828D Servo Optimisation

B100 Sinumerik 828D
Basic Servo Optimisation
1 Brief description
Module Objective:- To ensure the necessary level of compatibility and consistency between
machines configured with the Sinumerik 828D controller. A defined optimization procedure
should be adhered to and this procedure is defined in this module
Caution:- These procedures result in axis movement. All necessary safety precautions must
be taken into account. Make sure that that you read through and understand the entire
procedure before beginning.
Module Description:-
This module explains the step by step procedure to optimise the current, speed and position con-
troller loops within the Sinumerik 828D/ Sinamics S120 ………...
Content of the module:
Current Controller Optimisation

Speed Controller Optimisation
Position Controller Optimisation
Velocity Feed Forward
Sinumerik 828D
Acceleration
Circularity test
Spindle optimisation
Advanced Surface
SINUMERIK 828D Training, Operation and Service Page 1 This document was produced for training purposes.
Siemens assumes no responsibility for its contents.
B100
B100
Section 6
Current Controller Optimisation Page 7
Speed Controller Optimisation

Proportional Gain
Section 2
Integral Gain Page 10
Reference Model
Current Setpoint Filters
Section 3
Position Controller Optimisation Page 25
Velocity Feed Forward

Axis Jerk Section 4
Page 31
Equivalent Time Constant
Section 5
Acceleration Page 36
Section 6
Circularity Test Page 38
Section 7
Spindle Optimisation Page 43
Section 8
Advanced Surface Page 59
B100 Page 2 SINUMERIK 828D Training, Operation and Service

Introduction
Activating Machine Data changes Notes
Throughout this procedure, certain machine data changes need to be activated.

To the right of each parameter value there is an indication of how the particular
change takes effect. The following is a list of these indications and their meaning.
po The relevant machine data requires an ―NCK Reset‖ to take effect

re The relevant machine data requires activation of the ―Reset‖ key to take
effect
cf The relevant machine data requires activation of the ―Set MD active‖ soft-
key to take effect.
im The relevant machine data is immediately active.
Saving Drive settings
Every time the S120 drive is powered on or a ―Drive Reset‖ is performed, the S120
drive data is loaded to the relevant drive from a stored file. Therefore when drive
machine data are altered, the drive data must be saved so that the change is re-
tained after the next power off/on or ―Drive Reset‖. NOTE:- an ―NCK Reset‖ does
not affect the drive data.
In order to save drive data:-

In the ―Drive MD‖ area, press the ―Save/Reset‖ then the ―Save‖ then the ―Drive
System‖ softkeys. Messages at the bottom left of the screen indicate the status of
the save process. When the save process is complete, the message ―All drive ob-
jects backed up‖ appears.
Controller Block Diagram
828-D SL/ S120 controller structure: The 828-D SL CNC and S120 drive controller
structure contains three cascaded closed loop controllers (current, speed and po-
sition). Each controller must be optimized in succession starting with the inner-
most current controller, then the speed controller and finally the position controller.
The machine dynamic limits for velocity, acceleration and jerk are set in the inter-
polator. The speed control loop is always closed via the motor encoder while the
position control loop can be closed via the motor encoder or direct measuring sys-
tem.
SINUMERIK 828D SL PROFIBUS –DP DRIVE
SINUMERIK 828D Training, Operation and Service Page 3 B100

Introduction
Notes
828D HMI Advanced Start Up tools:
- To get to the start up tool selection page from the “Machine page” press the
“Menu Select” key.
- Press the “Start Up” softkey and then the “Optimiz / test” softkey. From this
page, the relevant start-up tool can be selected
Note: Only some of the available tools are used during these procedures.
- Press the “Axis +” or “Axis - ” softkey to select the desired axis.
Current control Description Active

loop tools: Mode
"Ref. Frequency The closed loop frequency response tool is used to optimize the Jog
respo. (after cur- current controller proportional gain. The current setpoint filters
rent setpoint filter) have no influence on the measurement result.
Speed control Description Active
loop tools: Mode
―Speed controller This tool measures the open frequency response of the mechan- Jog
path (active after ics as seen by the motor shaft, without the influence of the cur-
current setp filter) rent setpoint filters.
"Ref. Frequency This tool measures the closed loop speed controller frequency Jog
respo ( after response including any mechanical resonance. Used for setting
speed setpoint the speed controller proportional gain, integral time and current
filter)" setpoint filters. The speed setpoint filter has no influence on the
measurement.
"Disturbance step Speed controller torque disturbance step change. Used to Jog
change (after measure the speed controller response to a torque or ―load‖ step
current setpoint change.
filter)"
Position control Description Active
loop tools: Mode
"Ref. Frequency Position controller closed loop frequency response used to opti- Jog
respo" mize the position controller proportional gain, (KV factor).
―Circularity Test‖ Used for circle analysis from either the motor encoder or direct MDA
measuring system. Automatic
―Servo Trace‖ The servo trace tool is a built in four channel oscilloscope. Jog, MDA
Automatic
Frequency Response Tool Display:

All frequency response tools display the measurement result as db gain and phase.
Trace 1 is pre-assigned as the db gain and Trace 3 is pre-assigned as the phase. It
is normally sufficient to use a fixed scale of +20 db to –60 db for Trace 1 and +180
deg to –180 deg for Trace 3. The frequency scale is logarithmic e.g. 1 Hz at the far
left and ending with the defined bandwidth e.g 4000 Hz. The first 1% and the last
50% of the frequency response range of measurement is disregarded.
Traces can be saved and recalled easily using the ―File Functions‖ softkey.
Up to 4 traces can be displayed at one time for comparison if desired.

Introduction
MD DESCRIPTION Notes
10200 $MN_INT_INCR_PER_PER_MM 100000
10210 $MN_INT_INCR_PER_PER_DEG 100000
20150[3] $MC_GCODE_RESET_VALUES[3] 3 FIFOCTRL
20150[9] $MC_GCODE_RESET_VALUES[9] 2 G64
20150[20] $MC_GCODE_RESET_VALUES[20] 2 SOFT
20600 $MC_MAX_PATH_JERK 10000
20602 $MC_CURV_EFFECT_ON_PATH_ACCEL 0
20603 $MC_CURV_EFFECT_ON_PATH_JERK 0
33000 $MA_FIPO_TYPE 3
32200 $MA_POSCTRL_GAIN xx
32640 $MA_STIFFNESS_CONTROL_ENABLE 1
32644 $MA_STIFFNESS_DELAY_TIME xx
33100 $MA_COMPRESS_POS_TOL 0.010
32300 $MA_MAX_AX_ACCEL xx
32310 $MA_MAX_ACCEL_OVL_FACTOR xx
32400 $MA_AX_JERK_ENABLE xx
32402 $MA_AX_JERK_MODE 2
32410 $MA_AX_JERK_TIME xx
32420 $MA_JOG_AND_POS_JERK_ENABLE xx
32430 $MA_JOG_AND_POS_MAX_JERK xx
32431 $MA_MAX_AX_JERK xx
32432 $MA_PATH_TRANS_JERK_LIM xx
32433 $MA_SOFT_ACCEL_FACTOR xx
32434 $MA_G00_ACCEL_FACTOR xx
32435 $MA_G00_JERK_FACTOR xx
32620 $MA_FFW_MODE 3
32630 $MA_FFW_ACTIVATION_MODE x
32810 $MA_EQUIV_SPEEDCTRL_TIME xx
32900 $MA_DYN_MATCH_ENABLE x
32910 $MA_DYN_MATCH_TIME x
32930 $MA_POSCTRL_OUT_FILTER_ENABLE x
32940 $MA_POSCTRL_OUT_FILTER_TIME x
P1400 bit3 Speed controller reference model enable x

P1400 bit5 Speed controller Kp and Tn adaption 0 Disable on axis
P1414 Speed setpoint filter activation x
P1421 Type of speed setpoint filter x
P1422 Speed setpoint filter time constant x
P1460 Speed controller Kp x
P1462 Speed controller Tn x
P1433 Speed controller reference model frequency x
P1434 Speed controller ref model damping x
P1656 Activate current setpoint filters x
P1657/1676 Current filter settings x
P1715 Current controller gain x

Notes

Current Controller Optimization
Section 1
Notes
1. 1 Current Controller Optimization
- The current controller gain is automatically loaded into P1715 when the motor
type is established during drive configuration.
- A reference frequency response of the current controller is a useful check of the

current controller parameterisation.
- With Siemens motors the parameters are automatically established and should
not need to be changed.
- With a current controller cycle time of 125us, The db gain should be above –3db
to where the phase passes through –90 degrees. As a minimum the –90 phase
point should be above 550Hz
- If the amplitude is greater than 0db then P1715 should be reduced. If the ampli-
tude is lower than -20db then the motor type should be checked. ( recalculate
regulator data P0340)
WARNING :- Do not carry out this test on a vertical axis unless it is supported.
During this procedure the speed controller is disabled internally, and therefore ver-
tical axes could fall if not supported.
Select ―Start up‖
Select ―Optimiz/test‖

Section 1 Current Controller Optimization
Notes
Select ―Curr contr

loop‖
!!!!! Information !!!!!

