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

Extended stop and retract

21.3 ESR executed autonomously in the drive

21.3.5

ESR is enabled via system variable

The ESR response of an axis, configured via drive parameter, must be programmed on a user-

specific basis in a part program/synchronized action using the following axis-specific system

variable:

$AA_ESR_ENABLE[<axis>]

Value

Meaning

ESR responses enabled in the drive

ESR responses inhibited in the drive

21.3.6

Triggering ESR via system variable

Triggering ESR responses, configured via drive parameter and enabled via

$AA_ESR_ENABLE[<axis>], must be programmed on a user-specific basis in a part program/

synchronized action via the following NC-specific system variable:

$AN_ESR_TRIGGER

Value

Meaning

trigger drive-integrated ESR reactions that have been released

do not trigger drive-integrated ESR reactions that have been released

Note

The trigger signal must be active in the part program/synchronized action for at least 2 IPO cycles

to ensure that the PROFIdrive telegram is transferred to the drive.

Mapping in the drive unit

System variable $AN_ESR_TRIGGER is mapped to drive parameter p0890.0. Interconnecting

drive parameter p0890.0 with the corresponding information in telegram 390 or 391 to the

Control Unit is realized automatically when the drive unit commissions the ESR reactions.

Further information

For a detailed description of drive parameters, refer to:

SINAMICS S120/S150 List Manual

21.3.7

Feedback of the ESR status

The drive signals back the actual ESR status to the control using the message word (MELDW) of

the cyclic PROFIdrive telegram. In the PLC, the status can be read via system variables and NC/PLC

interface signals.

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21.3 ESR executed autonomously in the drive

System variable

The system variables can be evaluated in the part program / synchronized action, for example,

in order to trigger the drive-autonomous ESR (see Section "Triggering ESR via system variable

(Page 918)") or to acknowledge the ESR reactions triggered in the drive (see Section

"Acknowledge ESR reactions (Page 919)").

Interrelationship between signals

MELDW

System variable

NC/PLC interface sig-

Meaning

nal

MELDW.Bit 9

$AA_ESR_STAT.Bit 2

DB31, … DBX95.2

ESR: Reaction triggered or generator operation

active (r0887.12)

(r0887.12)

MELDW.Bit 4

$AA_ESR_STAT.Bit 3

DB31, … DBX95.1

ESR: DC link undervoltage (p1248)

(r0056.15)

MELDW.Bit 2

$AA_ESR_STAT.Bit 4

DB31, … DBX95.3

ESR, generator operation: Speed lower than min-

imum (p2161)

(r2199.0)

21.3.8

Acknowledge ESR reactions

Acknowledging axis-specific drive-independent ESR reactions must be programmed on a user-

specific basis in a part program/synchronized action. After the ESR reaction in the drive has been

completed, an edge change must be generated in the system variables $AA_ESR_ENABLE:

1→0→1. In order that the drive-integrated ESR reactions can be retriggered, the system variable

$AN_ESR_TRIGGER must also be reset to a value of 0.

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21.3 ESR executed autonomously in the drive

System variable and drive parameters

The following diagram shows the relationship between system variables and drive parameters

when triggering and acknowledging ESR reactions.

$$B(65B(1$%/(> D[LV!@

$1B(65B75,**(5

$$B(65B67$7 %,7 > D[LV!@

(65 WULJJHUHG

(65 UHDFWLRQ EHLQJ H[HFXWHG

① NC: Enabling the ESR reaction via $AA_ESR_ENABLE = 1 (axis-specific)

② NC: Triggering ESR responses via $AN_ESR_TRIGGER = 1

③ Drive: The triggering of the ESR reaction has been detected (CU_STW.2 == 1) ⇒

r0887.12 = 1 AND r0887.13 = 1

Feedback signal to the NC via $AA_ESR_STAT.BIT2 = 1 (axis-specific)

④ NC: Acknowledging the ESR reaction via $AA_ESR_ENABLE = 0 (axis-specific)

Black: At instant in time ④, the ESR reaction no longer runs (r0887.13 == 0) ⇒

⑤ Drive: Reset "ESR triggered": r0887.12 = 0

Feedback signal to the NC via $AA_ESR_STAT.BIT2 = 0 (axis-specific)

⑥ NC: The ESR reaction can be re-enabled ⇒

$AA_ESR_ENABLE = 1 AND $AN_ESR_TRIGGER = 0

Red: At instant in time ④, the ESR reaction still runs (r0887.13 == 1) ⇒

⑤ Drive: "ESR initiated" is only reset (r0887.12 = 0), if the ESR response in the drive has been

completed: r0887.13 == 0

Feedback signal to the NC via $AA_ESR_STAT.BIT2 = 0 (axis-specific)

⑥ See ⑥ above

Figure 21-6

Sequence: Trigger and acknowledge drive-integrated ESR reactions

21.3.9

Configuring ESR in the part program

Configuring drive-autonomous ESR functions "stop" and "retract" can be changed using the

commands from the part program described in the following.

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21.3 ESR executed autonomously in the drive

21.3.9.1

Stopping (ESRS)

Syntax

ESRS(<access_1>,<stopping time_1>[,...,<axis_n>,<stopping time_n>])

Meaning

ESRS:

Using the function, drive parameters can be changed regarding the drive-au-

tonomous "stop" ESR function.

Special situations:

• Must be alone in the block

• Triggers a preprocessing stop

• Cannot be used in synchronized actions

• A maximum of five axes can be programmed per function call; n = 5

<axis_n>:

For the specified axis, writes to drive parameter p0888 (configuration): p0888

= 1

Data type:

AXIS

Range of values:

Channel axis name

<stopping

For the axis specified under <Axis_n>, writes to drive parameter p0892 (timer):

time_n>:

P0892 = <stopping time_n>

Unit:

Data type:

REAL

Range of values:

0.00 - 20.00

21.3.9.2

Retraction (ESRR)

Syntax

ESRR(<axis_1>,<retraction distance_1>,<retraction

velocity_1>[,...,<axis_n>,<retraction distance_n>,<retraction

velocity_n>])

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21.3 ESR executed autonomously in the drive

Meaning

ESRR:

Using the function, drive parameters can be changed regarding the drive-au-

tonomous "retract" ESR function.

Special situations:

• Must be alone in the block

• Triggers a preprocessing stop

• Cannot be used in synchronized actions

• A maximum of five axes can be programmed per function call; n = 5

<axis_n>:

For the specified axis, writes to drive parameter p0888 (configuration): p0888

= 2

Data type:

AXIS

Range of values:

Channel axis name

<retraction

For the axis specified under <Axis_n>, writes to drive parameter p0893 (re-

velocity_n>:

traction speed):

p0893 = (<retraction velocity> based on the currently effective total transmis-

sion ratio converted into the corresponding retraction speed)

Unit:

mm/min, inch/min, degrees/min (depending on the unit of

the axis)

Data type:

REAL

Range of values:

0.00 - MAX

<retraction

For the axis specified under <Axis_n>, writes to drive parameter p0892 (re-

distance_n>:

traction time):

p0892 = <retraction distance_n> / <retraction velocity _n>

Unit:

mm, inches, degrees (depending on the unit of the axis)

Data type:

REAL

Range of values:

MIN - MAX

Note

Retraction speed

It should be ensured that the drive can reach the programmed retraction speed (see parameters

<retraction velocity_n>) within the retraction time (see parameter <retraction distance _n>).

The settings in the following drive parameters should be checked:

• p1082[0...n] (maximum speed)

• p1135[0...n] (OFF3 ramp-down time)

Retraction path

The conversion of the retraction path into a retraction duration for drive parameter p0892 is

performed under the assumption that the retraction motion is triggered at axis standstill (see

"Figure 21-5 Configuring_drive_integrated_generator_operation (Page 917)").

If retraction motion is triggered while the axis is traversing, the actually traversed retraction

distance differs from the programmed retraction distance due to the fact that traversing motion

is superimposed on the retraction motion.

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21.3 ESR executed autonomously in the drive

Dependencies

The programmed values for the retraction path and the retraction velocity refer to the load side.

Before writing to the drive parameters these are converted over to the motor side. The

transmission ratio effective in the NC at the execution time is applicable for the conversion. If the

drive-autonomous ESR for an axis is enabled ($AA_ESR_ENABLE[<axis>] == 1), then it is not

permissible to change the axial transmission ratio.

Note

Changing the transmission ratio

If the drive-autonomous ESR is not enabled for an axis ($AA_ESR_ENABLE[<axis>] == 0), then

the axial transmission ratio can be changed. After the change, it is the sole responsibility of the

user/machine manufacturer to appropriately adapt the retraction distance and the retraction

velocity.

See also

Configuring generator operation in the drive (Page 916)

21.3.9.3

Boundary conditions

Description

Consistent parameter change

In order that the drive parameters are consistently effective, in the part program the drive-

autonomous ESR enable signals must be withdrawn before the functions ESRS(...) and

ESRR(...).

Example:

Program code

Comment

N100 $AA_ESR_ENABLE[X1]=0

;Withdraw ESR enable signals

N110 $AA_ESR_ENABLE[Z1]=0

N120 $AA_ESR_ENABLE[Y1]=0

N130 ESRR(X1,20.0,10000.0,Z1,-15.0,20000.0)

;Change ESR parameters

N140 ESRS(Y1,0.5,B1,0.5)

N150 $AA_ESR_ENABLE[X1]=1

;Set ESR enable signals

N160 $AA_ESR_ENABLE[Z1]=1

N170 $AA_ESR_ENABLE[Y1]=1

When executing the functions ESRS(...) and ESRR(...) further execution of the part

program is stopped until writing to the drive parameters has been acknowledged. During this

time, the following message is used as feedback signal for the user: "Wait for drive parameters

from <Function>" is displayed.

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21.3 ESR executed autonomously in the drive

Block search with calculation

During the block search with calculation, the functions ESRS(...) and ESRR( ... ) are

collected and executed in the action block.

Block search with calculation in "Program test" (SERUPRO) mode

During SERUPRO, the functions ESRS(...) and ESRR( ... ) are executed immediately.

Reset behavior

The parameter values written using the functions ESRS(...) and ESRR(...) are

overwritten with the parameter values saved in the drive when the drive runs up or for a drive

warm restart.

Drive parameters can be saved from the HMI user interface or in the drive. From the HMI user

interface:

• Operating area "Commissioning" > "Machine data" > "Drive MD" > "Save/Reset" > "Save" >

"Drive object"or "drive unit" or " drive system"

Control power-up (POWER ON)

If the drive-autonomous ESR should already be active after the control has powered up (POWER

ON), then the programming and enable must be realized within one of the ASUBs started from

the PLC - or using the PROGEVENT mechanism.

Further information

For detailed information about event-controlled program calls, refer to:

Function Manual Basic Functions; Mode group, channel, program mode, reset response, event-

driven program calls

21.3.10

ESR and Safety Integrated

Delay times

In order that drive-integrated ESR reactions in conjunction with Safety Integrated are executed

before the safety reactions associated with STOP E, STOP F or communication failure, then the

corresponding delay times regarding safety reactions must be configured in the control and in

the drive.

Delay times are configured in the controller using the following machine data:

• MD36954 $MA_SAFE_STOP_SWITCH_TIME_E (transition time, STOP E to safe standstill)

• MD36955 $MA_SAFE_STOP_SWITCH_TIME_F (transition time, STOP F to STOP B)

• MD36961 $MA_SAFE_VELO_STOP_MODE (stop response, safely-reduced speed)

• MD36963 $MA_SAFE_VELO_STOP_REACTION (stop response, safely-reduced speed)

• MD10089 $MN_SAFE_PULSE_DIS_TIME_BUSFAIL (wait time pulse cancellation when the

bus fails)

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21.4 Boundary conditions

Delay times in the drive are configured using the following drive parameters:

• p9554 (transition time from STOP E to "Safe Operating Stop" (SOS))

• p9555 (transition time STOP F to STOP B)

• p9561 (SG stop response)

• p9563 (SG-specific stop response)

• p9580 (wait time after which the pulses are safely cancelled after bus failure)

• p9697 (delay time for the pulse suppression after bus failure)

• p9897 (delay time for the pulse suppression after bus failure)

Note

The drive parameters are automatically aligned with the corresponding NC machine data

using the Safety Integrated commissioning function "Copy SI data".

