Motor Sizing With NX MCD: NX MCD v1872, SIZER v3.19, SIMOTION SCOUT v5.2

Motor sizing with
NX MCD
Siemens
NX MCD v1872, SIZER v3.19, SIMOTION SCOUT v5.2 Industry
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Motor sizing with NX MCD

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Legal information
Table of Contents
Legal information ......................................................................................................... 2
1 Introduction ........................................................................................................ 4
1.1 Overview............................................................................................... 4
1.2 Software Versions ................................................................................ 4
2 Modeling of the digital twin in NX MCD ........................................................... 5
2.1 Import a Cam profile from SCOUT to NX MCD.................................... 5
2.2 Export Cam profile from MCD to SCOUT ............................................ 9
2.3 Set up a digital twin movement .......................................................... 10
2.4 Advanced settings .............................................................................. 12
2.4.1 Specific settings in MCD .................................................................... 12
2.4.2 Friction models and friction compensation in MCD ............................ 13
3 Transfer of physical simulation results......................................................... 16
3.1 Export a load curve from MCD ........................................................... 16
3.2 Import a load curve to SIZER ............................................................. 18
3.3 Selecting a motor in SIZER ................................................................ 20
4 Examples .......................................................................................................... 24
4.1 Example 1: Rotating Table ................................................................. 24
4.1.1 Comparison of MCD simulation result and measured values of
a real machine .................................................................................... 24
4.1.2 Comparison of MCD simulation result and SIZER result ................... 27
4.2 Example 2: Metal press ...................................................................... 31
5 Additional information .................................................................................... 34
5.1 Reliability of simulated load curves .................................................... 34
5.2 Advice on selecting the correct sizing software ................................. 35
5.3 Limitation of the physics simulation .................................................... 35
6 Appendix .......................................................................................................... 36
6.1 Application support ............................................................................. 36
6.2 Links and literature ............................................................................. 36
6.3 Change documentation ...................................................................... 36

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1 Introduction
1 Introduction
1.1 Overview
In the process of developing a machine, motor selection is one required step. With
NX MCD (Mechatronics Concept Designer), it is possible to do motor selection in
collaboration with the software SIZER. Due to the kinematic design, including
mechanics and physics simulation in MCD, it’s possible to export the simulation
result to SIZER to do further selection. Motor sizing analysis of the virtual model
can be performed using custom applications to ensure proper performance and
reduce over-sizing.
Figure 1-1 The Process Motor Selection using MCD and SIZER
© Siemens AG 2019 All rights reserved
The application example contains an introduction about defining a kinematic

movement in MCD. The definition of a cam profile can be done in NX MCD
standalone or in the engineering system, e.g. SIMOTION SCOUT. In this case it is
possible to easily import the existing cam profile. It will also be explained how to
build a friction model to have realistic results containing a dynamic friction.
Furthermore, it is described how to analyze and export speed and torque profile to
the software SIZER to do the motor selection. In the end of this document you can
find a comparison between simulation and measured results of existing machines.
1.2 Software Versions

The following table lists the software versions used to create this application example.
Table 1-1 Software versions

Software Package Version Article Number
NX Mechatronics Concept Designer NX1872 NX11113
SIZER V 3.19
SIMOTION SCOUT V 5.2 6AU1810-1BA52-1XA0

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2 Modeling of the digital twin in NX MCD

To obtain the simulation results of a specific movement, including the speed and
torque of an axis, it is necessary to define these movements in NX MCD. In this
application example it will be explained how to create a movement based on a cam
profile.
Cam profiles can be created in NX MCD standalone via cam profile editor or can
be imported from an automation engineering system like SIMOTION SCOUT. The
import and export functionality are working in both ways as shown in Figure 2-1.
Figure 2-1 Cam profile import and export
Export
MCD
SCOUT
Import
Download
Mechanical Cam Motion Controller
2.1 Import a Cam profile from SCOUT to NX MCD
NOTE In order to import a cam profile from SCOUT in NX MCD, the cam profile must
be interpolated.
1. Open a cam curve in SCOUT, then choose the option Cam → Export geometry
→ “As polynomials” to export cam profile, as shown in Figure 2-2.
2. Fill in a file name and format, then press the Save button as shown in
Figure 2-3.