Current Controller
Cycle Time
Select
―Measurement‖ and
then Type of meas-
urement ―Refer.
Frequ. Response‖
Select ―Measuring
parameters‖ and
then Select
―Standard pa-
rameters‖
The amplitude will

vary depending
upon motor type
and current limit

Current Controller Optimization Section 1
Notes
Select
―Measurement‖
and then Select
―Start‖
You will then get a

message saying
Press NC Start.
Press ―Cycle
Start‖ on the Ma-
chine Control
Select ―Display‖
when the meas-
urement has fin-
ished to see the
result
As can be seen from the example above the amplitude stays at the 0db line until
around 900 Hz.
The db gain should be above –3db to where the phase passes through –90 de-
grees. As a minimum the –90 phase point should be above 550Hz
Example of P1715 Example of P1715

Too High Too Low

Section 2 Speed Controller Optimization
Notes
2.1 Speed Controller Optimization
- The Speed Controller proportional gain (Kp, P1460) default value is based on the
motor type. The Speed Controller integral time (Tn, P1462) default value is 10ms.
Both values are automatically loaded into the relevant parameters when the motor
type is established during drive configuration. These values are conservative to allow
a reliable start up, and they now have to be optimized.
- The end result of an optimized speed controller (Kp, Tn) is that the amplitude re-
sponse is at 0db out to as high a frequency as possible with a maximum of +3db at
frequencies below the phase response crossing below –130 degrees. If the axis is to
carry load then it is better to keep the amplitude response at 0db as the addition of a
load may change resonant frequencies.
- To help achieve this there are 4 independent current setpoint filters ( P1656 to
P1676) that can be activated as needed to suppress mechanical resonance. These
filters can be assigned as ―Low Pass‖ or ―Bandstop‖. As a default the first filter is acti-
vated and set as a ―Low Pass‖. Additional current setpoint filters can be assigned if
required and are usually configured as ‗Band Stop‖
- When using ―Bandstop‖ filters you should always try to keep the bandwidth and
notch depth conservative. If you let the filter have the full effect then this reduces the
bandwidth of the speed controller. A notch depth of –20 to –40 should be used
- Normally with a Speed Controller cycle time of 0.125 ms it should NOT be neces-
sary to use filters below 200Hz.
Speed Controller Optimization Procedure Summary
2.11 Use the ―Speed controller path (active. After setp filter) to accurately identify me-
chanical resonance ―pole ― and ―zero‖points. The result determines whether current
setpoint filters are required and also initial parameter settings.
2.12 Use the ―Refer. Frequency response (after setpoint filter)‘ to optimize the speed
controller proportional gain (Kp) separately from the speed controller (Tn) and enable
current setpoint filters if required.
2.13 Use the ―Disturbance step change (after setpoint filter)‘ to optimize the speed
controller integral time (Tn) , and then use the ―Refer. Frequency response (after set-
point filter)‘ tool to check the setting.
2.14 Use the ―Speed controller reference model‖ to reduce overshoot in response to
setpoint step changes.
Speed Controller Optimization Procedure
2.11:- Use the “Speed Controller Path (active. After setp filter)” measurement to
identify resonant ―Pole‖ and ―Zero‖Points.
- This measurement compares torque to speed and at the end you can identify the
resonant ―Pole‖ and ―Zero‖ Points so that they can be noted for use when we use the
―Reference Frequency Response‖ of the Speed Controller.
- The reason for this is that when the ―Reference Frequency Response‖ measurement
is carried out the ―Pole Points‖ can appear slightly higher in frequency than they really
are.
- Ensure that Dynamic Stiffness is disabled MD32640 = 0 and that (Tn) Drive P1462
is 100ms for horizontal axes and 30ms for vertical or inclined axes, this decreases the
influence of the speed controller integrator for this measurement.

Speed Controller Optimization Section 2
Notes
Select ―Speed
contr loop‖

Speed Controller
Cycle Time
Select
then ―Speed control-
ler path (active. After
current setp. Filter).
This measurement is
without the influence
of filters.
Select ―Measuring
parameters‖ and
―Values in %‖.
Then enter the val-
ues as shown.
Also switch the

display to ‖Values
in phys. quant‖ to
make sure the Off-
set and Amplitude
are not too large.
The amplitude
should be varied if
the measurement
is too noisy.
Values in %

Notes
Move cursor bar down to enter ―Ramp-up time‖
Select
then Select ―Start‖
You will then get a

message saying
Press NC Start.
Press ―Cycle Start‖

on the Machine
Control Panel
Pole at 769 Hz Pole at 1600 Hz
When the measure-

Zero at 600 Hz Zero at 1400 Hz
ment is finished se-
lect ―Display‖
Select ―Display‖ and then make a note of the ―Pole‖ and ―Zero‖ Points as above. In
this example ―Pole‖ points are at 769 Hz and 1600 Hz and ―Zero‖ points are at 600
Hz and 1400 Hz. The first 1% and the last 50% of the measurement can be disre-
garded.
Speed Controller Optimization
Section 2
Mechanical resonance is identified by ―Pole‖ and ―Zero‖ points as shown by the ex- Notes
ample on the previous page. The ―Zero‖ is to the left of the associated ―Pole‖ i.e the
lower frequency. At the ―Zero‖ points the db gain goes negative while the phase
shifts sharply from –90 deg towards +90 deg. At the ―Pole‖ points the db gain goes
positive while the phase shifts sharply back to –90 deg. In these cases additional
current setpoint filters configured as ―bandstop‖ may be required to allow a reason-
able speed controller gain setting.
The next step is to determine possible filter settings, do not enable them at this time.
Current setpoint filters are not normally required below 200Hz
Pole at 769 Hz Pole at 1600 Hz
Zero at 1400 Hz
Zero at 600 Hz
Estimate notch depth, here –14db & -16db
Example settings in this case are :- ( These values should be recorded )

Pole frequency 769, Zero frequency 600, notch depth –14db and
Pole frequency 1600, Zero frequency 1400, notch depth –16db.
It is now a good idea to make the same measurement up to a bandwidth of 400 Hz

to give a good overview of what is happening at lower frequencies. This also
shows the lowest natural frequency of the axis and from this value we have a good
idea of what Kv factor can be reached
Select
then ―Speed con-
troller path (active.
After current setp.
Filter)
Change the
―Bandwidth‖ from
4000 Hz to 400Hz,
and ―Meas periods‖
to 2

Notes
Select ―Measurement‖
and then Select
―Start‖
You will then get a

message saying
Press NC Start.
Press ―Cycle Start‖ on

the Machine Control
Panel
Take a note of the fre-

quencies from 10 Hz
to 200 Hz . Here it
shows the lowest natu-
ral frequency at 66 Hz
and also another reso-
nance at 120 Hz.

2.12:- Using the “Reference frequency response” measurement to adjust Kp Notes
(P1460) and Tn (P1462).
- The reference frequency response displays the db gain and phase lag. This
gives an indication of how well the speed actual value follows the setpoint within a
frequency range, e.g. 1 HZ to 4000 HZ. 0 db indicates that the actual speed is the
same amplitude as the setpoint and 0 phase lag indicates that the actual speed
follows the setpoint with minimal delay. The speed controller KP and Tn settings
affect the db gain and phase response.
- With the Tn at a relative high value, e.g. 100 ms, it is ineffective. The Kp can be
adjusted independently so that the db gain is 0 to –3db at –90 deg and does not
exceed 0 at any point on the db gain graph. The db gain should not exceed 0
when the phase crosses –180 deg. Note: When the Tn setting is relatively high,
(100 ms), the db gain at low frequencies may not be on the 0 db line because of
friction. After the Tn is adjusted, the db gain at low frequencies should be 0.
- If it was necessary to use the default 10 ms for the Tn setting to get a readable
result, the KP can be adjusted so that the db gain is +3 db above the 0 db line at
frequencies below the -130 degree phase point.
To calculate a good optimization of the speed controller P-gain use the formula:
P1460=(Motor Inertia)P341*1200= Example 0.001510kgm²*1200=1,812kgm²
First measurement with high Tn=100ms (p1462). This reduces the effect of the Tn
and allows Kp (p1460) to be optimized separately.
Be sure that Dynamic stiffness control is disabled MD32620 = 0
Attention: On a vertical axis without a counterbalance e.g. the Z-axis on a ―C