Trigger drive-integrated ESR reactions

The feedback signal of the safety stop reaction - currently active in the drive - sent to the control

is realized using the following axis-specific system variable:

• $VA_STOPSI[<axis>] (actual stop reaction)

By evaluating the system variable in a part program/synchronized action, a user-specific

response can be realized to the particular stop reaction of the axis, e.g. by triggering the drive-

integrated and/or control-managed ESR reactions using the system variable $AN_ESR_TRIGGER

and/or $AC_ESR_TRIGGER or $AA_ESR_TRIGGER.

Further information

A detailed description for configuring and the interaction of drive-integrated ESR responses and

Safety Integrated functions is given in:

Function Manual SINUMERIK Safety Integrated

21.4

Boundary conditions

Transformation

If NC-controlled extended stopping and retraction is activated for anaxis involved in an active

transformation, then extended stopping and retraction must also be activated for all other axes

involved in the transformation. Otherwise, when activating extended stopping and retraction,

it is possible that the transformation group will ungrouped.

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21.5 Examples

Drive components

In order that the configured stopping or retraction responses can be executed, the drive

components involved must be fully functional. Axis-specific servo or drive alarms, which indicate

the failure of one of these components, are also implicitly signaling that the configured stopping

or retraction response of the axis involved is no longer available or only partially.

Motion-synchronous actions

Motion-synchronous actions are executed in the interpolator clock cycle. Increasing the

interpolator clock cycle, e.g. due to a high number of active motion-synchronous actions, results

in a coarser time grid for evaluating trigger conditions and triggering responses for extended

stopping and retraction.

21.5

Examples

21.5.1

NC-controlled reactions

Task

The A axis is to operate as the generator drive, while the X axis should retract 10 mm at

maximum velocity in the event of a fault. The Y and Z axes should stop after a delay of 100 ms

so that the X retraction axis has sufficient time to cancel the mechanical coupling.

The example is performed using NC-controlled reactions.

Only the essential parts of the entire functionality are displayed.

Requirements

The following functions must be available:

• Extended stopping and retraction (ESR)

• Static synchronized actions

• Asynchronous subprograms (ASUBs)

Settings

Machine data

Axis-specific operating mode of the ESR

• MD37500 $MA_ESR_REACTION[X] = 21 (NC-controlled retraction axis)

• MD37500 $MA_ESR_REACTION[Y] = 22 (NC-controlled stop axis)

• MD37500 $MA_ESR_REACTION[Z] = 22 (NC-controlled stop axis)

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21.5 Examples

Configuration: NC-controlled extended stop

• MD21380 $MC_ESR_DELAY_TIME1 = 0.1 (duration of the path interpolation in seconds)

• MD21381 $MC_ESR_DELAY_TIME2 = 0.04 (braking duration in seconds)

Programming

Program code

Comment

LFPOS

Axis-specific lift to a position

POLF[X]=IC(10)

Retraction position, incremental

POLFMASK(X)

Enable retraction

; Enable "Extended stop and retract"

$AA_ESR_ENABLE[X]=1

; X axis

$AA_ESR_ENABLE[Y]=1

; Y axis

$AA_ESR_ENABLE[Z]=1

; Z axis

Trigger conditions and static synchronized actions

Example 1

Trigger condition is the occurrence of alarms, which activate the follow-up (tracking) mode:

Program code

IDS=02 WHENEVER ($AC_ALARM_STAT B_AND 'H2000') > 0 DO $AC_ESR_TRIGGER=1

Example 2

Trigger condition is when the ELG synchronous monitoring responds, if, e.g. Y is defined as ELG

following axis and the max. permissible synchronism difference is 100 mm:

Program code

IDS=03 WHENEVER $VA_EG_SYNCDIFF[Y] > 0.1 DO $AC_ESR_TRIGGER=1

21.5.2

Retraction while thread cutting

During thread cutting, for a fault/interruption, axis X should be retracted to the position

specified under POLF as response. Axis Z continues to traverse until it is stopped as normal.

Program code

Comment

N10 G0 G90 X200 Z0 S200 M3

;

N20 G0 G90 X170

;

N30 POLF[X]=210

; Retraction position axis X, absolute

N40 LFPOS

; Retraction via POLF/POLFMASK ON

N50 POLFMASK(X)

; Enable retraction, axis X

N60 LFON

; Fast retraction for thread cutting ON

; Thread cutting

N70 G33 X100 I10

; Retraction response, axial: X (abs.)

N80 X130 Z-45 K10

; dto.

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21.5 Examples

Program code

Comment

N90 X155 Z-128 K10

; dto.

N100 X145 Z-168 K10

; dto.

N110 X120 I10

; dto.

N120 G0 Z0 LFOF

; Fast retraction for thread cutting OFF

N130 POLFMASK()

; Disable retraction of all axes

21.5.3

Rapid lift using ASUB and fast input

Activating ASUB using the LIFTFAST program command (rapid lift) via fast input 1:

Program code

Comment

N10 SETINT (1) PRIO=1 ABHEB_Y LIFTFAST

; ASUB activation, fast input 1

N20 LFPOS

; Retraction via POLF/POLFMASK ON

N30 POLF[X]=19.5 POLF[Y]=33.3

; Retraction positions axis X Y, absolute

N40 POLF[Z]=100

; Retraction position axis Z, absolute

N50 X0 Y0 G0

;

N60 POLFMASK(X, Y)

; Enable retraction, axis X Y

N70 Z100 G1 F1000

; Retraction response, axial: X, Y (abs.)

N80 POLFMASK(Z)

; Disable retraction, axis X Y and

; Enable retraction, axis Z

N90 Y10

; Retraction response, axial: Z (abs.)

N100 POLFMASK()

; Disable retraction of all axes

21.5.4

Rapid lift, absolute and incremental

Retraction to absolute positions and through an incremental distance:

Program code

Comment

N10 $AA_ESR_ENABLE[X]=1

; Enable retraction, axis X

N20 $AA_ESR_ENABLE[Z]=1

; Enable retraction, axis Z

N30 $AA_ESR_ENABLE[Y]=1

; Enable retraction, axis Y

N40 LFPOS

; Retraction via POLF/POLFMASK ON

N50 POLF[X]=IC(3.0) POLF[Y]=-4.0

; Retraction position axis X, incremental

; Retraction position axis Y, absolute

N60 POLF[Z]=100

; Retraction position axis Z, absolute

N70 G0 X0 Y0 Z0

;

N80 POLFMASK(X, Y)

; Enable retraction, axis X Y

N90 Z100 G1 F1000

; Retraction response, axial: X (inc.), Y (abs.)

N100 POLF[X]=10

; Retraction position axis X, absolute

N110 Y0 G1 F1000

; Retraction response, axial: X, Y (abs.)

N120 POLFMASK(Z)

; Disable retraction, axis X Y and

; Enable retraction, axis Z

N130 Y10

; Retraction response, axial: Z (abs.)

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21.6 Data lists

Program code

Comment

N140 POLFMASK()

; Disable retraction of all axes

21.5.5

Lift fast with linear relation of axes

Retracting in a linear relationship, absolute and incremental

Program code

Comment

N10 $AA_ESR_ENABLE[X]=1

; Enable retraction, axis X

N20 $AA_ESR_ENABLE[Y]=1

; Enable retraction, axis Y

N30 $AA_ESR_ENABLE[Z]=1

; Enable retraction, axis Z

N40 LFPOS

; Retraction via POLF/POLFMASK ON

N50 POLF[X]=IC(3.0) POLF[Z]=-4.0

; Retraction position axis X, incremental

; Retraction position axis Z, absolute

N60 POLF[Y]=100

; Retraction position axis Z, absolute

N70 X0 Y0 Z0 G0

; ---

N80 POLFMLIN(X, Y)

; Enable retraction, axis X Y, linear

; Relationship

N85 POLFMASK(Z)

; Enable retraction, axis Z

N90 Z100 G1 F1000

;

Retraction response:

;

- linear relation: X (inc.), Y (abs.)

;

- axial: Z (abs.)

N95 POLF[X]=10

; Retraction position axis X, absolute

N100 Y0 G1 F1000

;

Retraction response:

;

- linear relation: X (inc.), Y (abs.)

;

- axial: Z (abs.)

N110 POLFMLIN()

; Disable retraction, axis X Y

N120 Y10

; Retraction response, axial: Z (abs.)

N130 POLFMASK()

; Disable retraction of all axes

21.6

Data lists

21.6.1

Machine data

21.6.1.1

Channelspecific machine data

Number Identifier: $MC_

Description

21204

LIFTFAST_STOP_COND

Stop characteristics for rapid lift

21380

ESR_DELAY_TIME1

Delay time (STOPBYALARM, NOREAD) for ESR axes

21381

ESR_DELAY_TIME2

Time for interpolatory braking of ESR axes

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21.6 Data lists

21.6.1.2

Axis/spindlespecific machine data

Number

Identifier: $MA_

Description

37500

ESR_REACTION

Reaction definition with extended stop and retract

21.6.2

System variables

Identifier

Meaning

$A_DBB

Read/write data byte from/to PLC

$A_IN

Digital input

$A_OUT

Digital output

$AA_ESR_ENABLE[<axis>]

Enable "Extended stop and retract"

$AA_TYP[<axis>]

Axis type

$AA_ESR_TRIGGER[<axis>]

Initiate ESR for PLC controlled axis (single axis)

$AC_ALARM_STAT

Alarm status in the channel

$AC_ESR_TRIGGER

Trigger ESR, channel-specific

$AC_STAT

Channel status

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Path length evaluation

22.1

Brief description

Function

With the "Path length evaluation" function, the NC specific machine axis data is made available

as the system and OPI variables, with whose help it is possible to assess the strain on the machine

axes and thereby make an evaluation on the state of the machine's maintenance.

Recorded data

The following data is recorded:

• Total traverse path

• Total travel time

• Total travel count

• Total traverse path at high axis speeds

• Total travel time at high axis speeds

• Travel count at high axis speeds

• Total sum of jerks

• Axis travel time with jerk

• Travel count with jerk

Evaluation

When the function is activated, the selected control data is automatically sent and made

available via the system and OPI variables for evaluation in the part program or synchronized

actions, as with user-specified HMI functions.

Meaning

The data remains saved in the control, so that it may continue to be used after POWER OFF / ON.

Consequently, the actual value of a data item represents the sum of all measured values since

the function was activated.

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22.3 Parameterization

22.2

Data

The following data is available:

System variable ¹⁾

OPI variable

Meaning

$AA_TRAVEL_DIST

aaTravelDist

Total traverse path:

sum of all set position changes in MCS ²⁾ in [mm] or [deg.].

$AA_TRAVEL_TIME

aaTravelTime

Total travel time:

sum of IPO clock cycles from set position changes in MCS ²⁾ in [s] (sol-

ution: 1 IPO clock cycle)

$AA_TRAVEL_COUNT

aaTravelCount

Total travel count:

a complete machine axis trip is defined by the following succession of

states, as based on set position: standstill > traversing > standstill

$AA_TRAVEL_DIST_HS

aaTravelDistHS

Total traversing distance at high axis velocities ³⁾

$AA_TRAVEL_TIME_HS

aaTravelTimeHS

Total traversing time at high axis velocities ³⁾

$AA_TRAVEL_COUNT_HS

aaTravelCountHS

Total number of traversing operations at high axis velocities ³⁾

$AA_JERK_TOT

aaJerkTotal

Total sum of axis jerks:

Sum of all jerk setpoints in [m/s³] or [deg./ s³].

$AA_JERK_TIME

aaJerkTime

Total travel time with jerk:

sum of IPO clock cycles from jerk setpoint changes in [s] (solution: 1 IPO

clock cycle)

$AA_JERK_COUNT

aaJerkCount

Total number of traversing operations with jerk

¹⁾ System variables can be read from part programs and synchronized actions

²) MCS: Machine coordinate system

³⁾ Actual machine axis velocity ≥ 80% of the maximum parameterized axis velocity (MD32000 MAX_AX_VELO)

22.3

Parameterization

22.3.1

General activation

The function is generally activated via the NC-specific machine data:

MD18860 $MN_MM_MAINTENANCE_MON (Activate recording of maintenance data)

22.3.2

Data groups

The data has been collected into data groups.