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Figure 2-2 Export Cam profile from Scout
Figure 2-3 Fill out the file name and format

After a successful export of the cam profile, it is necessary to import this cam profile
to NX MCD.
1. Open the NX MCD project, go to Toolbar “Home - Design Collaboration” and
select the Button ”Import Cam Profile” as shown in Figure 2-4. Cam profile is a
physics object in NX MCD, which includes a cam curve and specific settings.
2. Click the browse button in Figure 2-4 and select the previously exported cam
file (.csv). Add a cam profile name and click the button “OK”.
3. Configuration of a cam profile can be done as shown in Figure 2-5. In this
dialog, it’s possible to define and change the information of a cam profile and
the simulation preferences. In the Axes part, it’s needed to define the master
and slave axis type, these settings must fit to the chosen project and cam
profile. Axis type of master can be linear, rotary and time based. The slave axis

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can be a linear or rotary, speed or position. If it’s an imported cam profile, the
minimum and maximum value can be filled in automatically. Otherwise, it’s
possible to insert the limits manually, based on the information of the curve.
Additionally, the cycle type must be selected correctly.
Explanation of cyclic types:
- “Non-cyclic”: Cam profile only cycles once. Only in this mode, it’s possible
to export the cam profile from NX MCD.
- “Cyclic”: Cam profile cycles continuously, starting from the same absolute
slave position.
- “Relative Cyclic”: Cam profile cycles continuously, starting relative to the
end position of the slave’s previous cycle.
Figure 2-4 Import Cam profile in MCD


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Figure 2-5 Configuration of a cam profile


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2.2 Export Cam profile from MCD to SCOUT

In the case of exporting a Cam profile from MCD to SCOUT, it’s necessary to
create a cam object in SCOUT in advanced. If a cam is created by “CamEdit”, it’s
necessary to select type “Polynomials” to create a cam. If type “Interpolation point
table” is chosen, there will be an error caused by incompatibility. After the
preparation, choose SCOUT CamEdit in MCD and then export the cam profile.
Figure 2-6
If it’s a cam profile created by “CamTool” in SCOUT, it’s necessary to select
SCOUT CamTool in MCD cam profile dialog. Figure 2-7
Figure 2-6 Create a cam profile in SCOUT by using “CamEdit”

Figure 2-7 Create a cam profile in SCOUT by using “CamTool”

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2.3 Set up a digital twin movement

In NX MCD a physics object called “Position- or Speed Controller” is needed to
perform a movement, depending on the application. Via the cam profile dialog, it’s
necessary to map a cam profile to the desired controller.
1. Click the extension button in Toolbar “Home - Mechanical” and select
“Electronic Cam”. Figure 2-8
2. Select the axes master type in Figure 2-5. As a hint, the master type can also
be axis or signal based. Afterwards select the physics object of the slave axis
(speed or position controller). Figure 2-9
3. Choose the imported cam profile.
Explanation of additional settings:
- “Initial Time”: Sets the start point of the cam profile relative to the master
axis. This is only available, if the Master Type is set to Time.
- “Slave Offset”: Sets velocity offset of the slave axis.
- “Slave Scale Factor”: Sets the dynamic scaling of the slave axis.
If the master type axis or signal has been chosen, there are more specific settings
available.
- “Master Offset”: Sets the start point of the cam profile relative to the slave
axis. This is only available, if the master type is set to axis.
- “Master Scale Factor”: Sets the dynamic scaling to the master axis. This is
only available, if the master type is set to axis.
Figure 2-8 Create Electronic Cam

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Figure 2-9 Configurate Electronic Cam

NOTE Avoid over-determined definitions, like using two motors to drive one gantry. This
might lead to unstable calculation results. Try to simplify the model, use one
motor to drive one axis.