Frame‖ milling machine, start Tn from a value of 30ms, to prevent the axis from
dropping and for the first measurement keep some support close to the axis
Also if working on a rotary axis only use small values for Amplitude and Offset,
quite often if you just use standard values they will be too high.
Select ―Drive MD‖

Notes
Search for 1462 and

enter 100
This makes Tn inef-

fective during the
measurement
Then Select ― ^ ―
and then Select
―Refer. Frequency
response (after speed
setpoint filter)‖
Select ―Measuring
parameters‖ and
then ―Standard pa-
rameters‖ but
change the offset to
100 mm/min to over-
come any friction

Section 2
Notes
Change Ramp-up
time to 500 ms
Select
You will then get a

message saying
Press NC Start.

on the Machine Con-
trol Panel
When the measure-

ment is finished No Filters Filters
select ―Display‖ and
then you can see
the resonant fre-
quencies in the me-
chanics. We now
need to build in a
filter to dampen any
resonant frequen-
cies above 200 Hz.
In this example 769
Hz so Select ―Filter‖
200 Hz
In general with a speed controller cycle time of 0.125 ms no filters should be re-
quired below 200Hz, as this area falls in the bandwidth of the speed controller and
therefore we have phase in reserve. Below 200Hz the filters have too much nega-
tive influence on the speed control behaviour (they lower the bandwidth, that
means less dynamics)

Notes The HMI Advanced start up tool contains a user friendly mask to set filters. All 4 filters
are configured as PT2 low pass in the default state with only the first filter activated.
The 3 other filters can be added and configured as necessary. The additional filters
shown here are normally entered as ―Bandstop‖ filters.
As a default the first filter is active as a PT low pass filter with a frequency of 2000Hz
and damping of 0.7. This setting should not be changed.
We should start here with filter number 2 and configure it as a ―Bandstop‖
Select ―Filter +‖ to
reach Filter No 2.
Assign filter 2 as a
Band Stop filter and
then enter the values
for the frequency,
bandwidth and notch
depth.
Then Select ―Accept‖
For starting values use

the notch frequency of
the spike, the band-
width equal to Pole
frequency minus Zero
frequency * 2,and
notch depth to the de-
sired depth of the filter
in db.
Reduction should re-
main at 0.
The filter parameters

are automatically
loaded into the rele-
vant area and the
2nd filter is activated
Repeat the ―Reference

frequency response‖
measurement to see
the effect of the filter.

Notes
The Kp(P1460) was now increased to 2Nms/rad with the following result:
Where the phase goes below -130° shows the range of the speed-controller.
Below this point we can go up to +3dB, above this point we should not exceed
0dB.
On series machine types that use 828D it is always best to leave some amplitude
in reserve to allow for variations in mechanical build.
0 db
-130
2.13 Use the “Disturbance step change (after setpoint filter)” to optimize Tn
(P1462).
When the Tn is reduced, the db gain normally lifts above 0 db. The Tn setting
range is dependant on the mechanics and on machines of the type that 828D is
fitted to is normally less than 10 ms but greater than 3ms. The Tn should not be
set to values below 3ms.
The end result of optimized speed controller Kp and Tn settings is that the db gain
is 0 db out to as high a frequency as possible with a maximum of +3db at frequen-
cies below the -130 phase point.
If the axis is to carry an additional load i.e. a table or a fixture, it is best to set the
db gain at 0db, as the additional load may push the db gain up to the +3db maxi-
mum.
To optimize Tn se-
lect measurement
type ―Disturb. Step-
change (interf. After
current setp.filter)
Measured quantity 1
is Actual torque
value

Notes
Select parameters as
shown.
Also switch the display

to ‖Values in phys.
quant‖ to make sure
the Offset and
Amplitude are not too
large
and then Select ―Start‖
You will then get a

message saying Press
NC Start.
Press ―Cycle Start‖ on

the Machine Control
Panel
Tn too big 10ms
Tn correct 5ms
Tn too small 2ms
Start with Tn (P1462) at 10ms which is the standard value. Decrease Tn until you
see an undershoot in the lower graph. Then just increase Tn until you see no un-
dershoot. Most machines of the type fitted with 828D will end up with a value of
between 3 to 10ms.

Section 2
Notes
Once the best setting for Tn has been established a check should be made of the
speed controller reference frequency response. This is because a low setting of
Tn will cause the amplitude at lower frequencies to rise above 0db
Select type of meas-

urement ―Refer. Fre-
quency response‖
Select
You will then get a

message saying
Press NC Start.

on the Machine Con-
trol Panel
The result shows

the amplitude re-
spose rising up to
3db in the lower
frequency area
2.14 Use of the “Speed controller reference model”

For high dynamic applications such as high speed machining and mould & die,
especially those that require high position loop gain, or velocity feed forward, the
speed reference model can be implemented to reduce overshoot in response to
speed setpoint changes. The reference model is a model for the P controlled
speed controller.
As a rule when optimizing the speed controller, it is desired to achieve a low Tn

setting so that the drive can respond quickly to load changes and counteract the
effects of friction. With optimized Tn settings, there is an expected overshoot in
response to setpoint step changes. The ―speed reference model‖ reduces this
overshoot while not affecting the response to load changes. The advantage is
better quality surface finish.
P1433, (reference model frequency), can be adjusted in a range of 50 HZ to 250

HZ and is most effective when high KV factors are required and/or when direct
scale feedback is used. The lower the value in MD 1433, the more effect the
speed reference model has. The reference model should have the same value for
all axes and the main spindle.
P1434, (reference model damping factor) A setting of 0.7 should be used as a

start value. Typically values are between 0.5 to 1.0.
Notes
First we have to switch

the speed reference
model on.
Search for P1400

―Speed control configu-
ration‖
Turn on Bit 3
―Reference model
speed setpoint‖
To get an idea of an
initial setting for P1433
take a look back at the
frequency response of
the speed controller
when P1460 was be-
ing adjusted. Take a
look where the phase
passes through –90
degrees and use this
frequency as the start
value in P1433. For
P1434 use a start
value of 0.7
In this case P1433 =

220 Hz

Notes
Enter the values

into P1433[0] and
P1434[0]
The speed refer-

ence model will be
active if P1433[0]
>0
P1433 should be
reduced gradually
until the amplitude
response is at a
maximum of 3db in
the lower frequency
area

Notes

Position Controller Optimization Section 3
3.1 The position loop gain, (KV factor) is optimized using the position controller Notes
―reference frequency response‖ tool. Stability and overshoot should then be
checked by making a position step and using the servo trace tool.
- The position loop proportional gain, (Kv factor MD 32200), influences the follow-
ing error and contour accuracy. the default value is 1. As the KV factor is in-
creased, the following error is proportionally reduced. For typical machine tool
applications the final KV factor setting can fall in a range of 1 to 10[m/min/mm]
- A good optimization of the position controller means small following error, small
contour deviation and no overshoot when the axis comes into position.
- Prerequisite :- That the current and speed controllers have been correctly opti-
mized.
Important! Be sure to take machine mechanical limitations as well as maximum

work-piece and fixture weight into account when setting the Kv factor and accel-
eration parameters! If the machine is optimized without load, overshoot and insta-
bility can occur when significant weight is added to the moving table. To avoid this
situation, it is recommended to optimize the KV factor with the maximum weight
securely mounted to the table. In addition, check if there are any pre-determined
mechanical limitations before beginning!
- Use the position loop ―Ref. frequency respo‖ tool to optimize the KV factor :-
The position loop ―Ref. frequency respo‖ tool is used to set the KV factor to the
optimum value based on the components that are included in the closed position
loop, including work-piece and fixture weight. The attainable results vary depend-
ing on the machine mechanics and type and mounting location of the feedback
device that is used to close the position loop, (direct scale or indirect motor en-
coder).
The following parameters should be checked :-
Deactivate Feed Forward ………………MD 32620 = 0

Deactivate Speed Setpoint Filter……….P1414 = 0
Deactivate any Position Setpoint Filter..MD 32900 DYN_MATCH_ENABLE = 0
...MD 32400 AX_JERK_ENABLE = 0
- Dynamic stiffness control should be enabled. This enables position control in a

faster cycle time. NOTE:- With Dynamic Stiffness control ENC_FEEDBACK_POL
32110 must be 1. If the feedback polarity needs to be swapped it must be done in
the Sinamics drive with P410 = 3H.
Activate DSC (Dynamic Servo Control)..MD 32640 = 1

Adjust Stiffness Delay Time …MD 32644 = 0.0000 PPU281
= -0.0015 PPU261
Select ―Position
contr. Loop‖

Position Controller
Cycle Time

Section 3 Position Controller Optimization
Notes
Select
then type of meas-
urement ―Ref fre-
quency response‖
Select ―Measuring
parameters‖ and then
enter tha values
shown.
Bandwidth 166 Hz for