The data groups are activated via the axis-specific machine data:

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22.4 Examples

MD33060 $MA_MAINTENANCE_DATA (configuration to record maintenance data)

Value

Activation of the following data: System variable / OPI variable

• Total traverse path: $AA_TRAVEL_DIST / aaTravelDist

• Total travel time: $AA_TRAVEL_TIME / aaTravelTime

• Total travel count: $AA_TRAVEL_COUNT / aaTravelCount

• Total traversing distance for high velocities:

$AA_TRAVEL_DIST_HS / aaTravelDistHS

• Total traversing time for high velocities:

$AA_TRAVEL_TIME_HS / aaTravelTimeHS

• Total number of traversing operations at high velocities:

$AA_TRAVEL_COUNT_HS / aaTravelCountHS

• Total sum of jerks: $AA_JERK_TOT / aaJerkTotal

• Travel time with jerk: $AA_JERK_TIME / aaJerkTime

• Total travel count with jerk:

$AA_JERK_COUNT / aaJerkCount

22.4

Examples

22.4.1

Traversal per part program

Three geometry axes AX1, AX2 and AX3 exist in a machine. For geometry axis AX1, the part

program-driven total traverse path, total travel time and travel count should be calculated.

Parameter assignment

Activation of the overall function:

MD18860 $MN_MM_MAINTENANCE_MON = TRUE

Group activation: "Total travel distance, total travel time and number of travel operations" for

geometry axis AX1:

MD33060 $MA_MAINTENANCE_DATA[AX1] = 1

Programming

To determine the values referred to the part program, the actual value of the system variables

at the beginning of the part program must be saved in a calculation variable. The difference is

acquired at the end of the part program.

Part program (extract):

Program code

Comment

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22.5 Data lists

Program code

Comment

; Current values:

R10=$AA_TRAVEL_DIST[AX1]

; Total traversing distance AX1

R11=$AA_TRAVEL_TIME[AX1]

; Total traversing time AX1

R12=$AA_TRAVEL_COUNT[AX1]

; Number of traversing operations AX1

; Traversing motion of axes

; Generating the difference:

R10=R10-$AA_TRAVEL_DIST[AX1]

; Traversing distance AX1 in the part pro-

gram

R11=R11-$AA_TRAVEL_TIME[AX1]

; Traversing time AX1 in the part program

R12=R12-$AA_TRAVEL_COUNT[AX1]

; Number of traversing operations AX1 in

the part program

22.5

Data lists

22.5.1

Machine data

22.5.1.1

NC-specific machine data

Number

Identifier: $MN_

Description

18860

MM_MAINTENANCE_MON

Activate recording of maintenance data

22.5.1.2

Axis/spindlespecific machine data

Number

Identifier: $MA_

Description

33060

MAINTENANCE_DATA

Configuration, recording maintenance data

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23.1

Function

Note

The "Automatic post optimization with AST" function is an option that requires a license.

With the "Automatic post optimization with AST" function, axes with a changed mechanical

system can be post optimized from the part program.

SIEMENS provides predefined cycles for the functions of the Automatic Servo Tuning (AST) (post

optimization) (see "Programming (Page 938)"). They can be used by machine manufacturers

to create their own tuning cycles. The machine operator must only use the machine

manufacturer's cycle.

Note

Storage location for optimization cycles

In order that the machine operator can call the optimization cycles generated by the machine

manufacturer based on AST cycles, these must be saved in the manufacturer cycle directory

(_N_CMA_DIR) of the NC memory.

Application

General problem description: Dependency on the loading

After changing the load - and therefore the moment of inertia, for all directly-driven axes, the

current setpoint filters must be adapted to ensure that the speed control loop remains stable.

Such axes are:

• Tables with torque motors

• Linear axes with linear motors that support different masses

• Directly driven main spindles with different clamping fixtures (lathe chuck)

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23.1 Function

All conventionally driven axes (servomotor with ball screw spindle and possibly with gearbox)

do not require that the speed controller is post optimized (retuned).

Note

If, after the load has changed, the actual parameter data set no longer fits, in order to traverse

directly-driven axis reliably without any instability, then parameter values must be

adapted before setting the controller enable (DB31, ... DBX2.1 = 1). Automatic post

optimization with AST is only possible after the controller has been enabled.

The following measures are possible:

• The active parameter data set is set so that it is suitable for all load conditions - and can be

used without adaptation ("moderately" adjusted parameter data set).

• A "moderately" adjusted parameter data set is adapted using automatic post optimization

with AST, and is then subsequently activated.

• The required parameter values are assigned by the PLC (FB3, PI services, …) and/or

manufacturer cycle before setting the controller enable.

Typical applications

For typical applications, see Section "Examples (Page 960)".

Setting up optimization cycles/troubleshooting

We recommend that an optimization cycle that has been newly created or modified is executed

and tested before the machine is shipped.

The reasons for this are as follows:

• For programming errors - or if the appropriate preconditions are not available (e.g. XML file

with optimization strategy is missing), then the program is canceled. Based on the alarm that

is output, the program line with the error can be identified and the error subsequently

resolved. As soon as the optimization cycle can be executed without any errors, program

stops should no longer occur for the end user.

• If the user interface-based automatic servo optimization (AST) had not been previously used

on the machine, and the machine data is not set for the current recommendation for

precontrol (e.g. MD33000 $MA_FIPO_TYPE = 3, MD32620 $MA_FFW_TYPE = 4), then the

first time that the AST cycles are executed results in this machine data being set, and a power

on (NC reset) or a channel reset is necessary.

Further information

For information on user interface-based automatic servo optimization, see:

• CNC Commissioning Manual: NC, PLC, drive

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23.2 Commissioning

23.2

Commissioning

System requirements

• SINUMERIK NCU with SINUMERIK Operate

• "Automatic post optimization with AST" option is set.

Machines with several HMI components

The "Automatic post optimization with AST" function can always be assigned to an HMI.

In order to change the actual assignment, in the HMI intended for the function, window

≫Automat. servo optimization: options≪ must be called, and option ≫Assign this HMI for "Call

AST from the part program" ≪ selected.

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23.3 Programming

23.3

Programming

23.3.1

Overview

Predefined cycles for automatic post optimization with AST

SIEMENS provides machinery builders (OEMs) the following cycles so that they can program

their own optimization cycles:

• CYCLE751 - Open/execute/close optimization session (Page 940)

• CYCLE752 - Add axis to an optimization session (Page 940)

• CYCLE753 - Select optimization mode (Page 943)

• CYCLE754 - Add/remove data set (Page 944)

• CYCLE755 - Backup/restore data (Page 945)

• CYCLE756 - Activate optimization results (Page 947)

• CYCLE757 - Save optimization data (Page 948)

• CYCLE758 - Change a parameter value (Page 951)

• CYCLE759 - Read parameter value (Page 953)

Internally, each of these cycles calls CYCLE750, which contains the MMC command with the

actual function call.

Data handling

Archived in standard directories

Automatic servo optimization (AST) uses three standard directories in the file system to save

specific data:

Directory path

To archive the following files

/user/sinumerik/nck/data/optimization

• XML files with axis and/or path-specific optimization data, which

are automatically generated for the user interface-based auto-

matic servo optimization.

• XML files with axis and/or path-specific optimization data, which

are automatically generated for automatic post optimization

with AST using CYCLE757.

/user/sinumerik/nck/data/optimization/restore

• Backup files that are generated by the automatic post optimiza-

tion with AST using CYCLE755.

/user/sinumerik/nck/data/optimization/data

• CSV files that are generated by the automatic post optimization

with AST using CYCLE757.

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23.3 Programming

Note

Secure archiving of strategy files

When the optimization strategy is created with the aid of Sinumerik Operate, the optimization

strategies are archived in the following folder: /user/sinumerik/nck/data/optimization/.

To ensure that the right strategy file is always used when CYCLE752 is called, it is recommended

that the strategy file (e.g. "oem_ax1.xml") is moved to another folder that can only be accessed

by the machine manufacturer, e.g.: /oem/sinumerik/nck/data/optimization/.

The option "Optimization data from a user-defined optimization file" (Page 940) is explicitly

recommended.

CYCLE752(myaxiswithnewload,2,...)

When CYCLE752 and CYCLE755 are called, the corresponding OEM path must then be

specified, e.g.:

CYCLE752(myaxiswithnewload,2,false,"/oem/sinumerik/nck/data/

optimization/oem_ax1.xml")

Furthermore, archiving of the results with absolute path data to an OEM folder is recommended

to protect the results of measurements.

Addressing using absolute path data

Optimization files must be addressed using absolute path data. That is to say, path data must

include the complete address.

For Linux, the complete address comprises the following elements:

• Directory path

• File name

Example:

oem/sinumerik/nck/data/optimization/my_ast_ax1.xml

Addressing files in external memories

When addressing optimization files in an external memory, the drive name must be specified at

the beginning of the path.

All symbolic device names configured in card/user/sinumerik/hmi/cfg/logdrive.ini are

permissible.

Examples:

• LOCAL_DRIVE:/… (local drive)

•

//DEV_5:/… (user-defined drive)

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23.3 Programming

23.3.2

CYCLE751 - Open/execute/close optimization session

Syntax

CYCLE751(<S_I_SESSIONCOMMAND>)

Parameter

No.

Parameters

<S_I_SESSIONCOMMAND>

Data type:

INT

Value:

Not defined

Open new optimization session

Note:

Multiple sessions cannot be open concurrently. Opening a new session closes the current session

automatically.

Close current optimization session

Execute optimization functions of the current session with immediate transfer of the optimization

results

The scope of the optimization functions (measurement of the speed control loop, measurement of

the position control loop, optimization of the path interpolation) to be executed depends on the axis-

specific optimization strategies set from the user interface.

The optimization results are transferred immediately (update the axis and drive parameters, update

the optimization files).

Execute optimization functions of the current session without immediate transfer of the optimiza-

tion results

Unlike 3, the optimization results are not transferred immediately. Transfer can be realized later in the

optimization session using CYCLE756.

23.3.3

CYCLE752 - Add axis to an optimization session

After opening the optimization session, CYCLE752 specifies which axes should be reoptimized.

If a reoptimization of the path interpolation is provided, CYCLE752 also specifies the axes

required for the comparison of the path interpolation.

Syntax

CYCLE752(<S_I_AXIS>, <S_I_ACTIONREQUEST>, <S_B_ISPATHMEMBER>,

<S_SZ_FILENAME>)

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23.3 Programming

Parameter

No.

Parameter

<S_I_AXIS>

Meaning:

Machine axis number

Specifies the axis to be added to the optimization session.

Note:

For gantry or master-slave couplings, only the leading or master axis of the coupling group should be

specified.

Data type:

INT

<S_I_ACTIONREQUEST>

Meaning:

Specifies whether the stored optimization data (optimization strategy and optimization results) should

be used or the axis with AST default settings reoptimized for the axis to be added.

Note:

If the axis has already been optimized and the optimization data has been saved in an optimization file,

this data is normally accessed first. CYCLE753 can then specify the further procedure.

Data type:

INT

Value:

Not defined

Reoptimization with AST default settings

The axis should be remeasured and reoptimized with the AST default settings. The selected AST

settings are not considered on the user interface.

Optimization data from a user-defined optimization file

The stored optimization data from the specified user-defined optimization file (see <S_SZ_FILE-

NAME> parameter) is used for the axis.

Note:

This setting is only possible if the axis has already been optimized once, and the results have been

saved to a user-defined optimization file.

Optimization data from the standard optimization file

The stored optimization data from the axis-specific standard optimization file is used for the axis.

The selected AST settings are considered on the user interface.

Note:

For the user interface-based automatic servo optimization, the standard optimization files are

automatically generated to backup optimization information and data (optimization strategy,

measuring and optimization results) and saved in the file system under /user/sinumerik/nck/data/

optimization. There is a standard optimization file for every axis - and a standard optimization file

for the path interpolation.

For example, the setting <S_I_ACTIONREQUEST> = 2 or 3 is used in the following cases:

• The axis should be post-optimized using the saved strategy and measurement settings. To do this,

the saved optimization data is loaded with CYCLE752 and the deployed optimization mode defined

with CYCLE753.

• On completion of the reoptimization of the individual axes, the path interpolation must be reopti-

mized.

• Saved optimization results (values for NC and drive parameters) should be restored.

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23.3 Programming

No.

Parameter

<S_B_ISPATHMEMBER>

Meaning:

Consideration of the axis for the last optimization step (optimization of the path interpolation)

Data type:

BOOL

Value:

0 (FALSE)

Do not consider the axis for the optimization of the path interpolation

1 (TRUE)

Consider the axis for the optimization of the path interpolation

All axes, which are added using CYCLE752( , , TRUE, ), are taken into account when

optimizing path interpolation. This is realized within the scope of the optimization, e.g.

started using CYCLE751(3).