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2.4 Advanced settings

2.4.1 Specific settings in MCD
The physical calculation in MCD is based on a physics engine. If the complexity of

a project increases, it could be necessary to limit the calculation accuracy.
Figure 2-10
Explanation of MCD preferences – Physics engine tuning:
- Tolerance: Sets the distance between two objects and still be considered as
aligned by a joint. A larger value is solved faster but results in more
backlash in the joint positioning.
- Error Reduction Amount: Sets a factor that determines how fast joint
positions are solved. A larger value causes the solver to pull joints together
in fewer steps, but a value that is too high can cause instability.
- Maximum Iteration: Sets the maximum number of iterations per time step,
which the solver uses to solve for the position of the joints and bring all their
positions within the tolerance. A larger value gives the solver more time to
bring a large number of joints into position, but it can potentially take longer
to solve.
- Sticky Force: Sets a bonding force between collision bodies to counteract
the repelling force caused by a collision.
The figure below shows the parameters that are used in the following examples.
Figure 2-10 Parameter about Physics Engine
NOTE In order to make the digital twin closer to the real machine, it’s also very
important to define the correct materials to each part. This is a basic function in
NX, click “Menu”→ “Tools” → “Materials” to assign a material.

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2.4.2 Friction models and friction compensation in MCD
In theory, the usage of motor torque is divided into the following main parts:
- Acceleration: Considered/Calculated in MCD
- Overcoming gravity: Considered/Calculated in MCD
- Overcoming friction: Friction occurs in all mechanical systems e.g.
bearings, transmissions, hydraulic and pneumatic cylinders. Friction exists
at the physical connection between two surfaces. If a realistic behavior of
friction is needed, a specific friction model is necessary. In this case choose
a simple friction model to get an almost realistic calculation.
According to “Friction models and friction compensation1”, the following model was
built and evaluated. The meaning of the variables used in the formula is shown in
Figure 2-11.
−𝐹_𝑐𝑜𝑢𝑙𝑜𝑚𝑏/𝑍𝑒𝑟𝑜𝑆𝑝𝑒𝑒𝑑 ∗ 𝑠𝑝𝑒𝑒𝑑 𝑠𝑝𝑒𝑒𝑑 < 𝑍𝑒𝑟𝑜𝑆𝑝𝑒𝑒𝑑 𝑠𝑝𝑒𝑒𝑑 > −𝑍𝑒𝑟𝑜𝑆𝑝𝑒𝑒𝑑

𝐹={
−𝐹_𝑐𝑜𝑢𝑙𝑜𝑚𝑏 ∗ 𝑆𝑖𝑔𝑛(𝑠𝑝𝑒𝑒𝑑) − 𝛽 ∗ 𝑠𝑝𝑒𝑒𝑑 − 𝑍𝑒𝑟𝑜𝑆𝑝𝑒𝑒𝑑 ⩽ 𝑠𝑝𝑒𝑒𝑑 ⩽ 𝑍𝑒𝑟𝑜𝑠𝑝𝑒𝑒𝑑
NOTE In the design phase, it’s hard to evaluate the friction of a real machine. This
example provides a simple friction model called “Coulomb and Viscous Friction”
as shown in Figure 2-11. “ZeroSpeed” represents a very low speed close to the
origin point. Within this interval from -ZeroSpeed to ZeroSpeed, the friction is
continuously changing. If there is no such interval, the calculation of MCD’s
physics engine would be unstable. As a hint: NX MCD is using the “Bullet”

physics engine.
Figure 2-11 Coulomb and Viscous Friction model
The slope of the line is β
(ZeroSpeed,F_coulomb)
The next step is to implement the calculation of the physics objects in MCD. To do
so, open physics object “Runtime Parameters” as shown in Figure 2-12, to create a
reusable object that contains physics parameters. These parameters can be
referenced by any physical object in a model. The physics object “Runtime
Expression” defines an expression for a runtime parameter.
(Toolbar “Home – Mechanical”, Runtime Parameters / Runtime Expression)
1 Olsson H, Åström K J, De Wit C C, et al. Friction models and friction compensation[J]. Eur. J. Control, 1998, 4(3): 176-195

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Usage of “Runtime Expressions”:

- Create relationships between runtime parameters
- Use mechatronics simulation settings in functions
- Determine the minimum or maximum value from a group of values
- Scale values
- Determine output ranges
- Output a random number
1. Create one “Force/Torque Controller” and add specific friction to each joint if not
negligible. In this example we focus on adding friction to the axis which was
connected to a PositionController before.
2. Create one “Runtime Parameters” and add the parameters as shown in
Figure 2-12. After selecting the parameter attributes, remember to click the
green check button.
Figure 2-12 Configurate Runtime Parameters
3. Create one “Runtime Expression”. Firstly, click “Select object” and choose the
Force/Torque control added before.
4. Select the torque property to assign the calculation result to the torque value.
5. Select the physics object and add the needed parameters as shown in
Figure 2-13, step 3 to 5. Via double click the step 6 area, it’s possible to change
the alias name, which is used for the formula.
6. Click the step 7 button “Insert Conditional”. A conditional builder will be opened
to fill in the formula. Figure 2-14
If: speed < ZeroSpeed & speed > -ZeroSpeed
Then: -F_coloumb/ZeroSpeed*speed
Else: -F_coloumb*Sign(speed)-ß*speed