Position controller
cycle 3ms, 333 Hz for
Position controller
cycle 1.5ms
Select
You will then get a

message saying
Press NC Start.

on the Machine Con-
trol Panel

Notes
When the meas-

urement is finished
select ―Display‖
This example
shows that the Kv
can be increased
Increase the value

in Axis MD 32200
[0] until the ampli-
tude response is at
the 0db line for as
high a frequency
as possible, but
not rising above
0db
This results in a 0 db
correctly optimized
position controller

Notes
Kv too high, the am-

plitude response is
rising above 0db
-The positioning response of the axis should now be checked using the servo trace
tool and a commanded position step via part program at different feedrates. In cases
where a direct scale is used, the actual slide response can easily be viewed. In
cases where the motor encoder is used to close the position loop, (indirect feed-
back), the actual response of the axis is not visible to the closed loop or the servo
trace tool.
-The test part program should traverse the axis a sufficient distance that allows the
programmed velocity to be reached, e.g. 50 mm. A check should also be made over
shorter distances e.g. 3 - 10mm. A dwell time should be used after the velocity is
reached and then after the setpoint position is reached, e.g. 0.5 second. The initial
programmed velocity can be approximately ½ of the maximum axis velocity and the
response should be checked at all of the feedrate override increments as well as the
maximum speed.
-The aim is to check the stability of the position controller and also to check position-
ing accuracy. A check is also made for any overshoot or vibration.
-The position actual value trace results should be magnified for a finer view by
changing the scale, e.g. position 0.005 mm/div
The following NC program can be used
FFWOF
SOFT
LAB:
G01 X210 F10000
G04 F0.5
$AA_SCTRACE[X]=1; trigger for servo trace
X260
G04 F0.5
GOTOB LAB
M30

Notes
Select the NC program, in Automatic Mode so that it is ready to run when ―Cycle
Start‖ is pressed on the Machine control panel
Select ―Servo trace‖
Select
enter the trace pa-
rameters as shown.
Select ―Start‖ which

starts the trace
function and then
press ‗Cycle Start‖
on the machine
control panel to
start the part pro-
gram.
When the trace

function has fin-
ished press
―Display‖
Positioning without
Feed Forward.
Change the ―Scale

of trace 1 & 2 to
show a
Resolution
0.005mm/div
around the target
position
Without Feed For-

ward at all
feedrates, no over-
shoot is permissi-

Notes
This is an example where the KV factor setting is adequate and the jerk limit set
too high. The oscillation that occurs upon position settling is generated from the
mechanics and should be smoothed by a lower value for jerk limit, MD 32431. MD
32431 should be set to as high a value as possible that results in smooth position-
ing response without overshoot.
This is an example where the jerk limit setting is adequate but one or more of the
controller settings are not correct. The overshoot without oscillation upon position
settling could be a result of the KV factor, (MD 32200), being set too high. This
might occur when a load weight is added to an axis where the KV factor had been
optimized without a load weight.

Velocity Feed Forward Optimization
Section 4
4.1 With Velocity Feed Forward, a high effective Kv factor (low following error), Notes
very high accuracy and contour precision can be obtained. With dynamically high
quality machines with high natural frequencies and good damping it is possible to
reduce the following error even at very high speeds.
If high precision is a requirement, then feed forward control is necessary. When

Feed Forward is activated, the servo response becomes very dynamic, thus, jerk
limited acceleration is always necessary to smooth the setpoint profile.
Before the feed forward function can be enabled and optimized, the current, speed
and position controllers must have previously been optimized!
The following parameters should be checked
MD 32200 POSCTRL_GAIN as previously optimized

MD 32300 MAX_AX_ACCEL as specified by the builder
P1460 SPEEDCTRL_GAIN_1 as previously optimized
P1462 SPEEDCTRL_ INTEGRATOR_TIME_1 as previously optimized
P1433 SPEEDCTRL_REF_MODEL_FREQ = as previously optimized
P1414 NUM_SPEED_FILTERS = 0
MD 32610 VELO_FFW_WEIGHT = 1.0
MD 32810 EQUIV_SPEEDCTRL_TIME = 0
MD 32431 MAX_AX_JERK = 100
MD 20600 MAX_PATH_JERK = 10000
MD 32620 FFW_MODE = 0
The easiest way to optimize Feed Forward control is to make a position step.
Therefore the position setpoint and the position actual value of the active encoder
have to be viewed with the servo trace. Then the machine data must be adjusted
until the position behavior (i.e. the last 20 μm when the axis goes into desired po-
sition) is satisfactory.
If positioning alarms occur during parts of the procedure then set the following MD
but make a note of the original values and put them back to original at the end.
MD 36012 STOP_LIMIT_FACTOR = 100

MD 36400 CONTOUR_TOL = 20
Experience shows that a traversing range of approx. 50 mm and a velocity of 10

m/min is useful to get a good result. A check should also be made over shorter
distances as excitation of mechanical resonance is more prevalent over shorter
distances e.g 5 - 10 mm
The following NC program can be used
FFWON
SOFT
LAB:
G01 X210 F10000
G04 F0.5
X260
G04 F0.5
GOTOB LAB
M30

Section 4 Velocity Feed Forward Optimization
Notes
Select the NC program, in Automatic Mode so that it is ready to run when ―Cycle
Start‖ is pressed on the Machine control panel
and enter the trace
parameters as shown.
Select ―Start‖ which

starts the trace func-
tion and then press
‗Cycle Start‖ on the
machine control panel
to start the part pro-
gram.
When the trace func-

tion has finished press
―Display‖
Change the ―Scale of

trace 1 & 2 to show a
Resolution 0.005mm/
div around the target
position
Without Feed Forward

at all feedrates, no
overshoot is permissi-
ble.
Positioning without Feed Forward:-should be comparable with measurement of

position controller on the previous pages. The position controller without feed for-
ward must have no overshoot and minimal vibration.

Velocity Feed Forward Optimization Section 4
Now, feed forward can be switched on with MD 32620 FFW_MODE = 3. Check that Notes
the equivalent speed control time is switched off
MD 32810 EQUIV_SPEEDCTRL_TIME = 0.The optimal EQUIV_SPEEDCTRL_ TIME
depends on the mechanics and the time constants in the controller loops of an axis. It
is possible that different axis with the same EQUIV_SPEEDCTRL_ TIME show differ-
ent positioning behavior. The aim now is to find the correct equiv. time constant and
check the vibration behaviour because excitation of vibration is more likely when us-
ing feed forward
Positioning with Feed Forward

active
Resolution 0.005mm/div.
It can be seen here that the

actual value shows a crawling
behavior in the last 0.01mm to
position.
In this case the

EQUIV_SPEEDCTRL_TIME
must be decreased. It is possi-
ble to have a negative value.

MD 32810 EQUIV_SPEEDCTRL_TIME = 0.0025

active

actual value shows overshoot
as it comes into position.
In this case the

must be increased


active

actual value shows no over-
shoot as it comes into posi-
tion.
In this case the

was correct at 0.002

Section 4 Velocity Feed Forward Optimization
Notes
Now Jerk limited acceleration can be optimized: Jerk is used to smooth the accel-
eration response by applying a time for the change in acceleration. Jerk is defined
in units/sec3, i.e. (acceleration [units/sec2 / time [sec]). The time it takes for the
acceleration change to take place, [sec] = acceleration [units/s 2] / jerk [units/s3].
Axes do not have to have the same Jerk value.
The result of jerk-limited acceleration is rounded corners at the start and end of
the acceleration phase of the velocity profile and smoothed motion.
Jerk limiting is active when ―SOFT‖ is programmed and de-activated when
―BRISK‖ is programmed. ―SOFT‖ mode is set as the default reset state via chan-
nel MD 20150[20] = 2. It is recommended to use ―SOFT‖ as the default reset
value.
If channel MD 20150[20] = 1, "BRISK" mode is active as a default on power up,

(acceleration without jerk limit).
If channel MD 20150[20] = 2, "SOFT" mode is active as a default on power up,
(acceleration with jerk limit).
The positioning response of the axis can be checked using the servo trace tool
and a commanded position step via part program at different feedrates. In cases
where a direct scale is used, the actual slide response can easily be viewed. In
cases where the motor encoder is used to close the position loop, (indirect feed-
back), the actual response of the slide is not visible to the closed loop or the servo
trace tool. On machines with 828D in general jerk values will be between 20 and
100
The test part program should traverse the axis a sufficient distance that allows the
programmed velocity to be reached, e.g. 50 mm. A dwell time should be used
after the velocity is reached and then after the setpoint position is reached, e.g.
0.5 second. The initial programmed velocity can be approximately ½ of the maxi-
mum axis velocity and the response should be checked at all of the feedrate over-
ride increments as well as the maximum speed.
The previous part program can be used as a basis and the servo trace settings
are the same.
Positioning without
position controller Kv =
0
Resolution 0.005mm/
div.
Without the position

controller the axis po-
sitions with no over-
shoot. The remaining
positioning error exists
because the position
controller is switched
off and the axis is
moving with just feed
forward signals. The
overshoot when com-
ing into position comes
MD 32200 POSCTRL_GAIN = 0 from the mechanics
MD 32610 VELO_FFW_WEIGHT = 1.0 and can be eliminated
MD 32620 FFW_MODE = 3 using jerk limitation.