<S_SZ_FILENAME>

Meaning:

Address of the user-defined, axis-specific optimization file (only relevant for <S_I_ACTIONREQUEST> = 2!)

When the optimization strategy is created with the aid of Sinumerik Operate, the optimization strategies

are archived by default in the following folder: /user/sinumerik/nck/data/optimization/.

To ensure that the right strategy file is always used when CYCLE752 is called, it is recommended that the

strategy file (e.g. "oem_ax1.xml") is moved to another folder that can only be accessed by the machine

manufacturer, e.g.: /oem/sinumerik/nck/data/optimization/.

Using the option "Optimization data from a user-defined optimization file" (<S_I_ACTIONREQUEST> = 2)

is explicitly recommended:

CYCLE752(myaxiswithnewload,2,...)

When CYCLE752 is called, the corresponding OEM path must then be specified, e.g.:

CYCLE752(myaxiswithnewload,2,false,"/oem/sinumerik/nck/data/optimization/

oem_ax1.xml")

Data type:

STRING [100]

Note

Gantry/master-slave coupling

For gantry or master-slave couplings, with CYCLE752, only the leading or master axis of the

coupling group is specified. The AST software automatically adds the coupled following or slave

axes.

AST then automatically measures all axes of a coupling group - and optimizes them with

identical controller settings. The position controller gains are set the same, the integral time in

the speed controller is selected the same and the effective speed controller gain (relative to the

overall moment of inertia) is selected the same. The current setpoint filters can be optimized

differently.

Coupled axes must be referenced (homed) before the automatic optimization!

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23.3 Programming

Note

Premeasurement

The decision for performing a premeasurement depends on the available axis optimization data.

• Cases in which the control unit performs a premeasurement for determining the measuring

parameters:

- The optimization strategy envisages a premeasurement; data from an earlier

premeasurement is not available.

- The optimization data does not specify any optimization strategy.

• Cases in which no premeasurement is performed:

- The optimization strategy envisages a premeasurement; data from an earlier

premeasurement is available.

- The optimization strategy does not envisage any premeasurement (the optimization

strategy takes precedence over the "Perform premeasurement for determining the

excitation" option selected from the user interface).

See also

Example 6: Measuring an axis without optimization (Page 975)

23.3.4

CYCLE753 - Select optimization mode

CYCLE753 must be programmed when different strategy settings should act for the axis than

those stored as standard or selected from the user interface. For example, this the case when an

axis with user-defined strategy and measuring settings from a stored optimization file should be

remeasured and reoptimized.

Syntax

CYCLE753(<S_I_AXIS>, <S_I_ACTION>, <S_B_SAVEBOOTFILES>)

Parameters

No.

Parameters

<S_I_AXIS>

Meaning:

Machine axis number

Data type:

INT

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23.3 Programming

No.

Parameters

<S_I_ACTION>

Meaning:

Specifies the optimization mode for the specified axis.

Data type:

INT

Value:

Not defined

Match the path interpolation

The axis (path axis) should not be remeasured and reoptimized, but rather considered and adap-

ted only for the optimization of the path interpolation.

The stored results from the optimization file are used for the axis. The optimization of the path

interpolation means that the axis-specific machine data and drive parameters can change.

Reoptimization with a different optimization strategy based on stored measurements

The axis should be reoptimized based on the results from an earlier measurement and currently

valid optimization strategy changed from the user interface or CYCLE758.

This mode is used, for example, to eliminate known periodic disturbance frequencies (see "Ex-

ample 5: Reoptimize the speed control loop to eliminate known periodic disturbance frequencies.

(Page 973)").

Measurement and reoptimization (→ Mode for changed mechanics/loading!)

The mechanics/loading has changed. The axis should be remeasured and reoptimized using the

user-defined strategy and measuring settings from an optimization file. The strategy and meas-

uring settings can be adapted from the user interface or with CYCLE758.

<S_B_SAVEBOOTFILES>

Meaning:

Save updated drive parameter values as persistent data

Data type:

BOOL

Value:

0 (FALSE)

1 (TRUE)

Yes (default)

23.3.5

CYCLE754 - Add/remove data set

If the optimization results rather than the current data set should overwrite a specific axis or drive

data set, the data set to be overwritten must be added to the data set list with CYCLE754. This

list involves an invisible internal function list used to define data sets to be optimized. As default

setting, only the currently selected data set is included in it. CYCLE754 must also be used to

remove a data set from the list.

Note

Adding or removing an axis or drive data set using CYCLE754 only refers to the data set list, i.e

an axis or drive data set removed from the list still remains in the control or in the drive.

Syntax

CYCLE754(<S_I_AXIS>, <S_I_ACTIONREQUEST>, <S_I_DATASETTYPE>,

<S_I_INDEX>)

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23.3 Programming

Parameters

No.

Parameters

<S_I_AXIS>

Meaning:

Machine axis number

Data type:

INT

<S_I_ACTIONREQUEST>

Meaning:

Specifies whether the specified axis or drive data set should be added to or removed from the data set

list.

Data type:

INT

Value:

Not defined

Add a data set

Remove a data set

Remove all data sets from the list

Note:

If the list is empty, the optimization results can be written only to the active data set.

<S_I_DATASETTYPE>

Meaning:

Data set type

Data type:

INT

Value:

Not defined

Axis data set (servo parameter set)

Drive data set (DDS)

<S_I_INDEX>

Meaning:

Data set index

Specifies the data set to be added and into which the optimization results should be written or should

be removed from the list.

Note:

The following applies to the axisdata set index: <n> = parameter set number - 1

Example: Index 0 ≙ parameter set 1

Data type:

INT

Range of values:

-1, 0, 1, ... <MAX_INDEX>

-1

active data set

23.3.6

CYCLE755 - Backup/restore data

Using CYCLE755, backup files can be created in the file system that permit the backup of the

actual data, and therefore facilitate specific data restoration at any time during the optimization

session. Data restoration is also called using CYCLE755. Further, CYCLE755 is used to query the

existence of a backup file as well as to delete backup files.

Note

The backup files are no longer required after the optimization session has been successfully

completed. This is the reason that these should be deleted again at the end of the optimization

session with CYCLE755.

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23.3 Programming

Typical examples for using CYCLE755 include:

• Undoing data changes, which are only to be temporarily valid.

• Restoring data after an interrupted optimization session.

A program that queries the existence of a backup file, and for a positive result, restores the

data from this file, can be used to return to a defined initial state after an optimization session

has been interrupted.

Syntax

CYCLE755(<S_I_ACTIONREQUEST>, <S_SZ_NAME>, <S_SZ_GUD_BOOL_NAME>)

Parameter

No.

Parameter

<S_I_ACTIONREQUEST>

Data type:

INT

Value:

Not defined

Backup data for a later restore

This setting saves the data values at the time of the cycle call in the specified file.

The following parameters define the content of the data backup:

• the currently valid optimization strategy

• the axes currently added to the optimization session

• the current list of parameter sets to be written

Restore data

This setting restores the data from the specified file.

Requirements:

• The optimization session is still active.

• The axis and data set selection at the time of the backup is still available.

Delete backup file

Querying the existence of a backup file

The result of the query is saved to a channel-global user variable (GUD), type BOOL (see parameter

<S_SZ_GUD_BOOL_NAME>).

<S_SZ_NAME>

Meaning:

Address of the backup file

The file name can be freely selected with the following restriction: it is not permissible that the sequence

of letters "AST" is located at the beginning of the file name.

It is recommended that the backup files be saved in a protected manufacturer directory and always

addressed with absolute path data.

Example: "oem/sinumerik/nck/data/restore/x1_original.xml"

Data type:

STRING [100]

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23.3 Programming

No.

Parameter

<S_SZ_GUD_BOOL_NAME>

Meaning:

Name of the GUD, in which the result of the file query should be saved

(only relevant, if <S_I_ACTIONREQUEST> = 4!)

Note:

The specified GUD must be defined in a definition file as a channel-global variable, type BOOL:

DEF CHAN BOOL

Data type:

STRING [50]

23.3.7

CYCLE756 - Activate optimization results

CYCLE756 can be used to activate the optimization results at a specific time / under specific

conditions. The conditions must be queried in the manufacturer cycle. CYCLE756 can also

specify which control parameters should be active: original data, axis-optimum data or path-

optimum data.

Syntax

CYCLE756(<S_I_AXIS>, <S_I_REGULATOR_ROLE>, <S_B_SAVEBOOTFILES>)

Parameters

No.

Parameters

<S_I_AXIS>

Meaning:

Machine axis number

Data type:

INT

<S_I_REGULATOR_ROLE>

Meaning:

Specifies which optimization results should act for the specified axis in the control unit and in the drive.

Note:

If the axis is part of a gantry group or a master-slave coupling, then optimization factors are included in

the optimization results, which would be necessary to adapt the dynamic response of all axes of the

coupling group.

Data type:

INT

Value:

Not defined

The original data should act for the specified axis.

The current optimization results without optimization of the path interpolation should become

active for the specified axis (axis-optimum data)

The current optimization results with optimization of the path interpolation should become active

for the specified axis (path-optimum data).

<S_B_SAVEBOOTFILES>

Meaning:

Save updated drive parameter values as persistent data

Data type:

BOOL

Value:

0 (FALSE)

1 (TRUE)

Yes (default)

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23.3 Programming

Application

Some situations for which CYCLE756 is useful:

• CYCLE751(4) executes the optimization functions of the current session without transferring

the optimization results immediately. The optimization results can be activated later during

the optimization session with CYCLE756. Prior to the activation, the data can be read and

tested with CYCLE758/759.

• CYCLE752 loads the saved optimization data from an optimization file. CYCLE756 activates

the loaded data.

23.3.8

CYCLE757 - Save optimization data

Contrary to the user interface-based automatic servo optimization, where optimization data are

automatically saved (standard optimization files), saving optimization data for program-based

automatic post optimization with AST must be explicitly called by programming CYCLE757.

The following user-defined optimization files can be created in CYCLE757:

• Optimization files in the XML format:

- for the axis-specific optimization data

- for the data to optimize path interpolation

• Optimization files in the CSV format with frequency, amplitude and phase of the following

frequency responses:

- measured speed-controlled system

- measured mechanical frequency response

- calculated closed speed controller

- calculated closed position controller

- measured closed speed controller

- measured closed position controller

NOTICE

Data loss

If CYCLE757 is not programmed, measurement data as well as parameters for assessment and

offline optimization are no longer available after the optimization session has been closed.

However, the optimization (depending on the strategy) is written to the axis and drive

parameters.

Remedy: Save optimization data to be backed up before closing the optimization session with

CYCLE757.

Syntax

CYCLE757(<S_I_AXIS>, <S_SZ_FILENAME>, <S_I_CONTENT_TYPE>,

<S_I_FORMATFILTER>, <S_I_SUPPINFO>)

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23.3 Programming

Parameter

No.

Parameter

<S_I_AXIS>

Meaning:

Machine axis number

Data type:

INT

<S_SZ_FILENAME>

Meaning:

Address of the optimization file to be created (file name with extension ".xml" or ".csv")

The file name can be freely selected with the following restriction: it is not permissible that the sequence

of letters "AST" is located at the beginning of the file name.

It is recommended that the optimization files be saved in a protected manufacturer directory and always

addressed with absolute path data.

Example: "oem/sinumerik/nck/data/optimization/my_ast_ax1.xml"

If a path is not specified (not recommended), the files are saved in the file system in the following default

directories:

• XML files: /user/sinumerik/nck/data/optimization

• CSV files: /user/sinumerik/nck/data/optimization/data

Special case:

• Empty string (""); only valid, if <S_I_CONTENT_TYPE> = 1 or 2

Entering an empty string means that the data of the program-based automatic post optimization are

written to the standard optimization file for the axis (<S_I_CONTENT_TYPE> = 1) or for the path

interpolation (<S_I_CONTENT_TYPE> = 2).

Notice:

The standard optimization files contain the data of the user interface-based automatic servo opti-

mization. By programming <S_SZ_FILENAME> = "", these are overwritten by the data of the program-

based automatic post optimization.

Data type:

STRING [100]

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23.3 Programming

No.

Parameter

<S_I_CONTENT_TYPE>

Meaning:

Specifies which optimization data should be saved in the created optimization file.

Data type:

INT

Value:

Not defined

Creates an XML file in which the axis-specific optimization data for the specified axis is saved.