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Figure 2-13 Configure Runtime Expression

Figure 2-14 Fill out the formular of the friction model

1
NOTE The damping parameters in Mechatronics Concept Designer Preferences –

General, will also influence the torque result. If a special friction calculation is
used, these damping parameters should be set to 0.

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3 Transfer of physical simulation results

A drive system, which is correctly dimensioned, will properly work throughout its
lifecycle. Taking all necessary factors into consideration, will help to secure trouble-
free performance over the system’s design lifetime.
Within the last chapter, an establishment of a simulation model has been
completed in NX MCD. This chapter explains, how to do the simulation in MCD.
Also how to obtain a “.mdix” file, which contains the load cycle data, like speed and
torque values. This “.mdix” file is needed for the SIZER export to do further motor
selection. E.g. the configuration of the SINAMICS drives, motors, and controllers.
Figure 3-1
Figure 3-1 Export load curve to SIZER
MCD simulation Torque SIZER sizing motor
time
Velocity
time
.mdix file
3.1 Export a load curve from MCD

1. Open Toolbar “Home – Design Collaboration” the “Export Load Curve” dialog
box and select the slave axis at “Axis Control”. Figure 3-2
2. Add the slave axis control to “output axis controls”.
3. In the “Record Load Curve” dialog box, it’s possible to define the trigger for the
load curve. For the “Time” option, it’s needed to set the start and end time for
data retrieval. For the “operation” option, it’s necessary to use the sequence
editor to set the start and end point for data retrieval.
4. Start the simulation with „Play Simulation”.
5. Choose the presentation style of the simulation results.
- “Graph”: The speed and torque data would be displayed as curves in the
following box.
- “Table”: More detailed information would be displayed in the following table,
which includes “Time”,”Duration”,”Speed”,”Torque” etc..
6. Select a file location where the load curve should be exported, then click “OK”.
NOTE The column of “Inertia” is 0, currently NX MCD cannot calculate the inertia
information.

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Figure 3-2 Configure Export Load Curve

NOTE In reality, there would be one or several gearboxes or synchronous belts after a
motor shaft. It’s possible to define the gearbox ratios in MCD by using the
physics object “Gear” or setting the gearbox ratios, when selecting motors in
SIZER. When trying to simplify a digital twin, be careful with combining several
speed reduction mechanisms. It may change the speed and torque of some
parts and leads to a wrong simulation result. This also depends on the selected
record point.

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3.2 Import a load curve to SIZER

During the last chapter, the final steps in NX MCD are done. The next step is to
choose a drive system and motor in SIZER. A mechatronic project needs to be
created, with this project type, motor configurations can be performed based on the
imported mechatronics data. If a project still exists, it is possible to update the load
data during further processing via an import. Menu → Project → Update of
mechatronic data. Figure 3-3
1. Choose Mechatronic project option to create a project.

2. Fill out the project name and path.
3. Click on the “Browse” Button of “Mechatronic data import file” and select the
export file of NX MCD.
4. Click the button “create project” to generate the project.
NOTE If the project type of Mechatronic project cannot be found in SIZER, one possible
reason is that the user didn’t select the complete features when installing it.
Figure 3-3 Create Mechatronic project in SIZER

A mechatronic project has been created. Afterwards it’s necessary to assign a

temporary system to this project.

