5.

SERVO FUNCTION DETAILS B-65270EN/08

5.9 UNEXPECTED DISTURBANCE TORQUE DETECTION

FUNCTION (OPTIONAL FUNCTION)

5.9.1 Unexpected Disturbance Torque Detection Function

(1) Overview
When a tool collides with the machine or workpiece, or when a tool is faulty or damaged, a load torque
greater than that experienced during normal feed is imposed.
This function monitors the load torque to the motor at servo high-speed sampling intervals. If it detects an
abnormal torque, it brings the axis to an emergency stop by issuing an alarm, or reverses the motor by an
appropriate amount.
In addition, the function enables the PMC to be used to switch the speed at warning occurrence or load
fluctuation.
NC software - An application on the PMC PMC ladder
PMC
uses a PMC ladder.
window
Disturbance load
Set unexpected
torque data disturbance torque
detection level.

Processes motor stop

TCMD Calculates Monitors disturbance
disturbance load load torque unexpected
Servo software
torque to the motor (at 1 ms intervals) disturbance torque
detection function

Amplifier Monitoring is performed at 1 ms

intervals to reduce stop time.
Actual acceleration
Collision

Table
Motor
Fig. 5.9.1 (a) Overview of unexpected disturbance torque detection

(2) Series and editions of applicable servo software

Servo software
CNC Remarks
Series Edition
Series 30i/31i/32i/35i-B 90G0 03.0 and subsequent editions
Power Motion i-A
Series 30i/31i/32i-A 90E0 A(01) and subsequent editions
90E1 01.0 and subsequent editions
Series 30i/31i-A 90D0 A(01) and subsequent editions HRV4
Series 0i-D 90C5 A(01) and subsequent editions
90C8 A(01) and subsequent editions
90E5 A(01) and subsequent editions
90E8 A(01) and subsequent editions

(3) Parameter adjustment methods

<1> Use SERVO GUIDE to observe the motor speed (SPEED) and estimated disturbance torque
(DTRQ).
(Example of channel settings on SERVO GUIDE)

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(See Chapter 7, " SERVO TUNING TOOL SERVO GUIDE " for detailed descriptions about how to
use the SERVO GUIDE.)

<2> Switch on the CNC.

<3> Enable the unexpected disturbance torque detection function

#7 #6 #5 #4 #3 #2 #1 #0
2016 ABNT
ABNT (#0) Specifies whether to enable the unexpected disturbance torque detection function as
follows:
0: To disable
1: To enable

Moreover, be sure to set 1 also the following parameters.

#7 #6 #5 #4 #3 #2 #1 #0
2200 IQOB
IQOB (#2) Specifies whether to eliminate influence of control voltage saturation when estimating
disturbance, as follows:
0: Not to take influence of control voltage saturation when estimating disturbance into
consideration
1: To eliminate influence of control voltage saturation when estimating disturbance

<4> Set up the parameters related to the observer.

2050 Observer gain

• When HRV1, HRV2, or HRV3 control is used:
[Standard setting value] 956 → To be changed to 3559.

• When HRV4 control is used:

[Standard setting value] 264 → To be changed to 1420

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2051 Observer gain

• When HRV1, HRV2, or HRV3 control is used:
[Standard setting value] 510 → To be changed to 3329.

• When HRV4 control is used:

[Standard setting value] 35 → To be changed to 332

NOTE
When using this function together with the observer, do not modify
the standard setting of the parameter above.
Observer:
Bit 2 of No.2003

<5> Make adjustments on the POA1 observer parameter.

2047 Observer parameter (POA1)

Turn the servo motor to perform linear back and forth operation at a speed equal to about
50% of the rapid traverse rate, and observe the motor speed (SPEED) and the estimated
disturbance value (DTRQ). The waveform observed before the adjustment should show
one of the following features:

NOTE
When a negative value is set for POA1, it is assumed to be |POA1|
× 10.

Example of measurement: 1000min-1 (when using a rotary motor)

Motor velocity

Estimated
disturb ance
value

Insufficient POA1 value Excessive POA1 value

Overshoot or undershoot on the
estimated disturbance value
Overshoot or undershoot on the
est imat ed disturbance value (in
the direc tion opposite to the
overshoot or undershoot caused
by an insufficient POA1 value)

Adjust the value of the observer parameter (POA1) so that neither an overshoot nor an
undershoot will not be observed on the estimated disturbance value at acc./dec. After
adjustment, the waveforms shown below should be obtained.
(A clear waveform as shown below may not be obtained in some machines. In such
machines, find the POA1 parameter value that can minimize the overshoot and
undershoot while watching the estimated disturbance waveform at acc./dec.)

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Motor velocity

Proper POA1

Estimated
disturbance valu

NOTE
The POA1 parameter is related to the load inertia ratio parameter
("velocity gain" on the servo screen) through the inside of the
software. When the load inertia ratio parameter is changed, the
POA1 parameter must also be changed. So, first determine the
load inertia ratio (velocity gain) when adjusting the servo.
If you must change the load inertia ratio (velocity gain) after the
POA1 parameter is determined, re-set the POA1 parameter using
the following expression.
(New POA1 value) =
(Previous POA1 value) ×
(Load inertia ratio value set after adjustment+256) /
(Load inertia ratio value set before adjustment+256)
Load inertia ratio: No. 2021
The velocity gain magnification (in cutting or high-speed HRV
current control) does not affect the setting of POA1.