The following data is included:

• Measuring conditions

• Measurement results

• Optimization strategy

• Optimization results

Note:

If the axis is part of a gantry group or a master-slave coupling, then the optimization information

for the axis, includes the optimization information for all other axes of the coupling group.

Creates an XML file in which the data for optimization of the path interpolation is saved.

The following data is included:

• List of all involved axes

• Strategy for optimization of the path interpolation

Creates a CSV file, in which the data for the frequency characteristic of the measured speed

controlled system is to be saved.

The data is stored as a 3-column table:

• Column 1: Frequency [Hz]

• Column 2: Linear amplitude

• Column 3: Phase [rad]

Creates a CSV file in which the data for the measured mechanical frequency response is saved.

The data is stored as a 3-column table:

• Column 1: Frequency [Hz]

• Column 2: Linear amplitude

• Column 3: Phase [rad]

Creates a CSV file, in which the data for the frequency response of the calculated closed speed

controller is saved.

The data is stored as a 3-column table:

Column 1: Frequency [Hz]

Column 2: Linear amplitude

Column 3: Phase [rad]

Creates a CSV file, in which the data for the frequency response of the calculated closed position

controller is saved.

The data is stored as a 3-column table:

Column 1: Frequency [Hz]

Column 2: Linear amplitude

Column 3: Phase [rad]

Creates a CSV file, in which the data for the frequency response of the measured closed speed

controller is saved.

The data is stored as a 3-column table:

Column 1: Frequency [Hz]

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23.3 Programming

No.

Parameter

Column 2: Linear amplitude

Column 3: Phase [rad]

Creates a CSV file, in which the data for the frequency response of the measured closed position

controller is saved.

The data is stored as a 3-column table:

Column 1: Frequency [Hz]

Column 2: Linear amplitude

Column 3: Phase [rad]

<S_I_FORMATFILTER>

Meaning:

Reserved

Data type:

INT

<S_I_SUPPINFO>

Meaning:

Reserved

Data type:

INT

23.3.9

CYCLE758 - Change a parameter value

CYCLE758 changes individual strategy and measuring settings prior to the optimization or the

optimization results after the optimization.

Syntax

CYCLE758(<S_I_AXIS>, <S_I_PARAMID>, <S_I_MEASTYPE>, <S_I_MEASINDEX>,

<S_SZ_NEWVALUE>)

Parameters

No.

Parameters

<S_I_AXIS>

Meaning:

Machine axis number (not relevant for parameters that affect the optimization of the path interpolation!)

Data type:

INT

<S_I_PARAM

ID>

Meaning:

ID number of the parameter whose value should be changed

Parameter IDs, see "List of the parameters for the automatic servo optimization (Page 954)".

Data type:

INT

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No.

Parameters

<S_I_MEASTYPE>

Meaning:

Measuring type to which the parameter refers (relevant only for measuring parameters!)

Uniquely identifies measuring parameters with the same ID number.

Data type:

INT

Value:

Mechanical frequency response

Closed position control loop

Closed speed control loop

Speed-controlled system

Speed setpoint step change

<S_I_MEASINDEX>

Meaning:

Measurement index to which the parameter refers (relevant only for measuring parameters!)

Uniquely identifies measuring parameters with the same ID number that refer to the same measuring

type. It must be specified only when multiple measurements of a measuring type exist.

Data type:

INT

<S_SZ_NEWVALUE>

Meaning:

New parameter value

Data type:

STRING [20]

Value:

The value should be specified as a character string in inverted commas. The character string can comprise

a maximum of 20 characters.

Values are only permissible that correspond to the data type of the parameter to be changed - and that

lie within the valid range.

Examples:

1. The parameter to be changed is of data type BOOL (e.g. <S_I_PARAMID> = 157).

Value range: 0 (= FALSE), 1 (= TRUE)

For <S_SZ_NEWVALUE>, the following permissible character string is obtained: "true", "false", "TRUE",

"FALSE", "0" or "1"

Inadmissible character strings would be, for example: 0, 1, true, false, "2", "my_bool"

2. The parameter to be changed is of data type REAL (e.g. <S_I_PARAMID> = 34).

In this particular case, with <S_SZ_NEWVALUE> theoretically, every real number within the value

range ± (∼ 2.2*10^-308 … ∼ 1.8*10⁺³⁰⁸) can be specified.

Permissible character strings are, for example: "14.1", ".0023"

Inadmissible character strings would be, for example "true", 14.1, "my_real", "R1"

Note

Gantry/master-slave coupling

If the measurement parameters of a specific following or slave axis must be changed, then in

CYCLE758 the corresponding number of this axis must be specified (not the number of the

leading or master axis, as when adding coupled axes with CYCLE752 (Page 940)).

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23.3 Programming

23.3.10

CYCLE759 - Read parameter value

CYCLE759 reads the strategy and measuring parameters and the optimized controller

parameters. This is useful for checking the file loaded with CYCLE752 prior to the optimization

or reading the results after the optimization (e.g. determined total inertia, determined gain).

Syntax

CYCLE759(<S_I_AXIS>, <S_I_PARAMID>, <S_I_MEASTYPE>, <S_I_MEASINDEX>,

<S_SZ_GUDRESULT>)

Parameters

No.

Parameters

<S_I_AXIS>

Meaning:

Machine axis number (not relevant for parameters that affect the optimization of the path interpolation!)

Data type:

INT

<S_I_PARAMID>

Meaning:

ID number of the parameter whose value should be read

Parameter IDs, see "List of the parameters for the automatic servo optimization (Page 954)".

Data type:

INT

<S_I_MEASTYPE>

Meaning:

Measuring type to which the parameter refers (relevant only for measuring parameters!)

Uniquely identifies measuring parameters with the same ID number.

Data type:

INT

Value:

Mechanical frequency response

Closed position control loop

Closed speed control loop

Speed-controlled system

Speed setpoint step change

<S_I_MEASINDEX>

Meaning:

Measurement index to which the parameter refers (relevant only for measuring parameters!)

Uniquely identifies measuring parameters with the same ID number that refer to the same measuring

type. It must be specified only when multiple measurements of a measuring type exist.

Data type:

INT

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23.3 Programming

No.

Parameters

<S_SZ_GUDRESULT>

Meaning:

Name of the global user variable (GUD) into which the parameter value should be copied.

Note:

The variable must be a global channel variable which has been defined by the manufacturer in the data

block MGUD.

For detailed information on the GUD definition, see the Programming Manual NC Programming.

Note:

The data type of the GUD must match the data type of the parameter. If the data type is not correct, the

program execution is stopped and an alarm displayed.

Parameter data types, see "List of the parameters for the automatic servo optimization (Page 954)".

Example: GUD for recording the measured total inertia

Procedure for the creation of GUD:

1. Display data tree ("Commissioning" operating area → "System data" softkey).

2. Navigate to the "NC data/definitions" directory.

3. Open the "MGUD.DEF" file for editing.

Note:

If the file does not exist, a new file must be created (→ “New” softkey).

4. Add the following entry:

DEF CHAN REAL AST_TOTAL_INERTIA

5. Save file.

Data type:

STRING [20]

This means that the variable name may comprise a maximum of 19 characters.

23.3.11

List of the parameters for the automatic servo optimization

The ID of a parameter for the automatic servo optimization whose value should be changed with

CYCLE758 or read with CYCLE759 can be taken from the following table:

Meaning

Unit

Data

Value range

Write

Read

type

with

CYCLE758

CYCLE759

Measuring conditions

001

Start position of the axis during a measurement

mm or de-

REAL

grees

002

Direction sequence during a measurement

INT

1, 2, 3, 4

•

1 = plus

•

2 = minus

•

3 = plus, then minus

•

4 = minus, then plus

003

Number of measurement repetitions for deter-

INT

0 to

mining the frequency range averaging

004

Number of time range windows in each time

INT

1 to

range averaging

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23.3 Programming

Meaning

Unit

Data

Value range

Write

Read

type

with

CYCLE758

CYCLE759

005

Settling time: The wait time after the PRBS exci-

REAL

0 to

tation before the first measuring window is ac-

quired

006

Measurement bandwidth

REAL

Float: 0 ... fs/2

This value only determines the measurement

bandwidth (i.e. excitation and sampling frequen-

cy). This allows the frequency resolution to be

influenced.

007

Time for performing an individual measurement

REAL

(without repetition, ramp-up and settling time)

008

Time required to bring the speed offset to the set-

REAL

point

009

Estimated travelled distance during the maxi-

m or rad

REAL

mum traversing motion in the repetition se-

quence

010

Estimated total time of the axis motion during the

REAL

measurement

011

Specifies the measurement type:

INT

1 ... 5

•

1 = frequency response of the mechanical

parts

•

2 = closed position control loop

•

3 = closed speed control loop

•

4 = speed-controlled system

•

5 = speed setpoint increment

012

Specifies whether the axis motion lies within the

BOOL

0 (= FALSE)

traverse range limits

1 (= TRUE)

013

Specifies whether a measurement is performed

BOOL

0 (= FALSE)

with the maximum bandwidth

1 (= TRUE)

021

Amplitude of the excitation

Nm, N,

REAL

Dynamic

m/s, rad/s,

m, rad (de-

pendent

on the

measure-

ment

type¹⁾)

022

Velocity offset

m/s or

REAL

Dynamic

rad/s (de-

pending

on meas-

urement

type¹⁾)

Speed control (controller)

031

Proportional gain for the speed control loop

Nms/rad

REAL

or Ns/m

032

Integral time for the speed control loop

REAL

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Meaning

Unit

Data

Value range

Write

Read

type

with

CYCLE758

CYCLE759

033

Motor moment of inertia

kgm²

REAL

or kg

034

Total moment of inertia of the axis expressed in

kgm²

REAL

the units of the motor

or kg

035

Specifies whether the reference model is activa-

BOOL

0 (= FALSE)

ted for the speed control

1 (= TRUE)

036

Frequency of the PT2 reference model

REAL

037

Damping of the PT2 reference model

REAL

038

Ratio of the Kp proportional gain to the moment

1/s

REAL

of inertia that represents the 1/s bandwidth of

the idealized PT1-equivalent (proportional-con-

trolled) systems

Position control (controller)

101

Position control loop gain

1000/min

REAL

102

Specifies whether DSC (dynamic stiffness control)

BOOL

0 (= FALSE)

is active

1 (= TRUE)

103

Specifies the precontrol type:

INT

0, 1, 2

•

0 = none

•

1 = speed precontrol

•

2 = speed and torque precontrol

104

Total moment of inertia of the axis as parameter

kg m²

REAL

for the torque precontrol

or kg

105

Delay of the speed precontrol in the drive (e.g.

REAL

p1429)

106

Equivalent time constant of the speed control

REAL

loop as parameter for the speed precontrol

107

Adapted parameter value 106 for considering the

REAL

following effects:

• Inconsistent delays

• Changes carried out by the NC

108

Equivalent time constant of the current control

REAL

loop as parameter for the torque precontrol

109

Adapted parameter value 108 for considering the

REAL

following effects:

• Inconsistent delays

• Changes carried out by the NC

110

PT1 time constant of the axis to adapt the dy-

REAL

namic response

(MD32910 $MA_DYN_MATCH_TIME)

111

Time constant used for the dynamic response

REAL

adaptation for the axis-specific setpoint phase fil-

ter (MD32895 $MA_DESVAL_DELAY_TIME)

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23.3 Programming

Meaning

Unit

Data

Value range

Write

Read

type

with

CYCLE758

CYCLE759

112

Calculated total time constant for the positioning

REAL

response, including precontrol and all prefilters.

This time constant is only intended to provide

users with information. You can use it as a target

time constant for the position controller strategy

for another axis. By forcing the same total time

constant, interpolation fits already after axis op-

timization.