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The following components are supported for the creation of a mechatronic project:
- Converter Systems
• SINAMICS S120 DC/AC multi-axis converter built-in units (with
Basic Line Module, Smart Line Module or Active Line Module)
• SINAMICS S120 AC/AC single drive
- Motor Types (editable properties)
• 1PH8
• 1FT/1FK (with/without mounted gearbox)
1. If only one axis is contained in the transferred mechatronic data, it can be
decided, whether a single-axis or a multi-axis drive system is to be created.
The appropriate options are offered in SIZER. If several axes are contained, a
multi-axis converter system is always created. Figure 3-4
2. The required type of the Line Module can be selected (BLM, SLM, ALM).
3. Select the motor type and its properties for each axis.
The linked mechanical system cannot be changed in a mechatronic project.
Figure 3-4 Select motor type


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3.3 Selecting a motor in SIZER

The mechatronic project must be converted to a SIZER project to continue
selecting a motor. Menu → Project → Convert to a SIZER project. Figure 3-5
Afterwards, the workflow for processing or completing the drive system is provided.
All components can be modified, including the load data. A SIZER project contains
the functionality of updating and exporting mechatronic data, too.
Figure 3-5 Convert to a SIZER project
There are different ways of choosing a motor, according to the actual requirement
as shown in Figure 3-6. The specification of the mechanical system, required for
the complete description of a drive, can be facilitated by using pre-configured
mechanical systems. For the first example machine, in order to analyze the torque
demand of a slip ring, select a motor of type “1FW”.

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Figure 3-6 Reselect the motor type


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Figure 3-7 shows the load cycle curve, which is calculated from the transfered
data, including the speed and torque values of the motor shaft. All mechanical
variables, in accordance with the mechanical entries are included in the calculated
torques. In the following dialog box, it’s possible to select basic type specifications,
such as cooling methods, winding systems and clamping elements. With the button
“Check all” a suitable motor can be selected, automatically.
Figure 3-7 Load data has been imported to SIZER

In Figure 3-8, the following data of the selected motor can be checked:
- The result of the dimensioning criteria
- The most important calculated load data
- The actual utilization of the motor
- The graph display of the load and motor characteristics
The system checks, whether the selected motor satisfies the required dimensioning
criteria, which is indicated by a green check mark. If the motor does not satisfy the
dimensioning criteria, a red cross is displayed.

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Figure 3-8 Motor check


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4 Examples
4 Examples
4.1 Example 1: Rotating Table
4.1.1 Comparison of MCD simulation result and measured values of a real
machine
This example shows a rotary table machine for testing different slip rings Figure 4-1.
It’s a quite simple model. All components of the moving part are connected via a
fixed joint to each other. So, the inertia of the machine is constant. The motor
installed in this machine is the selected one of the previous steps (1FW3150…).
Figure 3-8
Figure 4-1 A rotation machine for testing slip ring
The simplified model of this machine is shown in Figure 4-2. Since there are many
components in the model, each component is composed of multiple materials, it is
difficult to obtain theoretical inertia information. If the inertia calculation is not
performed by any software but manually calculated, the moment of inertia is first
calculated according to the following formula. Afterwards it will be multiplied by the
required angular acceleration to obtain the required torque.

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4 Examples
Figure 4-2 A simplified model and the moment of inertia calculation formula2
𝐹 =( 𝑚) = ( 𝑚)𝑟
Z
= 𝑟𝐹 = ( 𝑚 ) 𝑟
𝐹
=𝑟 = ( 𝑚 )𝑟
= = ( 𝑚 )𝑟 = ( 𝑚 )𝑟
ω
O 𝑟 𝑚
𝑜𝑚𝑒𝑛 𝑜 𝑖𝑛𝑒𝑟 𝑖 = 𝑚 𝑟
𝑜 𝑖𝑜𝑛 𝑙 𝑚𝑜𝑚𝑒𝑛 =
The motion of the device moves according to the cam curves in Figure 4-3. In the
point of position 1, the cam velocity is 0, but the acceleration is in minimum value
as position 2. When the direction of the speed changes, the theoretical applied
moment is continuous. The purpose of this design is that it’s obviously able to
observe the friction influence at this point.
There are three curves in Figure 4-4:

- The torque traced from the real machine (blue)
- The simulation torque with friction (red)
- The simulation torque without friction (green)
The range of the measured torque values is from -23.7 Nm to 17.0 Nm. There are
several steps in the curve which are caused by friction. At each step, the friction
direction changes.
The maximum value of the simulation torque curve with friction is 16.9 Nm and the
minimum value is -21.6Nm. The simulation torque value is less than the measured
one.
Comparing the two curves with the MCD curve without friction reveals, that friction
plays a crucial role and partially absorbs the motor torque.
NOTE For the Rotating table simulation case, it’s preferable to use the same
parameters shown in the previous sections, such as parameters in the Physics
Engine and friction coefficients.
2 Rotational Mechanics & Special Relativity - lectures from University of Cambridge