Velocity Feed Forward Optimization Section 4
The positioning step without the position controller is now dependant upon the Notes
speed controller and setpoints (Acceleration, JERK - profile).
The response of the feed forward driven axis should show no overshoot or vibra-
tion.
Positioning without
position controller
and jerk too high.
Resolution
0.005mm/div.
This diagram
shows how the jerk
is increased until
there is an over-
shoot in the re-
sponse of the me-
chanics.
Remove the over-

shoot
By decreasing the
MAX_AX_JERK
MD 32200 POSCTRL_GAIN = 0
Positioning with
feed forward and
position controller
active
Resolution
0.005mm/div.
Good positioning
without overshoot
when feed forward
and jerk are cor-
rectly optimized
MD 32200 POSCTRL_GAIN = 4.5

MD 20150[23] =2 Feed Forward can then be enabled as a

default.
MD 36012 STOP_LIMIT_FACTOR = original value

MD 36400 CONTOUR_TOL = original value

Section 5 Acceleration
Notes
5.1 Maximum axis acceleration: Axis MD 32300 defines the maximum axis ac-
celeration. The default value is, [1 m/sec2 (metric), 39.37 in/sec2 (inch) and 2.77
rev/sec2 (rotary)]. Each axis can have a different acceleration setting.
Important! Machine mechanics limit the maximum axis acceleration. The machine
builder must define the required setting value! If not defined, the default value
should be used unless the machine builder authorizes an increase.
Checking the maximum axis acceleration:

The torque utilization under worst-case load and velocity conditions should be
checked after the KV factor and Feed Forward have been optimized to be sure
that the torque limit is not reached.
The "Servo trace" start up tool is used to measure the velocity actual value of the
relevant active measuring system and the torque utilization percentage via the
―Utilization (m_set/m_set_limit)‖ trace signal. When the ―Utilization (m_set/
m_set_limit)‖ trace signal =100%, the drive is on current limit!
If allowed by the machine builder, MD 32300 can be set so that the torque utiliza-
tion during the acceleration phase of the worst case load and velocity lies between
80% and 90% of the limit depending on how much safety factor is desired.
A test part program should traverse the axis a sufficient distance that allows the
programmed rapid velocity to be reached, e.g. 300 mm.
Change the trace measuring parameters to view the load torque utilization and
change the part program as shown.
SOFT
LAB:
G0 X10
X310
GOTOB LAB
M30
Change the trace

measuring parame-
ters to view ―Velocity
act value meas sys-
tem 1‖, ―Utilization
(m_set/m_set_limit)‖
and ―Torque-prod
curr. Act. val i(q)‖

Acceleration Section 5
Notes
Select the part program in Automatic mode so that it is ready to be processed
when ―Cycle Start‖ is pressed
Select
―Measurement‖
and then Select
―Start to start the
servo trace.
Then Press
―Cycle Start‖ on
the machine con-
trol panel to start
the part program
The maximum
velocity of 48 m/
min is reached
with a utilization of
36%.
The ―Utilization (m_set/m_set_limit)‖ signal selection displays the utilized percentage

of the active current limit.
The active current limit is:

P 0640 = [RMS amps].
P 0640 is limited to whichever is the lower of P0323 Maximum Motor Current/ Mot I
Max [RMS amps] or r0209 Power Unit Maximum Current/ PU I Max [RMS amps]
In this example P640 was 35A
Therefore utilization is 35A x 36.28/100 = 12.7A

Section 6 Circularity Test
Notes
6.1 The “built-in” circularity test is used to check the interpolation of axes that will
work together. The tool measures a circle with reference to the motor or direct meas-
uring system. Machine mechanical alignment is not considered in the result. This
gives the commissioning engineer the ability to clearly separate controller optimiza-
tion issues from mechanical issues.
Axis MD32200,MD32400,MD32402,MD32410,MD32490,MD32500,MD32510,
MD32520, MD32540 MD32620, MD32640, MD32810, MD32900, MD32910,
MD32930, MD32940 and drive P1421 to P1426. P1400, P1433, P1434 are checked
via this procedure.
The following positional error compensations should be switched off when this proce-
dure is carried out. Backlash Comp MD32450, Encoder Comp MD32700, CEC Comp
MD32710, Temperature Comp MD32750, Friction Comp MD32500.
Note:- Backlash MD 32450 must be adjusted using an external device e.g ballbar or
dial gauge
The best overall contouring results are achieved when the circle test results in the
correct actual size, shape and minimum p/p deviation between combinations of inter-
polating axis, (X-Y, X-Z, Y-Z).
A circle test part program and the circularity test start up tool can be used to measure
and evaluate these results. The ―worst case‖ test circle radius and path feedrate
must result in a realistic radial acceleration that the machine is capable of. Machine
builders typically have specifications for test circle radius and feedrate.
Standard machine builder circle tests typically use a radius of 100 mm or 150 mm at
feedrates determined by the machine builder. The machine builder defines the ac-
ceptable result specifications.
High speed cutting requirements are usually more stringent and test circles for high
speed cutting machines might be in the range of 10 to 25mm radius at feedrates of 5
m/min to 10 m/min. For high speed cutting machines, the results are normally ac-
ceptable when the p/p deviation </= 0.010 mm, and the actual size is equal to the
programmed radius at the worst case path feedrate.
Example of an X-Y circle part program –

Position, feedrate and active plane must be adapted to the machine!
FFWON
SOFT
G90 G01 F3000 X400 Y200 Z500
LAB:
G91 G64 G02 X0 Y0 I10
GOTOB LAB
M30
Select ―Optimiz/test‖

Circularity Test Section 6
Notes
Select ―Circular.
Test‖
Select
―Measurement‖
and enter the
relevant parame-
ters. The pa-
rameters shown
are for a 10mm
radius in X-Y
plane at a
feedrate of 3m/
Setting the ―Circularity test‖ parameters:

> From the start up tool page, press the ―Circularity test‖ softkey.
After this keystroke sequence, the control is in Circularity test start up tool.
> Set the desired measuring parameters to match the programmed circle:
- Measurement, select the relevant axis and the ―active‖ measuring system.
- Parameter, enter the programmed radius and feedrate. The multiplier should
remain at 1.
- Resolution, set the resolution as desired, e.g. 0.010 mm/grad
- Representation, select ―Mean radius‖.

Notes
> The example program should first be modified to fit

the machine positions, feedrates and plane if neces-
sary. The example program uses circular interpolation
and runs the programmed circle continuously. Follow
the specific machine procedures to run the test part
program.
Important: The circularity test must be activated manu-

ally by pressing the "Start" softkey after the test pro-
gram is started.
> After the measurement is complete, press the

―Display‖ softkey to view the results.
Parameter:
Radius = Entered radius (e.g. 10 mm)
Feedrate = Entered feedrate (e.g. 3000 mm/min)
Measuring time = Calculated time for the measurement
Representation:
Resolution = units per graduation (e.g. 0.010 mm/div)
Represent = Type of display, (e.g. mean)
Radius = Actual radius
Delta R = p/p deviation

Circularity Test Section 6
Notes
As a general rule with feed forward optimized the actual

value radius is too large. This can be corrected using a
time constant MD32410 AX_JERK_TIME. If necessary
enable the time constant in all axes.
The circle above shows the results after feed forward has
been optimized however the mean radius is .0017 too
large.
32200 POSCTRL_GAIN 4.500 4.500

P1460 SPEEDCTRL_GAIN1 2.0 2.0
P1462 SPEEDCTRL_INTEGRATOR_TIME_1 4.0 4.0
P1433 SPEEDCTRL_REF_MODEL_FREQ 220.0 220.0
P1440 NUM_SPEED_FILTERS 0 0
32610 VELO_FFW_WEIGHT 1.0 1.0
32620 FFW_MODE 3 3
32810 EQUIV_SPEEDCTRL_TIME 0.002 0.002
32400 AX_JERK_ENABLE 0 0
The circle size is now corrected using AX_JERK_TIME
32200 POSCTRL_GAIN 4.500 4.500

