2.4.4

Programmed run-in and run-out path for G33, G34 and G35 (DITS, DITE)

The run-in and run-out path of the thread can be specified in the part program with the DITS

and DITE addresses.

The thread axis is accelerated or braked along the specified path.

=

;

① Run-in/run-out path, depending on the machining direction

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213

Feedrates

6.2 Path feedrate F

Short run-in path

Due to the collar on the thread runin, little room is left for the tool start ramp.

This must therefore be specified shorter via DITS.

Short run-out path

Because of the shoulder at the thread run-out, there is not much room for the tool braking ramp,

introducing a risk of collision between the workpiece and the tool cutting edge. The deceleration

ramp can be specified shorter using DITE. Due to the inertia of the mechanical system, however,

a collision can still occur.

Remedy: Program a shorter thread, reduce the spindle speed.

Note

DITE acts at the end of the thread as a rounding clearance. This achieves a smooth change in

the axis motion.

Effects

The programmed run-in and run-out path only increases the rate of acceleration on the path. If

one of the two paths is set larger than the thread axis needs with active acceleration, the thread

axis is accelerated or decelerated with maximum acceleration.

Syntax

DITS=<Value> DITE=<Value>

Meaning

DITS:

Define thread run-in path

DITE:

Define thread run-out path

<value>:

Only paths, and not positions, are programmed with DITS and DITE.

The programmed run-in/run-out path is handled according to the current dimension

setting (inches, metric).

Example

Program code

Comment

N40 G90 G0 Z100 X10 SOFT M3 S500

N50 G33 Z50 K5 SF=180 DITS=1 DITE=3

; Start of smoothing with Z=53.

N60 G0 X20

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Feedrates

6.2 Path feedrate F

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5HWUDFWLRQ PRYHPHQW KDV

1& VWRS

]

6WDUW RI

HQGHG WKUHDG FXWWLQJ LV VWRSSHG

6WDUW RI

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Figure 6-1

Interruption of G33 through retraction motion

Dynamic response of the retraction motion

The retraction motion is executed with maximum axis dynamic response:

• MD32000 $MA_MAX_AX_VELO[<axis>] (velocity)

• MD32300 $MA_MAX_AX_ACCEL[<axis>] (acceleration)

• MD32431 $MA_MAX_AX_JERK[<axis>] (jerk)

Example

Program code

Comment

N55 M3 S500 G90 G18

; Set active machining plane.

N65 MSG ("thread cutting")

MM_THREAD:

N67 $AC_LIFTFAST=0

; Reset before starting the thread.

N68 G0 Z5

N69 X10

N70 G33 Z30 K5 LFON DILF=10 LFWP

; Enable fast retraction for thread

ALF=7

cutting.

; Retraction path = 10 mm

; Retraction plane Z/X (because of G18)

; Retraction direction -X (with ALF=3;

retraction direction +X)

N71 G33 Z55 X15

N72 G1

; Deselect thread cutting.

N69 IF $AC_LIFTFAST GOTOB MM_THREAD ; If thread cutting has been

interrupted.

N90 MSG ("")

N70 M30

Axes and spindles

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Feedrates

6.2 Path feedrate F

N55 M3 S500 G90 G0 X0 Z0

N87 MSG ("tapping")

N88 LFOF

; Deactivate fast retraction before

tapping.

N89 CYCLE...

; Tapping cycle with G33.

N90 MSG ("")

N99 M30

Behavior at power on and reset

After power on and reset, the following settings are activated:

• Initial settings for the retraction motion (LFON / LFOF) and retraction direction

(LFTXT / LFWP): MD20150 $MC_GCODE_RESET_VALUES

• Retraction path: MD21200 $MC_LIFTFAST_DIST

6.2.4.6

Convex thread (G335, G336)

Function

The G commands G335 and G336 can be used to turn convex threads (= differing to the

cylindrical form). Application is the machining of extremely large components that sag in the

machine because of their self-weight. Paraxial thread would result in the thread being too small

in the middle of the component. This can be compensated with convex threads.

=

① Long, sagging workpiece

② Circular tool path

③ Threaded turning tool

Figure 6-2

Turning a convex thread

Axes and spindles

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219

Feedrates

6.2 Path feedrate F

Programming

The turning of a convex thread is programmed with G335 or G336:

G335:

Turning of a convex thread on a circular tool path in a clockwise direction

G336:

Turning of a convex thread on a circular tool path in a counter-clockwise direction

The programming is performed first as for a linear thread by specifying the axial block end points

and the pitch via parameters I, J and K.

An arc is also specified. As for G2/G3, this can be programmed via the center point, radius,

opening angle or intermediate point specification. When programming the convex thread with

center point programming, the following must be taken into account: Since I, J and K are used

for the pitch in thread cutting, the circle parameters in the center point programming must be

programmed with IR=..., JR=... and KR=

IR=...:

Cartesian coordinate for the circle center point in the X direction

JR=...:

Cartesian coordinate for the circle center point in the Y direction

KR=...:

Cartesian coordinate for the circle center point in the Z direction

Note

IR, JR and KR are the default values of the interpolation parameter names for a convex thread

that can be set via machine data MD10651 $MN_IPO_PARAM_THREAD_NAME_TAB.

Optionally, a starting point offset SF can also be specified.

Syntax

The syntax for the programming of a convex thread therefore has the following general form:

G335/G336 <axis target point coordinate(s)> <pitch> <arc> [<starting

point offset>]

Permissible arc areas

The arc programmed at G335/G336 must be in an area in which the specified thread main axis

(I, J or K) has the main axis share on the arc over the entire arc:

[

[

r

r

]

]

Permissible areas for the Z axis (pitch programmed

Permissible areas for the X axis (pitch programmed

with K)

with I)

A change of the thread main axis as shown in the following figure is not permitted:

Axes and spindles

220

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Feedrates

6.2 Path feedrate F

[

6WDUWLQJ SRLQW

(QG SRLQW

r

]

Figure 6-3

Convex thread: Area that is not permissible

Constraints

Frames

G335 and G336 are also possible with active frames. However, you must ensure that the

permissible arc areas are maintained in the basic coordinate system (BCS).