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4 Examples
Figure 4-3 Cam curve for slip ring
Cam Position
Cam Velocity
Cam Acceleration
Cam Jerk
Figure 4-4 Comparison of measured and simulation torque
Measured torque

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4 Examples
4.1.2 Comparison of MCD simulation result and SIZER result
When using SIZER to perform motor selection, the first step is to select a
mechanical system. After that a traversing profile must be defined. In the selection
mechanical system phase, it’s necessary to define efficiency, friction torque, the
additional moment of inertia in relation to the motor (e.g. clutch) and moment of
inertia of the mechanical system(load). In the phase of defining a traversing profile,
if “Other mechanical system” is chosen, a free traversing profile curve will be
generated from the entered values, which after the complete input of traversing
sections, is displayed as M-t and n-t diagram.
If the model system in SIZER is chosen, such as “Travel drive”, “Hoist drive” or
others, it’s possible to define a traversing profile by using one of the following
options in SIZER:
- Time optimization: Time is the value to be determined
- Variants of distance optimization: Distance is the value to be determined
- Optimizations based on dividing the total travel time into three on the
sections of the trapezoidal (acceleration, constant velocity, deceleration)
Movement profiles can be defined directly in SIZER. Figure 4-5

It’s more common to use triangular acceleration and it is not possible to use a user-
defined CAM profile.
Figure 4-5 Edit the movement profiles in SIZER

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4 Examples
In the Load cycle data dialog, a torque curve is displayed. Figure 4-6
It’s visible, that there are several jumps as well, which are also caused by friction.
The friction calculation in SIZER is based on a constant value, which is effective
opposite to the direction of motion, independent of the angle of inclination.
Figure 4-6 Select motor in SIZER
1
2
After the previous steps, the load curve is visualized in SIZER.

The next step is to define the movement in NX MCD to receive the simulation result.
This basic motion profile can be defined via the physics object “Position Control”.
1. Open the physics object “Position Control” and select the type of “Angular Path
Options”.
The following types are possible:
- “Track Multiple Turns”
- “Follow Shortest Path”
- “Rotate Clockwise”
- “Rotate Counter-clockwise”
In this example the type “Track Multiple Turns” must be chosen. This specifies
the direction of the movement. The position value of the physics object can be
used as single coil absolute value encoder. When choosing “Track Multiple
Turns”, the position value could be used as multi-loop absolute value.

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4 Examples
2. Insert the values for parameters of destination, speed and acceleration. MCD
would calculate the movement profile automatically as shown in Figure 4-7.
Figure 4-7 Basic movement profile in MCD

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4 Examples
After defining an equal motion profile in MCD, the simulation must be started to
receive the calculated load curve. Afterwards the torque curve calculated in SIZER,
the torque curve generated in MCD simulation and the actual curve traced from the
real machine are copied into one graph for comparison as shown in Figure 4-8.
The torque of the real machine is higher than the simulated torque of MCD and the
calculated one of SIZER. It’s also clearly visible, that the simulated torque curve is
more approximated to the torque curve of the real machine. The comparison
indicates also that the slope, while the acceleration phase, is consistent. The
curves calculated in MCD and SIZER are mostly composed of straight lines, which
means the calculation result is ideal.
Figure 4-8 Comparison of measured and simulation torque

This example was investigated using the following application data:
Table 4-1 the attached file description

File Name Description
1. Example1_RotatingTable.zip - MCD project of rotating table (MCD\!MACHINE.prt)
- SCOUT cam export (ExportedFromScout\...)
- MCD cam and loadcurve export (ExportedFromMCD\...)
- SIZER mechatronic project
(SizerProject\MechatronicProject.szn)
- SIZER project with MCD loadcurve
(SizerProject\SizerProject_1.szp) Chapter 3.3
- SIZER project with standard motion profile
(SizerProject\SizerProject_TriangleAcc.szp) Chapter 4.1.2
- SCOUT Project (ScoutProject\...)