(Details)
The observer estimates a disturbance torque by subtracting the torque required for
acc./dec. from the entire torque. The torque required for acc./dec. is calculated using
a motor model. The POA1 parameter corresponds to the inertia of the motor model.
If the parameter value differs from the actual value, it is impossible to estimate a
correct disturbance torque. To detect an unexpected disturbance torque correctly,
therefore, you must adjust the value of this parameter.
An estimated disturbance value when a usual condition is supposed to be related
only to frictional torque (for the horizontal axis), and proportional to the velocity.
Therefore, a program, like the one used for adjustment, that merely repeats simple
acc./dec. is supposed to generate a trapezoidal estimated disturbance torque
waveform like a velocity waveform.

<6> For the vertical axis, adjust the torque offset. (This is unnecessary for the horizontal axis.)
For the vertical axis, the estimated disturbance value is not centered at level 0. Torque offset
adjustment is done to center the estimated disturbance value at level 0.

2087 Torque offset parameter

[Unit of data] TCMD unit (7282 with the maximum current value of the amplifier)
[Valid data range] -7282 to 7282
(Example of torque offset setting)
Estimated disturbance values for constant-velocity movements in the + direction and
- direction are read. In the figure below, minimum value A (signed) is read in a
movement in the + direction, and maximum value B (signed) is read in a movement
in the - direction. A torque offset parameter setting is given using the following
expressions:
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A [Ap] + B [Ap]
Torque offset = × 3641
Maximum amplifier current value [Ap]

Estimated disturbance
value level 0
6.6A
Maximum
value B
Estimated disturbance
Minimum value center line
value A Influence by gravity

If you read the minimum value A and maximum value as –8.6 [Ap] and –4.5 [Ap] in
the above chart (the amplifier used is rated at 80 [Ap] maximum), the torque offset
parameter = -[(-8.6)+(-4.5)]/80×3641 = 596. The following chart applies when the
parameter is set with 596.

When the torque offset parameter is set, be sure to set the following parameter to 1.

#7 #6 #5 #4 #3 #2 #1 #0
2215 TCPCLR
TCPCLR(#1) The function for setting a value for canceling the torque offset at an emergency stop in
the velocity loop integrator is:
0: Disabled
1: Enabled

NOTE
When using the torque offset canceling function (bit 1 of parameter
No. 2215), do not use the function for adding a preload with a time
constant (bit 4 of parameter No. 2417).

<7> Compensate for dynamic friction.

(i) Method of canceling a dynamic friction in proportion to velocity
Measure an estimated disturbance value at a constant velocity. Then, by assuming this
measured value as a dynamic friction, set the proportional coefficient for a velocity and
dynamic friction compensation value.

2116 Dynamic friction compensation coefficient

[Unit of data] See the equation below.
[Valid data range] -264 to 264
[Measurement velocity] Rotary motor: 1000 min-1, Linear motor: 1000 mm/s

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Measure an estimated disturbance value at a measurement velocity, then set the results of
calculations made according to the table below.
Estimated disturbance value [Ap]
Dynamic friction compensation coefficient = × 440
Maximum amplifier current value [Ap]

NOTE
If the measurement velocity is too high, lower the measurement
velocity, and measure the estimated disturbance value. By
proportional calculation, obtain the estimated disturbance value at
the above measurement velocity.

Dynamic friction compensation value

No.1727(Series 15i)
No.2116(Series 16i and
so on)
Dynamic friction
compensation coefficient

Velocity
-1
1000 min (rotary motor)
1000 mm/s (linear motor)
Set a compensation value at a measurement
velocity, and correct the value proportional to the
velocity as a dynamic friction.

(Example of setting for a rotary motor)

- Suppose that the estimated disturbance value at 1000 min-1 is 1 [Ap] (the maximum amplifier current
value is 40 [Ap]).
Dynamic friction compensation coefficient = 1/40 × 440 = 11

Dynamic friction compensation Dynamic friction compensation

before setting after setting

Read value
A(A)

These portions represent The effect of dynamic friction is

disturbances due to dynamic reduced, and stable estimated
friction. An adjustment is made to disturbance values are obtained.
eliminate these portions.

(ii) Method of setting a dynamic friction as "portion proportional to velocity + constant portion"
and imposing a limit
If the compensation value for stop time to low-velocity movement is insufficient in adjustment
of (i), set a dynamic friction compensation value in the stop state. If the compensation value for
high-speed movement is excessive, a limit is imposed on the compensation value.

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Dynamic friction compensation value

No.2346
Compensation limit value
No.2116
Dynamic friction
compensation coefficient
No.2345
Compensation value in the
stop time

1000min-1 Velocity

Set a compensation value in the stop time a nd

a compensation limit value in addition to a
-1
compensation value at 1000 min .