32620 FFW_MODE 3 3
32402 AX_JERK_MODE 2 2
32410 AX_JERK_TIME 0.013 0.013

Notes
This circle shows the effect of AX_JERK_TIME being different, there-

fore it is also possible to use AX_JERK_TIME to correct this type of
error
32200 POSCTRL_GAIN 4.500 4.500

32620 FFW_MODE 3 3
32410 AX_JERK_TIME 0.012 0.014
32200 POSCTRL_GAIN 4.500 4.500

32620 FFW_MODE 3 3
32410 AX_JERK_TIME 0.015 0.011

Spindle Optimization
Section 7
Check Preset MD as below also any relevant parameter for spindle/axis in- Notes
terpolation
Example is for 8000 rpm Spindle Motor with no mechanical gear ranges
The following parameters can be pre-set to the suggested values in the

charts below. The values will vary depending upon the application.
Machine Machine Data Name Value

Data
MD 30300 IS_ROT_AX 1 Rotary axis/spindle
MD 30310 ROT_IS_MODULO 1 Modulo conversion for rotary axis/spindle
MD 30320 DISPLAY_IS_MODULO 1 Modulo 360 degree display for rotary axis/
spindle
MD 32000 MAX_AX_VELO[0] 8000 Max axis velocity
MD 32010 JOG_VELO_RAPID 60 Traverse rate in rapid jog
MD 32020 JOG_VELO 10 Traverse rate in jog
MD 32040 JOG_REV_VELO_RAPID 60 Rotary traverse rate in rapid jog
MD 32050 JOG_REV_VELO 10 Rotary traverse rate in jog
MD 32200 POSCTRL_GAIN[0] x To be optimized
MD 32200 POSCTRL_GAIN[1] x To be optimized
MD 32620 FFW_MODE 3 3 for Velocity Feed Forward
MD 32640 STIFFNESS_CONTROL_ENABLE 1 Dynamic Stiffness Control
MD 32810 EQUIV_SPEEDCTRL_TIME[0] x As per axis that interpolates with spindle.
MD 32810 EQUIV_SPEEDCTRL_TIME[1] x As per axis that interpolates with spindle.
MD 34000 REFP_CAM_IS_ACTIVE 0 If no bero switch
MD 34020 REFP_VELO_SEARCH_CAM 30 Reference point approach velocity

MD 34040 REFP_VELO_SEARCH_MARKER[0] 30 Creep velocity
MD 34040 REFP_VELO_SEARCH_MARKER[1] 30
MD 34060 REFP_MAX_MARKER_DIST[0] 370 Maximum distance to reference mark
MD 34060 REFP_MAX_MARKER_DIST[1] 370
MD 33000 FIPO_TYPE 3 Type of interpolator
MD 35000 SPIND_ASSIGN_TO_MACHAX 1 Assignment of spindle to machine axis
MD 35100 SPIN_VELO_LIMIT 8800 Maximum spindle speed
MD 35110 GEAR_STEP_MAX_VELO[0] 8000 Maximum spindle speed for gear change
MD 35110 GEAR_STEP_MAX_VELO[1] 8000
MD 35130 GEAR_STEP_MAX_VELO_LIMIT[0] 8000 Maximum spindle speed for gear stage
MD 35130 GEAR_STEP_MAX_VELO_LIMIT[1] 8000
MD 35200 GEAR_STEP_SPEEDCTRL_ACCEL X Acceleration in speed control mode
[0] To be optimized
MD 35200 GEAR_STEP_SPEEDCTRL_ACCEL X
[1]
MD 35210 GEAR_STEP_POSCTRL_ACCEL[0] X Acceleration in position control mode
To be optimized
MD 35210 GEAR_STEP_POSCTRL_ACCEL[1] X
MD 35500 SPIND_ON_SPEED_AT_IPO_START 2 Feedrate enable for spindle in the set range
MD 35550 DRILL_VELO_LIMIT[0] 4000 Maximum spindle speed for tapping
MD 35550 DRILL_VELO_LIMIT[1] 4000
MD 36000 STOP_LIMIT_COARSE 0.4 In position course limit
MD 36010 STOP_LIMIT_FINE 0.1 In position fine limit
MD 36030 STANDSTILL_POS_TOL 5 Standstill tolerance
MD 36040 STANDSTILL_DELAY_TIME 1 Delay for standstill monitoring
MD 36050 CLAMP_POS_TOL 1 Clamping tolerance
MD 36060 STANDSTILL_VELO_TOL 2 Tolerance for ―Axis/spindle‖ stopped
MD 36200 AX_VELO_LIMIT[0] 8800 Threshold for velocity monitoring
MD 36200 AX_VELO_LIMIT[1] 8800
MD 36300 ENC_FREQ_LIMIT[0] 100000 Encoder limit frequency
0
MD 36300 ENC_FREQ_LIMIT[1] 100000
0
MD 36400 CONTOUR_TOL[ 30 Tolerance band for contour monitoring
P 1433 SPEED_CONTROLLER_REFERENC x Same as the axis which interpolates with

E_MODEL_NATURAL_FREQUENCY The spindle e.g.Z

Section 7 Spindle Optimization
Notes
Field and Current Controllers:
The field controller gain, (Kp, P 1590[0], and Tn, P 1592[0]), and current controller
gain, (Kp, P 1715[0] and Tn, P 1717[0]), settings are automatically calculated and
entered into the relevant parameters at the time of start-up based on the motor
data and power module current rating. These settings match the motor to the
drive and do not require further optimization.
Speed controller gain settings:

The speed controller gain settings, (P 1460 through P 1465) are automatically cal-
culated and entered into the relevant parameters at the time of start-up. The de-
fault values are based on the motor data and power module current rating.
7.1 Carry out a frequency response measurement on the speed controller
Select ―Startup‖ then

―Optimiz./test‖.
Select ―Axis +‖ until

the Main Spindle is
reached.
Then Select ―Speed

contr. Loop‖
and then Type of
Measurement ―Refer
frequency response
(after speed setpoint
filter)‖

Spindle Optimization Section 7
Notes
Enter the measur-

ing parameters as
shown.
Select
―Measurement‖
and then Select
―Start‖
You will then get a

message saying
Press NC Start.
Press ―Cycle
Start‖ on the Ma-
chine Control
Panel
When the meas-

urement I finished
Select ―Display‖ to
view the results.
Here it can be
seen that the Pro-
portional Gain of
the speed control-
ler can be in-
creased.

Notes
Select ―Drive MD‖ and

search for P1460.
This value can now

be increased and the
frequency response
measurement can be
repeated.
After increasing
P1460 it can be seen
that we have a reso-
nance at 660 Hz and
so we can build in a
current setpoint filter.
NOTE :- If a low resolution spindle encoder is being used and only noise can be
seen at higher frequencies (e.g. above 800Hz) then a value can be used in
P 1441[0] ACTUAL_SPEED_SMOOTHING_TIME. Values between 0.3—0.5 are
useful
Select the 2nd filter

and make it a Band
Stop filter.
Then enter in the rele-

vant parameters

Notes
P 1460 can now be

increased to keep
the amplitude re-
sponse at 0db to as
high a frequency as
possible
7.2 Speed Controller Gain Adaption :-For main spindle applications with en-
coder feedback the speed controller gain adaption function is enabled by default.
The function allows different proportional and integral gains to be active at low and
high speeds. The result is dynamic performance for tapping, threading and orien-
tation without having oscillation at high speeds.
The speed control-

ler adaption func-
tion is switched on
by default with
P1400 bit 5
P1460-P Gain lower

adaption range
P1461-Kp Gain adaption
speed upper scaling
P1462-I Gain lower adap-
tion range
P1463-Tn adaption speed
upper scaling
P1464-Lower adaption
speed
P1465-Upper adaption
speed
Example: P1460 = 8, P1461 =20%, Kp upper adaption = 8 x 20% = 1.6 Nms/rad

P1462 = 10, P1463 = 600%, Tn upper adaption = 10 x 600% = 60 ms
P1464 = 850, P1465 = 3400.

Notes 7.3 The position controller should now be optimized using a ―Ref frequency re-
sponse‖ measurement. For this measurement Feed Forward should be switched off
therefore MD 32620 FFW_MODE = 0.
Because the spindle will interpolate with the Z axis during tapping/threading it is best
to try to keep the same values in MD 32810 EQUIV_SPEEDCTRL_TIME, MD 32200
POSCTRL_GAIN (check parameter sets) and
P1433SPEED_CONTROLLER_REFERENCE_MODEL_FREQ.
Select ―Position contr

loop‖
and then Type of
measurement ―Ref
frequency respo‖
Select ―Measuring pa-

rameters‖ and then
enter tha values
shown.
Bandwidth 166 Hz for

Position controller cy-
cle 3ms, 333 Hz for
Position controller cy-
cle 1.5ms

Notes
Select
―Measurement‖
and then Select
―Start‖
You will then get a

message saying
Press NC Start.
Press ―Cycle
Start‖ on the Ma-
chine Control
Panel
When the meas-

urement is fin-
ished select
―Display to view
the results.
It can be seen
here that MD
32200 can be in-
creased but the
amplitude should
not come above
0db
Select ―Axis MD‖

and search for
32200.
The value can

then be increased

Notes
The result here

shows that MD
32200 was in-
creased to bring the
amplitude closer to
0db but it should not
rise above the 0db
line
Feed Forward should now be switched back on.