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4 Examples
4.2 Example 2: Metal press

This example shows a servo press, which is an ideal application because it requires
a variable slide velocity at multiple points in the stroke profile. It’s a machine for
metal forming, shallow to medium drawing and forming. Normally a servo press is
driven by a servo motor, as opposed to a standard flywheel, including clutch and
brake. This provides full energy at any speed, but not full capacity at any stage in
the stroke (capacity is best at near bottom center).
The machine is a combination of servo press and flywheel press. It is using a servo
motor to drive a small pulley, which drives through a timing belt a large pulley. The
large pulley is connected to the rod by a clutch. Because of this connection the ram
moves up and down. Figure 4-9 describes the components of the servo press.
Figure 4-9 components of the servo press
1
2
3
1 Small pulley
2 Large pulley
3 Rod
4 Ram
In this example, according to different cam curves, the machine is projected to drive
in two different modes depending to process requirements:
- Mode 1: The speed is constantly changing, performed by an acceleration
motion. Figure 4-10
- Mode 2: The speed remains constant in some phases. Figure 4-12
The jerk values in the two CAM curves are bounded, thus ensuring continuous
movement and reducing the impact.

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4 Examples
Figure 4-10 Cam curve for mode 1
Cam position
Cam velocity
Cam acceleration
Cam jerk
Figure 4-11 The comparison of real data and the simulation data for mode 1
Measured torque
Measured speed
Figure 4-12 Cam curve for mode 2
Cam position
Cam velocity
Cam acceleration
Cam jerk

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4 Examples
Figure 4-13 The comparison of real data and the simulation data for mode 2
The comparisons of the simulated and real curves are shown for mode 1 in
Figure 4-11 and for mode 2 in Figure 4-13. These two comparisons of curves are
nearly equal. In both figures, precisely in the lower speed part, the dynamic friction
is relatively low. If the speed increases, a gap will be visible as shown in
Figure 4-132. Therefore, it is proved that using MCD for torque calculation and do
motor sizing is reliable.
However, the difference between the measured torque curve and the simulation
one, including the dynamic friction calculation, the torque curve is not constant.
The possible reasons are the changes of inertia in motion leads to the change of
torque and the friction modifies with the change of speed.

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5 Additional Information
5.1 Reliability of simulated load curves
There is a 5% to 10% difference between theory and practice.
Possible reasons:
1. The friction model is not accurate. The actual friction exists on almost all
contact surfaces, so it’s difficult to develop a friction model to constitute the real
friction.
2. Caused by e.g. assembly errors, usage of different materials or simplified
mechanical components like gears, the inertia information of the 3D model and
the real device can be inaccurate.
3. The measured torque on a real machine is calculated based on the current.
Because of this, the simulated torque cannot be exactly reflected.
The illustration below shows the negative direction friction and positive direction
friction traced from the real machine. Figure 5-1
Comparing these two curves, no regularities can be seen.
If needed, special friction coefficients can be added manually from e.g.:
- Mechanical design manual
- Bearing manual
- Motor manual
- Empirical values of previously used devices
Figure 5-1 The actual friction curve in negative and positive direction

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5.2 Advice on selecting the correct sizing software

In the following situations, it’s recommendable to use MCD combined with SIZER,
to select a motor.
1. When the inertia of the moving system may be changed, caused by design
changes.
2. In case of a high-speed or reciprocating motion system. If user-defined motion
profiles (cam curve) to control a movement have been used like in handling
machines. Most of the motor utilization is used to accelerate and decelerate
frequently. According to this it’s necessary to use the actual traversing profile
when doing motor sizing.
3. Kinematic models in SIZER cannot meet the selection requirements. Especially
in case of robotics (e.g. Delta 3D robot), when the body of the machine moves.
Due to this the moment of inertia relative to the motor shaft changes. In order to
select a very accurate motor, simulation software is necessary.
5.3 Limitation of the physics simulation

- Currently, MCD cannot export inertia information. Because of this restriction,
the external moment of inertia to motor moment of inertia ratio, cannot be
calculated at the end phase of motor selection. It’s not possible to use this
parameter to judge the system control stability.
- Within NX MCD, just a rigid body simulation is possible. Missing physics

calculation for e.g. flexible bodies like plastic ribbons or cables may have a high
influence on torque profiles. Caused by a rigid body simulation, also collisions
can influence the torque simulation.
- Dynamic friction model must be modelled manually.