Response for …

The G335/G336 response for:

• Power On / Power Off

• Mode change

• NCK / mode group / channel / part program end reset

• Block search / REPOS / ASUP

• Alarms / emergency stop / malfuncations

corresponds to the behavior for G33/G34/G35.

There are no specific restrictions.

Examples

Example 1: Convex thread in the clockwise direction with end and center point

programming

Program code

Comment

N5 G0 G18 X50 Z50

; Approach starting point.

N10 G335 Z100 K=3.5 KR=25 IR=-20 SF=90

; Turn convex thread in the clock-

wise direction.

Axes and spindles

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221

Feedrates

6.2 Path feedrate F

[

6WDUWLQJ SRLQW

(QG SRLQW

&HQWHU SRLQW

.5

]

Figure 6-4

Convex thread in the clockwise direction with end and center point programming

Example 2: Convex thread in the counter-clockwise direction with end and center point

programming

Program code

Comment

N5 G0 G18 X50 Z50

; Approach starting point.

N10 G336 Z100 K=3.5 KR=25 IR=20 SF=90

; Turn convex thread in the coun-

ter-clockwise direction.

[

&HQWHU SRLQW

6WDUWLQJ SRLQW

(QG SRLQW

.5

]

Figure 6-5

Convex thread in the counter-clockwise direction with end and center point programming

Example 3: Convex thread in the clockwise direction with end point and radius

programming

Program code

N5 G0 G18 X50 Z50

N10 G335 Z100 K=3.5 CR=32 SF=90

Axes and spindles

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Feedrates

6.2 Path feedrate F

[

6WDUWLQJ SRLQW

(QG SRLQW

&5

&HQWHU SRL

QW

]

Figure 6-6

Convex thread in the clockwise direction with end point and radius programming

Example 4: Convex thread in the clockwise direction with end point and opening angle

programming

Program code

N5 G0 G18 X50 Z50

N10 G335 Z100 K=3.5 AR=102.75 SF=90

[

6WDUWLQJ SRLQW

(QG SRLQW

$5

&HQWHU SR

LQW

]

Figure 6-7

Convex thread in the clockwise direction with end point and opening angle programming

Example 5: Convex thread in the clockwise direction with center point and opening angle

programming

Program code

N5 G0 G18 X50 Z50

N10 G335 K=3.5 KR=25 IR=-20 AR=102.75 SF=90

Axes and spindles

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223

Feedrates

6.2 Path feedrate F

[

6WDUWLQJ SRLQW

(QG SRLQW

$5

&HQWHU SRLQW

.5

]

Figure 6-8

Convex thread in the clockwise direction with center point and opening angle programming

Example 6: Convex thread in the clockwise direction with end and intermediate point

programming

Program code

N5 G0 G18 X50 Z50

N10 G335 Z100 K=3.5 I1=60 K1=64

[

,QWHUPHGLDWH SRLQW

6WDUWLQJ SRLQW

(QG SRLQW

&HQWHU SRL

QW

]

Figure 6-9

Convex thread in the clockwise direction with end and intermediate point programming

6.2.5

Feedrate for tapping without compensating chuck (G331, G332)

Function

A thread can be tapped by rigid tapping with the functions G331 (tapping) and G332 (tapping

retraction).

Path feedrate

With G331 / G332, the path feedrate F for the axes involved in tapping is derived from the

effective spindle speed S and the programmed pitch:

F [mm/min] = S [rpm] * thread pitch [mm/U]

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Feedrates

6.2 Path feedrate F

Machine data

•

Preventing stop events

In the machine data, the stopping response when G331 / G332 is active is defined:

MD11550 $MN_STOP_MODE_MASK, Bit <x> = <value>

Bit

Value

Meaning

0

0

When G331 / G332 is active, stopping is not performed during a path motion or

dwell time (G4).

1

When G331 / G332 is active, stopping is performed during interruption of path

control mode, for example, by G60 or G4.

If you always want to prevent stopping the traverse movement when G331 / G332 is active,

this area must be declared a stop delay area with the commands DELAYFSTON

and DELAYFSTOF.

Further information

Function Manual Basic Functions; Program operation, Influencing the stop events by stop

delay areas

Note

Single block

If the single block is activated in the stop delay area, the NC stops at the end of the first block

outside the stop delay area. If the single block is already selected before the stop delay area,

the NC stops at each block limit, i.e. also in the stop delay area! This deselects the stop delay

area.

Override changes

If the override is changed before a stop delay area, the override takes effect in the stop delay

area.

If the override is changed in the stop delay area, the change takes effect after the stop delay

area.

•

Override

Which override is active during rigid tapping is set in:

MD12090 $MN_OVR_FUNCTION_MASK, Bit <x> = <value>

Bit

Value

Meaning

0

0

The spindle override is active for G331/G332

Depending on the setting in the following machine data, the override is related

either to the programmed spindle speed or to the configured spindle speed limita-

tion:

MD12080 $MN_OVR_REFERENCE_IS_PROG_FEED

1

The path override is active for G331/G332

Depending on the setting in the following machine data, the override is related

either to the programmed path feedrate or to the configured path feedrate limita-

tion:

MD12082 $MN_OVR_REFERENCE_IS_MIN_FEED

Note

This only applies if the limitation value is lower than the programmed path feedrate.

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