7.4 A part program should now be created to check the spindle positioning
without overshoot, and the servo trace function should be used to view the results.
LAB:
SPOS=0
G4 F1
SPOS=130
G4 F0.2
GOTOB LAB
M30

from the ―Startup‖,
―Optimiz./test‖ menu

Notes
Enter the Trace

selections as
shown.
The part program

should be selected
in Automatic Mode
and then ―Cycle
Start‖ on the ma-
chine control panel
should be pressed.
Once the program

is running Select
―Start‖ .
Once the trace

function has fin-
ished Select
―Display‖ to view
the results.
There should be no
overshoot as the
spindle comes in to
position.
MD 35210[0]
GEAR_STEP_POS
CTRL_ACCEL can
now also be in-
creased but no
overshoot should
be seen.
In some cases it
may be necessary
to switch drive pa-
rameter sets in or-
der to optimize per-
formance in differ-
ent gear ranges

Notes
7.5 A check should now be made of the speed control acceleration. Firstly iden-
tify the acceleration time without any influence by the NC.
Set MD 35200[1] $MA_GEAR_STEP_SPEEDCTRL_ACCEL to a maximum e.g.

9999 rev/s2 ( t=V/a t=9000/60s/9999 t=15ms therefore no influence)
Now look at the motor data sheet
E.g. 1PH7101-2QF02-08J3 asynchronous motor

Notes
Acceleration/deceleration with the original motor data equates to the S1 curve
P640 Current limit 14,97 A

(P305 rated motor current x1,5)
P1121 Ramp function generator ramp-down(ori10s) 0s
P1520 Torque limit upper/motoring 23,55 Nm
P1521 Torque limit lower/regenerative -23,55 Nm
P1530 Power limit motoring 3,70 KW
P1531 Power limit regenerating -3,7 KW
P326 motor stall torque correction factor 78 %
Select ―Servo
trace‖ from the
―Startup‖, ―Optimiz./
test‖ menu
Enter the Trace

selections as
shown.
Select
then ―Start‖
Once spindle ac-

tual speed is above
5 rpm the trace will
start.

Notes
Enter a program in MDA.
S9000 M03
G04 F3
M30
Then press ―Cycle Start‖ on the machine control panel.
Once the trace func-

tion has finished Se-
lect ―Display‖ to view
the results.
The trace shows the acceleration taking 2.8 seconds from 0 to 9000 rpm and the
torque and power values relate to the motor S1 curve
Acceleration/deceleration with modified motor data equates to the S6 curve

Enter the values from the S6 curve as below.

P1520 Torque limit upper/motoring 40 Nm
P1521 Torque limit lower/regenerative -40 Nm
P326 motor stall torque correction factor (original 78 %

value)
Now repeat the servo trace test with the MDA program

Notes
The trace now shows the acceleration taking 2.3 seconds from 0 to 9000 rpm and
the torque and power values relate to the motor S6 curve
7.6 Acceleration/deceleration with modified stall torque correction factor.
The motor stall torque correction factor P326 can be modified to further improve
the acceleration.
This value is write protected when P300 = 107 ( 1PH7 induction motor)
First change P10 = 3 ( Motor commissioning)

Then P300 = 1 ( Induction motor)
Now P326 can now be adjusted
P10 should be returned to 0
P326 =100 %
Acceleration now
1.77 seconds

Notes
P326 =120 %
Acceleration now
1.58 seconds,
however under-
shoot can be
seen in the ac-
tual current trace
when decelerat-
ing and so P326
= 120 is too big.
P326 =105 %
Acceleration now
1.75 seconds,
this appears to
be the optimum
setting

P1520 Torque limit upper/motoring 40 Nm
P1521 Torque limit lower/regenerative -40 Nm
P326 motor stall torque correction factor 105 %
Adjust MD 35200[1] $MA_GEAR_STEP_SPEEDCTRL_ACCEL to give the machine

tool builders requirement for spindle acceleration

Notes
7.7 Circularity test to check Solid Tapping:

When tapping the NC system automatically switches the Z axis and Spindle into
the relevant parameter sets. If the Spindle has no gear ranges then both the Spin-
dle and the Z axis are switched into parameter set 2 i.e. [1].
The NC system also always switches into Feed Forward during tapping and there-
fore it is important that Feed Forward has been commissioned on the Z axis and
also that speed controller adaption has been used on the Spindle (see relevant
sections). It is also important that all of the time constants are similar between Z
and Spindle. (Equiv_Speedctrl_Time, Speedctrl_Ref_Model_Freq etc)
In order to see any error between Z and Spindle it is best to run a circularity test
program with the X and Z axes and then to use the Coupled axis feature to link the
Spindle with the X axis. You can then to view a circularity test between the Z axis
and the Spindle. Any errors in the circle between Z and Spindle can then be seen.
Circularity test:
A circle test part program and the circularity test start up tool can be used to
measure the actual size and shape of a given test circle.
Example of an X-Z circle part program with Spindle coupled to X axis
FFWON
SOFT
TRAILON(SP1,X,1)
G90 G01 F3000 X400 Z400
LAB:
G91 G64 G02 X0 Z0 I10
GOTOB LAB
M30
Select ―Circularity
test‖

Notes
Enter the values as

shown.
Then select the part

program in Automatic
mode and press
―Cycle Start‖ on the
machine control
panel.
Once the program is

running select ―Start‖
Once the circularity

test is finished select
―Display to see the
result.
NOTE spindle resolu-

tion is in fractions of a
degree.

Advanced Surface Section 8
Notes
8.1 Use the following Technology G groups
DYNNORM ( Standard Setting )

DYNPOS ( Standard Setting )
DYNROUGH ( AS - Setting )
DYNSEMIFIN ( AS - Setting )
DYNFINISH ( AS - Setting )
With the Technology G Groups a defined parameter state exists for each setting.
Because of this no machine data is ever overwritten and therefore at any time the
parameters are in a clearly defined state.
The following machine data are effective in the Technology Group
MD 32300 MAX_AX_ACCEL [0..4]

MD 20600 MAX_PATH_JERK [0..4]
MD 32431 MAX_AX_JERK [0..4]
MD 32432 PATH_TRANS_JERK_LIM [0..4]
MD 32310 MAX_ACCEL_OVL_FACTOR [0..4]
MD 20602 CURV_EFFECT_ON_PATH_ACCEL [0..4]
MD 20603 CURV_EFFECT_ON_PATH_JERK [0..4]
MD 32433 SOFT_ACCEL_FACTOR [0..4]
NOTE : - Check that there are no existing subroutines or cycles that over-
write these machine data. Also consider Cycle 832 and Cycle 832T. When
the Technology G Groups are used there is no longer a reason to over-
write machine data via cycles etc
!!!!!! Simplify the handling of the parameters as much as possible !!!!!

Section 8 Advanced Surface
Notes
8.2 Reduce the axis acceleration in the 5th Technology G Group ( DYN-
FINISH )
Even on very dynamic machines machines an acceleration of 2 m/s2 is rarely

reached ( limited by axial jerk) during finishing operations. Therefore reduc-
ing the acceleration in the 5th Technology Group rarely has an effect on the
processing time of the component, however it has the effect with LOOKA-
HEAD of a smoother path velocity
Recommendation :- MD 32300 MAX_AX_ACCEL = 1…..2 m/s2
8.3 De activate backlash and friction compensation
Under some conditions these compensations can lead to marks on the work
piece surface. If the cutting test has given a positive result and there is still a
requirement for friction compensation then adaptive friction compensation
should be used.
100
90
80
70
Switch Off amplitude in mm/min
60
50
Series1
40
30
20
10
0
0 0.1 0.2 0.3 0.4 0.5
Radial Acceleration in m/s^2
32520 FRICT_COMP_CONST_MAX 5 mm/min
32530 FRIDT_COMP_CONST_MIN 60 mm/min
32550 FRICT_COMP_ACCEL1 0.02 m/s^2