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6 Appendix
6 Appendix
6.1 Application Support

Siemens AG
Digital Factory Division
Factory Automation
Production Machines
DF FA PMA APC
Frauenauracher Str. 80
91056 Erlangen, Germany
mailto: tech.team.motioncontrol@siemens.com
6.2 Links and Literature

Table 6-1
No. Topic
\1\ Siemens Industry Online Support

https://support.industry.siemens.com
\2\ Link to this entry page of this application example
https://support.industry.siemens.com/cs/ww/en/view/109770271
\3\ Sizer for Siemens Drives
https://support.industry.siemens.com/cs/document/54992004/
\4\ Link to online help of NX
https://docs.plm.automation.siemens.com/tdoc/nx/1872/nx_help/#uid:index
6.3 Change Documentation

Table 6-2
Version Date Modifications
V1.0 08/2019 First Version

Entry-ID: 109770271, V1.0, 09/2019 36

Motor Sizing With NX MCD: NX MCD v1872, SIZER v3.19, SIMOTION SCOUT v5.2

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Motor sizing with

Motor sizing with NX MCD

Motor sizing with NX MCD

The application example contains an introduction about defining a kinematic

1.2 Software Versions

Table 1-1 Software versions

Motor sizing with NX MCD

2 Modeling of the digital twin in NX MCD

Figure 2-1 Cam profile import and export

Mechanical Cam Motion Controller

2.1 Import a Cam profile from SCOUT to NX MCD

Motor sizing with NX MCD

Figure 2-2 Export Cam profile from Scout

Figure 2-3 Fill out the file name and format

Motor sizing with NX MCD

Figure 2-4 Import Cam profile in MCD

Motor sizing with NX MCD

Figure 2-5 Configuration of a cam profile

Motor sizing with NX MCD

2.2 Export Cam profile from MCD to SCOUT

Figure 2-6 Create a cam profile in SCOUT by using “CamEdit”

Figure 2-7 Create a cam profile in SCOUT by using “CamTool”

Motor sizing with NX MCD

2.3 Set up a digital twin movement

only available, if the master type is set to axis.

Figure 2-8 Create Electronic Cam

Motor sizing with NX MCD

Figure 2-9 Configurate Electronic Cam

Motor sizing with NX MCD

2.4 Advanced settings

The physical calculation in MCD is based on a physics engine. If the complexity of

Figure 2-10 Parameter about Physics Engine

Motor sizing with NX MCD

2.4.2 Friction models and friction compensation in MCD

−𝐹_𝑐𝑜𝑢𝑙𝑜𝑚𝑏/𝑍𝑒𝑟𝑜𝑆𝑝𝑒𝑒𝑑 ∗ 𝑠𝑝𝑒𝑒𝑑 𝑠𝑝𝑒𝑒𝑑 < 𝑍𝑒𝑟𝑜𝑆𝑝𝑒𝑒𝑑 𝑠𝑝𝑒𝑒𝑑 > −𝑍𝑒𝑟𝑜𝑆𝑝𝑒𝑒𝑑

physics engine would be unstable. As a hint: NX MCD is using the “Bullet”

Figure 2-11 Coulomb and Viscous Friction model

The slope of the line is β

Motor sizing with NX MCD

Usage of “Runtime Expressions”:

Motor sizing with NX MCD

Figure 2-13 Configure Runtime Expression

Figure 2-14 Fill out the formular of the friction model

NOTE The damping parameters in Mechatronics Concept Designer Preferences –

Motor sizing with NX MCD

3 Transfer of physical simulation results

MCD simulation Torque SIZER sizing motor

3.1 Export a load curve from MCD

Motor sizing with NX MCD

Figure 3-2 Configure Export Load Curve

Motor sizing with NX MCD

3.2 Import a load curve to SIZER

1. Choose Mechatronic project option to create a project.

Figure 3-3 Create Mechatronic project in SIZER

A mechatronic project has been created. Afterwards it’s necessary to assign a

Motor sizing with NX MCD

Figure 3-4 Select motor type

Motor sizing with NX MCD

3.3 Selecting a motor in SIZER

Motor sizing with NX MCD

Figure 3-6 Reselect the motor type

Motor sizing with NX MCD

Figure 3-7 Load data has been imported to SIZER