Position control (strategy)

151

Adaptation factor (reduction) for the optimized

REAL

0.1 ... 1.0

maximum Kv value

152

Not defined

153

Specifies the additional method for maximizing

INT

0 ... 3

the Kv value:

•

0 = none (standard)

•

1 = PT1 speed filter 2

•

2 = damping of the optimum speed controller

•

3 = PT1 speed filter 1

154

DSC (Dynamic Servo Control):

BOOL

0 (= FALSE)

• TRUE = active

1 (= TRUE)

• FALSE = inactive

155

Select precontrol type:

INT

0, 1, 2

•

0 = none

•

1 = speed precontrol

•

2 = speed and torque precontrol

156

Maximum permissible Kv value

1000/min

REAL

0.1 ... 99.0

157

Specifies whether the precontrol should always

BOOL

0 (= FALSE)

be active for the axis

1 (= TRUE)

158

Setpoint for the equivalent time of the position

REAL

controller overall response (including precontrol

and setpoint filter)

159

Indicates whether an attempt should be made to

BOOL

0 (= FALSE)

attain the nominal equivalent time

1 (= TRUE)

160

Specifies the jerk filter technology to be selected:

INT

0 ... 2

•

0 = keep the existing jerk filter settings in the

machine data

•

1 = deactivates the jerk filter

•

2 = use jerk filter, type 2 (= sliding average

value generation)

161

Time constant (MD32410 $MA_AX_JERK_TIME)

REAL

0 … 0.5

for type 2 jerk filter (parameter 160 = 2)

Speed control (strategy)

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23.3 Programming

Meaning

Unit

Data

Value range

Write

Read

type

with

CYCLE758

CYCLE759

201

Setpoint for the amplitude reserve for the opti-

REAL

mization

202

Setpoint for the phase reserve for the optimiza-

deg

REAL

tion

203

Indicates whether the reference model should be

BOOL

0 (= FALSE)

activated

1 (= TRUE)

204

Specifies the permissible minimum value for the

REAL

0.001 ... 1.000

integral time of the speed control loop

205

Specifies whether the design of band-stop filters

BOOL

0 (= FALSE)

should deploy a constant reduction (for the case

1 (= TRUE)

that significantly more poles are available as filter)

206

Optimization aggressiveness of the speed con-

REAL

0 ... 1

troller

A higher value produces a better optimization re-

sult coupled with a reduction of the robustness

207

Kp upper limit based on the bandwidth of a PT1-

REAL

equivalent proportionally-controlled system

Specifying a maximum speed controller band-

width is an additional rule to limit the Kp. In so

doing, the dynamic response of the speed control

is limited in the form of a "Control bandwidth"

(speed controller response in the frequency do-

main). Just as before, amplitude and phase re-

serves must be maintained. As long as the ampli-

tude and phase reserve permit a higher Kp, Kp is

calculated under the following assumptions:

• The total moment of inertia is a rigid mass.

• The speed control loop can be approximated

as a first order (PT1) lowpass filter.

208

Indicates whether a gain filter for eliminating fre-

BOOL

0 (= FALSE)

quency-specific periodic disturbances should be

1 (= TRUE)

designed and deployed

209

Frequency of the optional gain filter for eliminat-

REAL

ing frequency-specific periodic disturbances

Optimization of path interpolation (strategy)

251

Indicates whether an attempt should be made to

BOOL

0 (= FALSE)

achieve an agreement with the effective Kp value

1 (= TRUE)

252

Indicates whether an attempt should be made to

BOOL

0 (= FALSE)

achieve an agreement with the Tn integral time

1 (= TRUE)

253

The maximum proportion with which the Kp val-

REAL

0.1 ... 1.0

ue may be reduced to order to achieve an agree-

ment with the effective Kp value

254

Specifies whether non-agreements of the Kv val-

BOOL

0 (= FALSE)

ue between axes are permitted

1 (= TRUE)

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23.4 Diagnostics

Meaning

Unit

Data

Value range

Write

Read

type

with

CYCLE758

CYCLE759

255

Indicates whether the axes without precontrol or

BOOL

0 (= FALSE)

with speed precontrol must have matched refer-

1 (= TRUE)

ence models

256

Specifies the strategy for the path compensation:

INT

0, 1

•

0 = adapt the equivalent time of the control

loop with controller parameters and/or

MD32800/MD32810

•

1 = use MD32895 (time constant for the axial

setpoint phase filter) for adaptation

257

Specifies whether the precontrol should always

BOOL

0 (= FALSE)

be active for all axes in the group

1 (= TRUE)

258

Specifies whether the equivalent times should be

BOOL

0 (= FALSE)

identical for all axes

1 (= TRUE)

¹⁾ The parameter value unit depends on the measurement type:

• The following measurements were carried out in the drive. This is the reason that the units

refer to the motor side. The resulting axis velocity is obtained, taking into account the

gearbox ratios or spindle pitch. The velocity specified here is only equal to the axis velocity for

linear motors and torque motors (without gearbox). Here, it should be noted that the axis

velocity is specified in the AST screen forms, e.g. mm/min. Here, the numerical values cannot

be taken from the screen forms.

Unit

Parameter 021:

Parameter 022:

Amplitude of the excitation

Velocity offset

Measurement type

Rotary motor

Linear motor

Rotary motor

Linear motor

Speed-controlled system

rad/s

m/s

Closed speed control loop

rad/s

m/s

rad/s

m/s

• The following measurement were carried out via the control. Here, the units refer to the axis,

i.e. to the load side. It may be necessary to convert to SI units.

Unit

Parameter 021:

Parameter 022:

Amplitude of the excitation

Velocity offset

Measurement type

Rotary axis

Linear axis

Rotary axis

Linear axis

Mechanical frequency response

rad/s

m/s

rad/s

m/s

Closed position control loop

rad

rad/s

m/s

23.4

Diagnostics

If an error occurs when executing cycles, then an appropriate HMI alarm is output (number

range 150001 to 150004) as well as NC alarm 61840. Based on the block number specified in

alarm 61840, the user can define which NC block with a CYCLE75x call caused the error.

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23.6 Examples

Further information

Alarm descriptions, see Diagnostics Manual Alarms.

23.5

Supplementary conditions

"Automatic post optimization with AST" for active coupling

The following table lists which coupling function support the "Automatic post optimization with

AST":

Coupling function

"Automatic post optimization with AST" can be used?

Gantry axes

Master-slave coupling

Coupled motion

Leading value coupling

Electronic gear

Synchronous spindle

23.6

Examples

23.6.1

Example 1: Measuring an axis with AST default settings

The rotary axis (here: 4th axis) driven with a torque motor depends greatly on the inertia of the

clamped mass. If the load inertia changes, the axis must be measured again. No controller values

for AST should be overwritten; the optimization, however, is determined with new

measurements. The results, such as the complete inertia, can be read with CYCLE759. The newly

calculated values also indicate whether the controlled system has changed. In specific cases,

switching can be made to predefined controller data sets or the acceleration changed. The AST

default setting includes the speed and position controller optimization with "normal"

optimization objective. The determined controller data is, however, not activated in this

example.

Programming

Definition of global user variables (GUD)

To read out the complete moment of inertia, a new type CHAN REAL variable must be defined in

file MGUD.DEF (it is possible that this file must be newly created):

; Definition of GUD to read out the total moment of inertia.

DEF CHAN REAL _AST_R_ESTINERTIA

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23.6 Examples

Optimization cycle

Note

In the following program example, those cycle calls required for the measurement are

highlighted bold.

Any cycle calls not highlighted are optional.

DEF INT myaxiswithnewload=4

; Switch to a safe data set.

; Traverse axis to the safe position / home position.

; Is the optimization strategy set from the user interface?

; Is a destination data set (DDS) available that may be overwritten?

; Open the optimization session.

CYCLE751(1)

; Optimize axis 4: Optimization with a selected strategy based on a new

measurement.

; Optimization with default values (the selection from the AST user

interface is not used).

; No path interpolation, no values are written by AST.

CYCLE752(myaxiswithnewload,1,false)

; Save the original state in a file.

CYCLE755(1,"/oem/sinumerik/nck/data/restore/restorepoint1")

; Start the optimization without activating the results.

CYCLE751(4)

; Save the optimization data in an XML file.

CYCLE757(myaxiswithnewload,"/oem/sinumerik/nck/data/optimization/

axis_retuned.xml",1,,)

; Export the speed-controlled system.

CYCLE757(myaxiswithnewload,"/oem/sinumerik/nck/data/optimization/

speedctrlplant.csv",3,,)

; Fetch the inertia.

CYCLE759(myaxiswithnewload,34,,,"_AST_R_ESTINERTIA")

; If required check the optimization results, and then activate.

; Do not activate the results.

; Use predefined parameter sets.

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23.6 Examples

; Close the optimization session.

CYCLE751(2)

; Switch to the newly optimized DDS or select the predefined DDS depending

on the load inertia.

; Limit the acceleration depending on the new inertia.

M17

23.6.2

Example 2: Reoptimize the speed controller of an axis

The controller setting of the rotary axis (here: 4th axis), which is driven by a torque motor,

depends on the clamping equipment and the load moment of inertia. If the clamping equipment

or the load inertia changes, the axis must be measured again. A new controller parameter set

must be determined (a DDS will be overwritten), otherwise the axis would be unstable because

of the new resonances. New current setpoint filters must probably by set. Only the speed

controller is reoptimized. Because the position control remains identical and the precontrol

should not be changed, a similar bandwidth of the speed controller should be attained again.

For this purpose, a target bandwidth can be selected in the speed controller optimization

strategy. This is set to 100 Hz for the "normal compensation" optimization objective. If the new

load inertia and the clamping make many filters necessary and the ratio from the load inertia /

motor inertia is large, this objective may possibly not be achieved. In this case, a message is

issued. And the axis machine data is still set correctly from the first optimization (initial

commissioning). This means that the precontrol mode (MD32620 $MA_FFW_MODE), DSC

(MD32640 $MA_STIFFNESS_CONTROL_ENABLE), position controller gain (MD32200

$MA_POSCTRL_GAIN) and equivalent time precontrol (MD32800 $MA_EQUIV_CURRCTRL_TIME

or MD32810 $MA_EQUIV_SPEEDCTRL_TIME) are set correctly so that the loop interpolation is

correct.

The results of the reoptimization, such as the complete inertia, can be read with CYCLE759. The

newly optimized speed controller is written to another data set. The path interpolation is not

considered here, because it is assumed that the precontrol data does not change significantly or

another axis has a larger time constant in MD32800 $MA_EQUIV_CURRCTRL_TIME. The

optimization strategy for axis and speed controllers is deployed that was stored in the XML file

for this axis (/oem/sinumerik/nck/data/optimization/oem_ax4.xml).

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23.6 Examples

Preparation

• Select optimization strategy 105 from the user interface:

• If necessary, change the optimization objective (fast, moderate, robust) with the "Speed"

softkey.

Programming

Definition of global user variables (GUD)

To read out the complete moment of inertia, a new type CHAN REAL variable must be defined in

file MGUD.DEF (it is possible that this file must be newly created):

; Definition of GUD to read out the total moment of inertia.

DEF CHAN REAL _AST_R_ESTINERTIA

Optimization cycle

Note

In the following program example, those cycle calls required for the reoptimization are

highlighted bold.

Any cycle calls not highlighted are optional.

DEF INT myaxiswithnewload=4

; Switch to a safe data set.

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23.6 Examples

; Traverse axis to the safe position / home position.

; Is the optimization strategy set from the user interface?

; Is a destination data set (DDS) available that may be overwritten?

; Open the optimization session.

CYCLE751(1)

; Optimize axis 4: Optimization with a selected strategy based on a new

measurement.

; Add axis 4.

; Transfer the optimization strategy from the user-defined optimization

file (XML file).

; The axis is not considered for an optimization of the path interpolation.

CYCLE752(myaxiswithnewload,2,false,"/oem/sinumerik/nck/data/optimization/

oem_ax4.xml")

; Remove the current DDS from the data set list.

CYCLE754(myaxiswithnewload,2,2,-1)

; Add DDS3 to the data set list and overwrite after optimization.

CYCLE754(myaxiswithnewload,1,2,3)

; Save the original state in a file.

CYCLE755(1,"/oem/sinumerik/nck/data/restore/restorepoint1")

; Start the optimization by activating the results.

; CYCLE751(3)

; Start optimization without activation of the results, if necessary, check

the results first.

CYCLE751(4)

; Save the optimization data in an XML file.

CYCLE757(myaxiswithnewload,"/oem/sinumerik/nck/data/optimization/

axis_retuned.xml",1,,)

; Export the speed-controlled system.

CYCLE757(myaxiswithnewload,"/oem/sinumerik/nck/data/optimization/

speedctrlplant.csv",3,,)

; The inertia can be used to limit the acceleration:

; Fetch the inertia.

CYCLE759(myaxiswithnewload,34,,,"_AST_R_ESTINERTIA")

; If required check the optimization results, and then activate.

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23.6 Examples

; Activate result:

; Activate axis-optimum results.

; Save boot files.

CYCLE756(myaxiswithnewload,2,1)

; Close the optimization session.