8.4 Monitoring of the AS function during operation using a Synchro-
nous Action
Using a synchronous action the variable $AC_IPO_STATE can be read and

this variable shows the state of the AS function
IDS=1 WHENEVER TRUE DO $R0=$AC_IPO_STATE
In the R parameter R0 the state of the AS function can now be observed.
Bit 0 = 0 Normal state

Bit 0 = 1 Advanced surface
Bit 1 = 0 COMPOF
Bit 1 = 1 COMPCAD
When finishing or when AS is required then Bit 0 = 1 and Bit 1 = 1

Notes
8.5 The following G-Codes must be active during AS processing
For 3 Axis operation
SOFT
COMPCAD
G642 for SW stands <= 72.05
G645 for SW stands >= 72.06
FIFOCTRL
FFWON
DYNROUGH, DYNSEMIFIN or DYNFINISH
8.6 Set $MA_MAX_ACCEL_OVL_FACTOR[4] to 1.01 for all axes for

operation with DYNFINISH

Notes 828D SL MACHINE DATA ADVANCED SURFACE

MD DESCRIPTION AS
10200 $MN_INT_INCR_PER_MM 100000 Manufact
10210 $MN_INT_INCR_PER_DEG 100000 Manufact
11400 $MN_TRACE_SELECT 0 System
11411 $MN_ENABLE_ALARM_MASK System
18360 $MN_MM_EXT_PROG_BUFFER_SIZE 500 Manufact
20150[3] $MC_GCODE_RESET_VALUES 3 FIFOCTRL Manufact

20150[44] $MC_GCODE_RESET_VALUES 2 UPATH Manufact
20170 $MC_COMPRESS_BLOCK_PATH_LIMIT 20 Manufact
20442[0] $MC_LOOKAH_SYSTEM_PARAM 0 System

20443[0] $MC_LOOKAH_FFORM 0 DYNNORM Manufact
20443[1] $MC_LOOKAH_FFORM 0 DYNPOS Manufact
20443[2] $MC_LOOKAH_FFORM 0 DYNROUGH Manufact
20443[3] $MC_LOOKAH_FFORM 1 DYNSEMIFIN Manufact
20443[4] $MC_LOOKAH_FFORM 1 DYNFINISH Manufact
20490 $MC_IGNORE_OVL_FACTOR_FOR_ADIS 1 Manufact
20550 $MC_EXACT_POS_MODE 3 Manufact
20600[0] $MC_MAX_PATH_JERK 10000 DYNNORM Manufact
20600[1] $MC_MAX_PATH_JERK 10000 DYNPOS Manufact
20600[2] $MC_MAX_PATH_JERK 10000 DYNROUGH Manufact
20600[3] $MC_MAX_PATH_JERK 10000 DYNSEMIFIN Manufact
20600[4] $MC_MAX_PATH_JERK 10000 DYNFINISH Manufact
20602[0] $MC_CURV_EFFECT_ON_PATH_ACCEL 0 Manufact
20603[0] $MC_CURV_EFFECT_ON_PATH_JERK 0 Manufact

20603[1] $MC_CURV_EFFECT_ON_PATH_JERK 0 Manufact Notes
20605[0] $MC_PREDYN_SMOOTHING_FACTOR 1 Manufact
20606[0] $MC_PREDYN_SMOOTHING_ON 0 DYNNORM Manufact
20606[1] $MC_PREDYN_SMOOTHING_ON 0 DYNPOS Manufact
20606[2] $MC_PREDYN_SMOOTHING_ON 0 DYNROUGH Manufact
20606[3] $MC_PREDYN_SMOOTHING_ON 1 DYNSEMIFIN Manufact
20606[4] $MC_PREDYN_SMOOTHING_ON 1 DYNFINISH Manufact
20607[0] $MC_PREDYN_MAX_FILT_LENGTH_GEO 2 Manufact
20608[0] $MC_PREDYN_MAX_FILT_LENGTH_RD 5 Manufact

20482 $MC_COMPRESSOR_MODE 100 Manufact
20484 $MC_COMPRESSOR_PERFORMANCE 9 System
28060 $MC_MM_IPO_BUFFER_SIZE 150 Manufact
28070 $MC_MM_NUM_BLOCKS_IN_PREP 80 Manufact
28302[0] $MC_MM_PROTOC_NUM_ETP_STD_TYP 28 System
28530 $MC_MM_PATH_VELO_SEGMENTS 5 Manufact
28533 $MC_MM_LOOKAH_FFORM_UNITS 18 Manufact
28540 $MC_MM_ARCLENGTH_SEGMENTS 10 Manufact
28610 $MC_MM_PREPDYN_BLOCKS 10 Manufact
29000 $OC_LOOKAH_NUM_CHECKED_BLOCKS 150 Manufact
32310[0] $MA_MAX_ACCEL_OVL_FACTOR 1,20 Manufact

32431[0] $MA_MAX_AX_JERK Standard DYNNORM Manufact
32431[1] $MA_MAX_AX_JERK Standard DYNPOS Manufact
32431[2] $MA_MAX_AX_JERK Standard DYNROUGH Manufact

32431[3] $MA_MAX_AX_JERK 20,00 DYNSEMIFIN Manufact
32431[4] $MA_MAX_AX_JERK 20,00 DYNFINISH Manufact
32432[0] $MA_PATH_TRANS_JERK_LIM Standard DYNNORM Manufact
32432[1] $MA_PATH_TRANS_JERK_LIM Standard DYNPOS Manufact
32432[2] $MA_PATH_TRANS_JERK_LIM Standard DYNROUGH Manufact
32432[3] $MA_PATH_TRANS_JERK_LIM 20,00 DYNSEMIFIN Manufact

Notes 32432[4] $MA_PATH_TRANS_JERK_LIM 20,00 DYNFINISH Manufact

32620 $MA_FFW_MODE 3 Manufact
42471 $SC_MIN_CURV_RADIUS 1 Manufact

828D Servo Optimisation

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828D Servo Optimisation

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B100 Sinumerik 828D

Basic Servo Optimisation

Content of the module:

Current Controller Optimisation

Speed Controller Optimisation

Velocity Feed Forward

B100 Page 2 SINUMERIK 828D Training, Operation and Service

Activating Machine Data changes Notes

Throughout this procedure, certain machine data changes need to be activated.

po The relevant machine data requires an ―NCK Reset‖ to take effect

Saving Drive settings

In order to save drive data:-

Controller Block Diagram

SINUMERIK 828D SL PROFIBUS –DP DRIVE

SINUMERIK 828D Training, Operation and Service Page 3 B100

- Press the “Axis +” or “Axis - ” softkey to select the desired axis.

Current control Description Active

Frequency Response Tool Display:

B100 Page 4 SINUMERIK 828D Training, Operation and Service

P1400 bit3 Speed controller reference model enable x

SINUMERIK 828D Training, Operation and Service Page 5 B100

B100 Page 6 SINUMERIK 828D Training, Operation and Service

- A reference frequency response of the current controller is a useful check of the

Select ―Start up‖

SINUMERIK 828D Training, Operation and Service Page 7 B100

Select ―Curr contr

!!!!! Information !!!!!

The amplitude will

B100 Page 8 SINUMERIK 828D Training, Operation and Service

You will then get a

Example of P1715 Example of P1715

SINUMERIK 828D Training, Operation and Service Page 9 B100

Speed Controller Optimization Procedure Summary

Speed Controller Optimization Procedure

B100 Page 10 SINUMERIK 828D Training, Operation and Service

!!!!! Information !!!!!

Also switch the

SINUMERIK 828D Training, Operation and Service Page 11 B100

Move cursor bar down to enter ―Ramp-up time‖

You will then get a

Press ―Cycle Start‖

Pole at 769 Hz Pole at 1600 Hz

When the measure-

Pole at 769 Hz Pole at 1600 Hz

Estimate notch depth, here –14db & -16db

Example settings in this case are :- ( These values should be recorded )

It is now a good idea to make the same measurement up to a bandwidth of 400 Hz

SINUMERIK 828D Training, Operation and Service Page 13 B100

You will then get a

Press ―Cycle Start‖ on

Take a note of the fre-

B100 Page 14 SINUMERIK 828D Training, Operation and Service

P1460=(Motor Inertia)P341*1200= Example 0.001510kgm²*1200=1,812kgm²

Be sure that Dynamic stiffness control is disabled MD32620 = 0

Attention: On a vertical axis without a counterbalance e.g. the Z-axis on a ―C

Select ―Drive MD‖

SINUMERIK 828D Training, Operation and Service Page 15 B100

Search for 1462 and

This makes Tn inef-

B100 Page 16 SINUMERIK 828D Training, Operation and Service

You will then get a

Press ―Cycle Start‖

When the measure-

SINUMERIK 828D Training, Operation and Service Page 17 B100

P1460=(Motor Inertia)P3411200= Example 0.001510kgm²1200=1,812kgm²