2345 Dynamic friction compensation value in the stop state

[Unit of data] TCMD unit (7282 when the estimated disturbance value is equivalent to the maximum
current value of the amplifier)
[Valid data range] 0 to 7282
[Measurement velocity] 10 min-1 (rotary motor), 10 mm/s (linear motor)
The absolute value of a setting is used.

2346 Dynamic friction compensation limit value

[Unit of data] TCMD unit (7282 when the estimated disturbance value is equivalent to the maximum
current value of the amplifier)
[Valid data range] 0 to 7282
[Measurement velocity] Maximum feedrate
The absolute value of a setting is used.

(Method of setting)
First, measure an estimated disturbance value when a movement is made at a
maximum feedrate on the axis, then set the results of calculations made according to
the table below in "dynamic friction compensation limit value".
|Estimated disturbance value [Ap]|
Dynamic friction compensation limit value = × 7282
Maximum amplifier current value [Ap]

Next, measure an estimated disturbance value when a movement is made on the axis
at the measurement velocity (10 min-1 or 10 mm/s) for "dynamic friction
compensation value in the stop state", then set the results of calculations made
according the table below in "dynamic friction compensation value in the stop state".
Dynamic friction compensation value in the |Estimated disturbance value [Ap]|
= × 7282
stop state Maximum amplifier current value [Ap]

Finally, measure an estimated disturbance value when a movement is made on the

axis at the measurement velocity (1000 min-1 or 1000 mm/s) for "dynamic friction
compensation coefficient", then set the results of calculations made according the
table below in "dynamic friction compensation coefficient".
|Estimated disturbance value [Ap]|
Dynamic friction compensation coefficient = × 440
Maximum amplifier current value [Ap]

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<8> Set an unexpected disturbance torque detection alarm level.
Perform several different operations (sample machining program, simultaneous all-axis rapid
traverse acc./dec., etc.), and observe estimated disturbance values, and measure the absolute
maximum value.
Then, set up an alarm level.
+ Estimated disturbance value

Maximum
value
-

2104 Unexpected disturbance torque detection alarm level

Alarm level conversion uses the following expression.

Unexpected disturbance torque detection alarm level =
|Estimated disturbance value [Ap]|
× 7282+500 to 1000 approximately
Maximum amplifier current value [Ap]

NOTE
1 Add some margin (usually about 500 to 1000) to the alarm level to
be set.
2 If the "unexpected disturbance torque detection alarm level"
parameter is 32767, no unexpected disturbance torque alarm
detection is performed.

<9> Set a distance to be retraced at unexpected disturbance torque detection.

If the retrace amount parameter is 0, the motor stops at the point where an unexpected disturbance
torque was detected. To retract the tool from the location of collision quickly, set the retrace distance
parameter.
Conceptual diagram illustrating retrace

The tool plunges in at full torque.

No unexpected disturbance torque
detected
The tool go beyond slightly, and returns to
Unexpected disturbance torque the location where the unexpected
detected, but no retrace is performed. disturbance torque was detected.

Unexpected disturbance torque The tool is retracted from the location where
detected, and retrace is performed. the unexpected disturbance torque was
detected to avoid mechanical contact at the
Retrace distance ultimate stop position.

Collision Unexpected disturbance

torque detected

2103 Retrace distance

[Unit of data] Detection unit
[Setting value] Approximately 3 mm

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NOTE
When the tool is moving faster or slower than the velocity listed
below, the tool will not go back even if this parameter is set. It stops
at the location where an unexpected disturbance torque was
detected.
Let the value set in the retrace distance parameter be A:
Minimum retract velocity =
A × detection unit (μm) × 60/512 [mm/min]
Example)
When detection unit = 1 μm, and retract amount setting = 3000,
the minimum velocity at which the tool is retracted is:
Minimum retract velocity =
3000 × 1 × 60/512 = 352 [mm/min]

[2-axis simultaneous retract function at detection of an unexpected disturbance

torque]
Usually, retraction at detection of an unexpected disturbance torque is performed
only on the axis with which the unexpected disturbance torque is detected. However,
when an unexpected disturbance torque is detected on one position tandem axis,
retraction can be performed on the other position tandem axis as well by setting the
parameter below.

(Setting parameters)
To use the unexpected disturbance torque detection function, set the following bit to 1 for both the
master and slave axes.

#7 #6 #5 #4 #3 #2 #1 #0
2271 RETR2
RETR2(#2) With the unexpected disturbance torque detection function, 2-axis simultaneous retraction
is:
0: Not performed
1: Performed
In the parameter for the distance to retract, specify the same value for both the master and
slave axes. If an unexpected disturbance torque is detected on one of the axes, both axes
are retracted.
NOTE
1 This function can be applied only when position tandem control is
used on the same DSP. Do not use this function for any axis that
has not been set for position tandem.
2 If different values are specified for the master and slave axes, an
invalid parameter alarm is issued. (The detail No. of the alarm is
1033.)

<10>Run the machine with the alarm level set up.

If the unexpected disturbance torque detection function works incorrectly, increase the alarm level.
<11>Now adjustment is completed.

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