CYCLE751(2)

; Switch to the newly optimized DDS or limit the acceleration depending on

the new inertia.

M17

23.6.3

Example 3: Reoptimize the speed controller and the position controller of an

axis

The controller setting of the rotary axis (here: 4th axis), which is driven by a torque motor,

depends on the clamping equipment and the load moment of inertia. If the clamping equipment

or the load inertia changes, the axis must be measured again. New current setpoint filters must

probably by set. The speed controller must be reoptimized. Because it is not known whether the

low-frequency behavior has changed, the position controller must also be reoptimized and the

associated mechanical frequency response measured.

The results, such as the complete inertia, can be read with CYCLE759. The newly optimized

speed controller is written to another data set. The newly optimized position controller can be

written to any desired axis parameter set. The correct path interpolation is guaranteed by a

target value for the (precontrolled) positioning behavior being specified in accordance with the

previously optimized axes. The optimization strategy for axis and speed controllers is deployed

that was stored in the XML file for this axis (/oem/sinumerik/nck/data/optimization/

oem_ax4.xml).

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Automatic post optimization with AST (option)

23.6 Examples

• Select the "Force equivalent time target value" option.

Note

The "Force equivalent time target value" option is set, when in addition to the speed

controller, the position controller is also reoptimized, and despite an equivalent time of the

precontrol specified, the path interpolation should not be reoptimized.

To ensure the correct path interpolation, an equivalent time can be specified. This should

correspond to the equivalent time of the axes previously optimized on the path.

• Take the equivalent time (MD32800 $MA_EQUIV_CURRCTRL_TIME or MD32810

$MA_EQUIV_SPEEDCTRL_TIME depending on MD32620 $MA_FFW_MODE) from the other

axes (here, 3 ms).

• The following parameters must be set in the servo parameter set:

- Precontrol equivalent time (MD32800 $MA_EQUIV_CURRCTRL_TIME) = 3 ms

- Position controller gain (MD32200 $MA_POSCTRL_GAIN)

Note

For the automatic operation, the servo parameter set with the appropriate path-optimum

values must then be selected in the other axes (here: with equivalent time = 3 ms).

Programming

Definition of global user variables (GUD)

To read out the complete moment of inertia, a new type CHAN REAL variable must be defined in

file MGUD.DEF (it is possible that this file must be newly created):

; Definition of GUD to read out the total moment of inertia.

DEF CHAN REAL _AST_R_ESTINERTIA

Optimization cycle

Note

In the following program example, those cycle calls required for the reoptimization are

highlighted bold.

Any cycle calls not highlighted are optional.

DEF INT myaxiswithnewload=4

; Switch to a safe data set.

; Traverse axis to the safe position / home position.

; Strategy settings: target value for the equivalent time!

; Is a destination data set (DDS) available that may be overwritten?

; Open the optimization session.

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23.6 Examples

CYCLE751(1)

; Optimize axis 4: Optimization with a selected strategy based on a new

measurement.

; Add axis 4.

; Transfer the optimization strategy from the user-defined optimization

file (XML file).

; The axis is not considered for an optimization of the path interpolation.

CYCLE752(myaxiswithnewload,2,false,"/oem/sinumerik/nck/data/optimization/

oem_ax4.xml")

; Remove the current DDS from the data set list.

CYCLE754(myaxiswithnewload,2,2,-1)

; Add DDS3 to the data set list and overwrite after optimization.

CYCLE754(myaxiswithnewload,1,2,3)

; Axis: Add parameter set 4 to the data set list and overwrite after

optimization.

CYCLE754(myaxiswithnewload,1,1,3)

; Save the original state in a file.

CCYCLE755(1,"/oem/sinumerik/nck/data/restore/restorepoint1")

; Start the optimization by activating the results.

; CYCLE751(3)

; Start optimization without activation of the results, if necessary, check

the results first.

CYCLE751(4)

; Save the optimization data in an XML file.

CYCLE757(myaxiswithnewload,"/oem/sinumerik/nck/data/optimization/

axis_retuned.xml",1,,)

; Export the speed-controlled system.

CYCLE757(myaxiswithnewload,"/oem/sinumerik/nck/data/optimization/

speedctrlplant.csv",3,,)

; The inertia can be used to limit the acceleration:

; Fetch the inertia.

CYCLE759(myaxiswithnewload,34,,,"_AST_R_ESTINERTIA")

; If required check the optimization results, and then activate.

; Activate result:

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23.6 Examples

; Activate axis-optimum results.

; Save boot files.

CYCLE756(myaxiswithnewload,2,1)

; Close the optimization session.

CYCLE751(2)

; Switch to the newly optimized DDS.

; Has Kv been optimized in the current parameter set?

; The equivalent time of the precontrol was forced by the strategy.

; For path interpolation, all axes must select the correct servo parameter

set.

; Limit the acceleration depending on the new inertia.

M17

23.6.4

Example 4: Reoptimization of the path interpolation

For a 5-axis machine, the rotary axis with torque motor (here: 4th axis) must position very

accurate and participate in the path interpolation. The changes of the clamping situation and

the inertia are completely unknown or so large that even large changes of the equivalent time

(also power controller) are expected. The unknown equivalent time means that the path

interpolation must be tested and compensated again after the axis optimization.

Only the rotary axis (workpiece-dependent) should be reoptimized. The other axes need to be

adapted in the precontrol only when the dynamic response of the rotary axis has changed

significantly. The rotary axis has several DDS. A safe data set that has a stable setting for clamping

the workpieces is selected. It must be considered that the mass inertia to be clamped is not

known. Consequently, the maximum inertia must be used for the calculation.

New current setpoint filters must probably be set for the rotary axis. The speed controller must

be reoptimized. Because it is not known whether the low-frequency behavior has changed, the

position controller must also be reoptimized and the associated mechanical frequency response

measured.

The results, such as the complete inertia, can be read with CYCLE759. The newly optimized

speed controller is written to another data set. The newly optimized position controller can be

written to any desired axis parameter set. The correct path interpolation is guaranteed by all axes

involved by being optimized by AST and now, after the reoptimization of the axis, the path

interpolation optimization is performed again by AST. The optimization strategy for axis and

speed controller is deployed that is stored in the XML file for this axis (/oem/sinumerik/nck/data/

optimization/oem_ax4.xml). The path optimization strategy set from the user interface is

deployed and stored in the XML file for the optimization of the path interpolation.

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Automatic post optimization with AST (option)

23.6 Examples

The following selection sets the balancing times (in MD32800 $MA_EQUIV_CURRCTRL_TIME

or MD32810 $MA_EQUIV_SPEEDCTRL_TIME) of all involved axes to the largest time constant:

• The following questions must be answered:

- Which axis parameter set may be reparameterized (for the path interpolation)?

- May the first axis parameter set be overwritten?

- Does the spindle need to be part of the path interpolation?

- If the thread cutting should also run with this axis configuration, parameter set 2 for the

axes and the gear stages in the spindle (parameter set 2 ... 6) may need to be optimized.

• Save the original path data!

Programming

Definition of global user variables (GUD)

To read out the complete moment of inertia, a new type CHAN REAL variable must be defined in

file MGUD.DEF (it is possible that this file must be newly created):

; Definition of GUD to read out the total moment of inertia.

DEF CHAN REAL _AST_R_ESTINERTIA

Optimization cycle

Note

In the following program example, those cycle calls required for the reoptimization are

highlighted bold.

Any cycle calls not highlighted are optional.

DEF INT myaxiswithnewload=4

; Switch to a safe data set.

; Traverse axis to the safe position / home position.

; Strategy settings: target value for the equivalent time!

; Is a destination data set (DDS) available that may be overwritten?

; Each axis was already optimized once with AST.

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Automatic post optimization with AST (option)

23.6 Examples

; As a consequence, a user-defined optimization file for CYCLE752 exists

for each axis.

; Open the optimization session.

CYCLE751(1)

; Optimize axis 4, with path interpolation.

; Select strategy:

; Add axis 4.

; Transfer the optimization strategy from the user-defined optimization

file (XML file).

; The axis is considered for an optimization of the path interpolation.

CYCLE752(myaxiswithnewload,2,true,"/oem/sinumerik/nck/data/optimization/

oem_ax4.xml")

; Measure axis 4 again and reoptimize, save the boot files.

CYCLE753(myaxiswithnewload,3,1)

; Add axis 1 because of the path interpolation.

CYCLE752(1,2,true,"/oem/sinumerik/nck/data/optimization/oem_ax1.xml")

; Axis 1, only post-optimize path interpolation.

CYCLE753(1,1,true)

; Add axis 2 because of the path interpolation.

CYCLE752(2,2,true,"oem/sinumerik/nck/data/optimization/oem_ax2.xml")

; Axis 2, only post-optimize path interpolation.

CYCLE753(2,1,true)

; Add axis 3 because of the path interpolation.

CYCLE752(3,2,true,"/oem/sinumerik/nck/data/optimization/oem_ax3.xml")

; Axis 3, only post-optimize path interpolation.

CYCLE753(3,1,true)

; Add axis 6 because of the path interpolation.

CYCLE752(6,3,true)

; Axis 6, only post-optimize path interpolation.

CYCLE753(6,1,true)

; Remove the current DDS from the data set list.

CYCLE754(myaxiswithnewload,2,2,-1)

; Add DDS3 to the data set list and overwrite after optimization.

CYCLE754(myaxiswithnewload,1,2,3)

; Axis: Add parameter set 4 to the data set list and overwrite after

optimization.

CYCLE754(myaxiswithnewload,1,1,3)

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Automatic post optimization with AST (option)

23.6 Examples

; Save the original state in a file.

CYCLE755(1,"/oem/sinumerik/nck/data/restore/restorepoint1")

; Start the optimization by activating the results.

CYCLE751(3)

; Save the optimization data in an XML file.

CYCLE757(myaxiswithnewload,"/oem/sinumerik/nck/data/optimization/

axis_retuned.xml",1,,)

; Save the measurement data of the speed controlled system to file.

CYCLE757(myaxiswithnewload,"/oem/sinumerik/nck/data/optimization/

speedctrlplant.csv",3,,)

; Save the result of the path optimization to file.

CYCLE757(1,"path_retuned.xml",2,0,0)

; Fetch the inertia.

CYCLE759(myaxiswithnewload,34,,,"_AST_R_ESTINERTIA")

; Close the optimization session.

CYCLE751(2)

; Switch to the newly optimized DDS.

; Kv has been optimized; switch to the appropriate parameter set.

; The path interpolation has been reoptimized.

; Limit the acceleration in axis 4 depending on the new inertia.

M17

23.6.5

Example 5: Reoptimize the speed control loop to eliminate known periodic

disturbance frequencies.

This example shows how the speed controller from the part program is reoptimized without new

measurement. The objective of the reoptimization is to minimize vulnerability to known process-

related periodic disturbance frequencies. The path interpolation is not reoptimized in this

example because the optimization strategy for the position controller provides a dynamic

customization by setting an equivalent time.

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Automatic post optimization with AST (option)

23.6 Examples

Preparation

In the simplest case, only a speed controller optimization is necessary:

• Select optimization strategy 105 from the user interface:

Programming

DEF INT myAxis=4

; Open the optimization session.

CYCLE751(1)

; Add axis.

; The optimization data are loaded from the user-defined optimization file.

; The axis is not considered for an optimization of the path interpolation.

CYCLE752(myAxis,2,false,"/oem/sinumerik/nck/data/optimization/

oem_ax4.xml")

; The axis dynamic response is not measured again.

; The axis is reoptimized on the basis of the loaded measurement results and

the currently valid optimization strategy.

CYCLE753(myAxis,2,)

; Activate the use of the gain filter.

CYCLE758(myAxis,208,,,"true" )

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Automatic post optimization with AST (option)

23.6 Examples

; Gain filter: set the optimum frequency to 40 Hz.

CYCLE758(myAxis,209,,,"40.0" )

; Perform the optimization.

CYCLE751(3)

; Save the axis-specific optimization data for the offline analysis.

CYCLE757(myAxis,"/oem/sinumerik/nck/data/optimization/

AX1_TEMP_40HZ.XML",1,,)

; For known periodic disturbance frequencies (40 Hz):

; Deactivate the use of the gain filter.

CYCLE758(myAxis,208,,,"false" )

; Perform the optimization.

CYCLE751(3)

; Close the optimization session.

CYCLE751(2)

; For normal broadband disturbances:

M17

23.6.6

Example 6: Measuring an axis without optimization

By selecting a strategy, which does not carry out any optimization, then the axis can be

automatically measured. This can be used to diagnose mechanical changes. These can involve:

• Load weight

• Component stiffness

Using the automatic measurement, it can also be checked as to whether the control loop has the

same response as when the system was originally delivered, for example. This AST strategy then

supplies the actual measurement of the closed loop in the CSV format.

The following data can be automatically measured and exported:

• Speed controlled system

• Closed speed control loop (calculated and/or check measurement)

• Mechanical frequency response (if there are 2 encoders)

• Closed position control loop (calculated and/or check measurement of the position control

loop)

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Automatic post optimization with AST (option)

23.6 Examples

Preparation

1. Select optimization strategy 109 from the user interface:

2. Measure and check controller settings.

3. Accept measurement results.

4. Save data under a new name (e.g. RESULT_STRATEGY109_AX1.xml) as a user-defined file in

a protected manufacturer directory.

Programming

Example of a cycle to measure an axis without optimization:

; Release brake

DEF INT AxNr=1

; Open the optimization session.

CYCLE751(1)

; For axis 1, the saved data are used from the user-defined file

RESULT_STRATEGY109_AX1.xml.

CYCLE752(AxNr,2,0,"/oem/sinumerik/nck/data/optimization/

RESULT_STRATEGY109_AX1.xml")

; Start automatic measurement.

CYCLE751(4)

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Automatic post optimization with AST (option)

23.6 Examples

; Export the speed-controlled system in the CSV format.

CYCLE757(AxNr,"/oem/sinumerik/nck/data/optimization/speedctrlplant.csv",3)

; Export the mechanical frequency response in the CSV format.

CYCLE757(AxNr,"/oem/sinumerik/nck/data/optimization/mechresponse.csv",4)

; Export the speed control loop (calculated) in the CSV format.

CYCLE757(AxNr,"/oem/sinumerik/nck/data/optimization/speedloopcalc.csv",5)

; Export the position control loop (calculated) in the CSV format.

CYCLE757(AxNr,"/oem/sinumerik/nck/data/optimization/posloopcalc.csv",6)

; Export the speed control loop (measured) in the CSV format.

CYCLE757(AxNr,"/oem/sinumerik/nck/data/optimization/speedloopmeas.csv",7)

; Export the position control loop (measured) in the CSV format.

CYCLE757(AxNr,"/oem/sinumerik/nck/data/optimization/posloopmeas.csv",8)

; Close the optimization session.

CYCLE751(2)

M17

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Intelligent load adjustment (option)

Note

The function "Intelligent Load Control" is an option for SINUMERIK 840D sl that requires a license.

Article no.: 6FC5800-0AS11-0YB0

24.1

Function

,/&

The "Intelligent Load Control" (ILC) function adapts dynamic and control parameters to the

actual load of an axis using predefined adaptation characteristic curves.

This results in the following advantages:

• Shorter machining times

• Increased dynamic response

• Greater accuracy

• Enhanced precision

Input variable and input value

The moment of inertia of the axis that depends on the load is used as the input variable for the

adaptation. The actual value to be determined for the input variable is used as the input value

for calculating the adaptation.

Output variable and adaptation factor

The control calculates a scaling factor (adaptation factor) for the output variable of the

adaptation (dynamic or closed loop control parameter) based on the input value and the

predefined adaptation characteristic.

Commissioning

When setting up the function, the machine OEM defines the adaptations available on the

machine tool. Dialog boxes on the user interface support the machine OEM in this task:

Operating area "Commissioning" → "NC" → Menu forward key → softkey: "Adaptations"

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Intelligent load adjustment (option)

24.2 Parameterization

More information: CNC Commissioning Manual: NC, PLC, drive

The settings made in the user interface are entered in the relevant machine data (Page 980).

Activation/deactivation

The activation behavior of an adaptation is determined by the activation mode which is

specified during the commissioning of the function (Page 980) for each adaptation. Without an

activation mode selected, an adaptation remains inactive. The activation mode can be set to

"permanently active" or "temporarily activatable":

Activation mode

Meaning

Adaptation permanently active

For permanently active load adaptations, the following applies:

• They are inactive at first after the controller ramps up.

• The adaptation is activated by calling CYCLE782. The input val-

ue is also calculated or specified with this cycle.

• They remain active beyond the end of the program reset and

channel reset. A previously programmed input value also re-

mains active.

Adaptation can be activated tem-

The following applies to temporarily activatable load adaptations:

porarily

• They are inactive at first after the controller ramps up.

• The adaptation is activated/deactivated by calling CYCLE782.

• On program end or channel reset, all adaptations not deactiva-

ted with CYCLE782 are deactivated implicitly.

Further information on CYCLE782, see:

• Operating Manual for SINUMERIK Operate

• NC Programming Programming Manual

24.2

Parameterization

Activation mode

The activation mode of an adaptation is set with machine data:

MD16501 $MN_CADAPT_MODE[<n>]

where <n> = number of the adaptation (0 ... 99)

Value

Meaning

Adaptation is not active (default setting)

Adaptation is permanently active

Adaptation can be activated temporarily

Input variable

The input variable of an adaptation is specified in machine data:

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24.2 Parameterization

MD16502 $MN_CADAPT_INPUT[<n>]

where <n> = number of the adaptation (0 ... 99)

Value

Meaning

The input variable for the adaptation is the moment of inertia of the axis

Output variable

The selection of the output value of an adaptation is done via the machine data:

MD16503 $MN_CADAPT_OUTPUT[<n>]

where <n> = number of the adaptation (0 ... 99)

Value

Meaning

No output variable, no adaptation active (default setting)

Axis acceleration with dynamic mode DYNNORM

Axis acceleration with dynamic mode DYNPOS

Axis acceleration with dynamic mode DYNROUGH

Axis acceleration with dynamic mode DYNSEMIFIN

Axis acceleration with dynamic mode DYNFINISH

Axis acceleration with dynamic mode DYNPREC

Position controller gain (servo gain factor)

Moment of inertia for torque feedforward control

Drive adaptation factor 1

Drive adaptation factor 2

Drive adaptation factor 3

Drive adaptation factor 4

Axial jerk with dynamic mode DYNNORM

Axial jerk with dynamic mode DYNPOS

Axial jerk with dynamic mode DYNROUGH

Axial jerk with dynamic mode DYNSEMIFIN

Axis jerk with DYNFINISH dynamic mode

Axial jerk with dynamic mode DYNPREC

Drive adaptation factor 1 ... 4

A maximum of 4 drive variables from parameter p2782[0...3] "Mode adaptation" can be

adapted:

• Kp speed controller P gain adaptation speed

• Tn speed controller integral time adaptation speed

• Current setpoint filter 1 denominator and numerator

• Current setpoint filter 2 denominator and numerator

• Speed setpoint filter 1 denominator and numerator

• Speed controller reference model natural frequency and damping

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Intelligent load adjustment (option)

24.2 Parameterization

• APC / APC ECO Tv (p3769)

• APC / APC ECO filter (p3766)

Note

The adaptation of drive variables requires use of telegram 146, 148, or 149.

More information:

• For information about adapting drive variables, see "SINAMICS S120 Drive Functions

Function Manual".

• For information about telegram 146/148/149, see "SINAMICS S120 Function Manual,

Communication".

Machine axis number of the input variable

The input variable of an adaptation is assigned to a machine axis using machine data:

MD16504 $MN_CADAPT_INPUT_AX[<n>]

where <n> = number of the adaptation (0 ... 99)

Value

Meaning

No machine axis assigned, adaptation is not active (default setting)

1 ... 31

Number of the assigned machine axis

Machine axis number of the output variable

The output variable of an adaptation is assigned to a machine axis using machine data:

MD16505 $MN_CADAPT_OUTPUT_AX[<n>]

where <n> = number of the adaptation (0 ... 99)

Value

Meaning

No machine axis assigned, adaptation is not active (default setting)

1 ... 31

Number of the assigned machine axis

Adaptation characteristic

The characteristic curve of a load adaptation is defined by interpolation points that are derived

from fixed moment of inertia values and the associated scaling factors (0% ... 3000%) for the

output variable. The values between the interpolation points are interpolated linearly.

Two interpolation points are sufficient for a simple adaptation:

• MD16506 $MN_CADAPT_INPUT_VALUE_1[<n>] (input value 1 of the adaptation)

• MD16507 $MN_CADAPT_INPUT_VALUE_2[<n>] (input value 2 of adaptation)

• MD16508 $MN_CADAPT_OUTPUT_VALUE_1[<n>] (output value 1 of the adaptation)

• MD16509 $MN_CADAPT_OUTPUT_VALUE_2[<n>] (output value 2 of adaptation)

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24.4 Example

24.3

Boundary conditions

Simulation behavior

With the "Determine total load" setting, CYCLE782 does not provide an inertia value in the

simulation. The adaptation is activated with an input value of zero.

Alternatively, CYCLE782 can be called up with the setting "Specify total load". The adaptation is

then activated with a specified input value.

24.4

Example

For a rotary table with highly variable loading, the effective acceleration should be adapted to

the current moment of inertia. The function "Intelligent Load control" is used to increase

acceleration at minimal loading to 150 %.

$FFHOHUDWLRQ

ZLWK DGDSWDWLRQ

ZLWKRXW DGDSWDWLRQ

-_PLQ

-_PD[

0RPHQW RI LQHUWLD >NJP @

J_min

⇒ MD16506[0] $MN_CADAPT_INPUT_VALUE_1

J_max

⇒ MD16507[0] $MN_CADAPT_INPUT_VALUE_2

150%

⇒ MD16508[0] $MN_CADAPT_OUTPUT_VALUE_1

100 %

⇒ MD16509[0] $MN_CADAPT_OUTPUT_VALUE_2

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Intelligent dynamic control (option)

Note

The "Intelligent Dynamic Control" function is an option for SINUMERIK 840D sl that requires a

license.

Article no.: 6FC5800-0AS23-0YB0

25.1

Function

With the function "Intelligent Dynamic Control" (IDC), it is possible to adapt control parameters

to the current position/speed of an axis with the aid of pre-defined adaptation characteristic

curves.

This results in the following advantages:

• Shorter machining times

• Increased dynamic response

• Greater accuracy

• Enhanced precision

Input variable and input value

The axis position or the axis speed is used as in input value for the Intelligent Dynamic Control:

• Axis position

Determined by the kinematics of the machine, a different position of the center of gravity of

the axis results depending on the position of the axes. From this, a variable dynamic behavior

of the machine results, which can negatively influence the stability of the control depending

on the axis position.

• Axis speed

A speed dependent adaptation of the position controller gain can be achieved, for example,

by means of the movement-dependent adjustment of the parameters in drives whose

stability changes due to the different traversing speeds.

The current input value is used as the initial value for adaption calculations.

Output variable and adaptation factor

The control calculates a scaling factor (adaptation factor) for the output variable of the

adaptation (closed loop control parameter) based on the input value and the predefined

adaptation characteristic.

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Intelligent dynamic control (option)

25.2 Parameterization

Commissioning

When setting up the function, the machine OEM defines the adaptations available on the

machine tool. Dialog boxes on the user interface support the machine OEM in this task:

Operating area "Commissioning" → "NC" → Menu forward key → softkey: "Adaptations"

More information: CNC Commissioning Manual: NC, PLC, drive

The settings made in the user interface are entered in the relevant machine data (Page 986).

Activation/deactivation

The activation behavior of an adaptation is determined by the activation mode which is

specified during the commissioning of the function (Page 986) for each adaptation. Without an

activation mode selected, an adaptation remains inactive. The activation mode can be set to

"permanently active" or "temporarily activatable":

Activation mode

Meaning

Adaptation permanently active

For permanently active adaptations, the following applies:

• They are active immediately after the controller ramps up.

• They remain active beyond the end of the program reset and

channel reset.

Adaptation can be activated tem-

The following applies to temporarily activatable adaptations:

porarily

• They are inactive at first after the controller ramps up.

• The activation/deactivation is done via the call-up of CADAP-

TON/CADAPTOF (Page 989).

• At the end of the program or with a channel reset, all of the

adaptations that are not yet deactivated by CADAPTOF are im-

plicitly deactivated.

Note

If the axis position is used as the input value, the input axis must be referenced to ensure that

the adaptation takes effect.

25.2

Parameterization

Activation mode

The activation mode of an adaptation is set with machine data:

MD16501 $MN_CADAPT_MODE[<n>]

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