Electric Drives Technical Training For Pneumatic Sales Engineers

Electric Drives Technical Training for
Pneumatic Sales Engineers
Part 6
Abteilung/Name Projektname 30.03.23 1

Enabling High Performance
TUNING

What is Tuning?
• The load consists of a motor/resolver (or encoder),
gearing and the driven load.
• Each may have the properties of inertia, friction,
backlash and compliance.
• Each of these properties affects how the system
responds
• Tuning is the process by which you adjust the servo
parameters to obtain the best trade-off between
performance and stability.
• Stability is the freedom from oscillation under the full
range of operating conditions.
• Performance could be steady-state accuracy, settling
time, dynamic accuracy or more usually, a
compromise between them.

Why tune a motion control system?
Unstable
Before Tuning
Needs a tune up
Over time the strings Stable
become loose
Tuned

Servo Loop Tuning

Servo Loop Tuning

Basic Position Loop
KP = Position Loop Gain

Control Loops

Tuning Goals

Problems - Backlash

Solutions to Backlash

Natural frequency of vibration
Motor Coupling or Gearbox - Load

acts like a spring
Compliance / backlash in the coupling or gearbox cause a
momentary delay / jerk before the load moves
Load and motor in motion

Tuning Fork
Motor reaches target position and stops
Backlash reverses and the load inertia jerks the system

Resonance away from target position causing the motor to reverse

Problems - Resonance

Resonance

Solutions for Resonance

Things to Remember

Solution for Backlash and Resonance with help of FCT
Step 1. Set current motor-axis configuration
(e.g. dimensioned in PositioningDrives)

Solution for Resonance with help of FCT
Step 2. Set current environment and maximal load

Solution for Resonance with help of FCT
Step 3. Push the button Calculate in Close Loop section
 Ready!

The way: from Task over BoM to Commissioning
Needed: x-axis:
- defined force
- defined velocity ?
- defined precision What to take
- defined acceleration and how to choose?
-
-
Result: BoM
Commissioning:

Sizing a system
POSITIONING DRIVES
SOFTWARE

PositioningDrives Software - Basics
m
Quick Start Extended by advanced session
Result parts list
Selected result information Extended by advanced session
Help
Drive selection exercises Extended by advanced session

Quick Start – Minimum motion specification
Required inputs
• Assembly position
• Dynamics: moved mass (m)
• Kinematics: maximum stroke = required usable length (L)
• Repetition accuracy
Main product filter inputs

1. Construction: Gantry 1. Construction: Cantilever
2. With or without integrated guide 2. With or without integrated guide
m
m
m
L L

Quick Start – System parameters
Part 1: Task description
Required inputs
1 Assembly position
Assembly position horizontal 0 °
See advanced session
1 5
6 2 Maximum moving mass

2
3 Usable length
3
4 4 Repetition accuracy
5 Options: (additional) external force
F = 0: Pure positioning task
6 Motion profile description

Default motion profile: „Usable
length, no time restriction“.
Travel time limited by maximum
product acceleration /speed
Quick Start – Motion profile „Usable length, no time restriction“
1 Calculation result of the motion is optimized travel
time (i.e. shortest travel time)
2 Optional pause time is important for dimensioning
servo motors
• Default is 200 ms which is an established value
coming out from experience
1 Default selection
Default value

Quick Start – Detailed motion profile
1
„Detailed motion profile“ is a set of motion steps
It can be described by values for position, speed,
acceleration, pause time, etc.

Quick Start – Motion profile „Critical stroke“
1
A specified displacement within a
2
maximum travel time
3
Calculated motion is travel time optimized
(i.e. shortest possible travel time)
Pause time
• is calculated with maximum duty ratio
duty ratio = travel / (travel + pause)
• is not shown in the diagram
• default minimum duty ratio is 25 %
1

Quick Start – Motion profile „Pause Time“ input
1 Environment temperature
Default = 25 °C
Settings | User defined  Data valid for a specific user Considered with motor calculation
2 Pause time for servo motors at

motion profile „Usable length, no
time restriction“
Default: TPause = 0,2 s
4
3 Minimum duty ratio at motion
1
profile: „Critical stroke“
2
3
Default: Duty ratio = 25 %
Deviations from default can be stored
4 Project values different from settings

are shown during project loading

Quick Start – System parameters
Part 2: Product filter
Sample: Gantry
Main product selection
1
Guide
integrated or not
2 Axis construction
Gantry or Cantilever
Sample: Gantry
3 Axis technology list

1
3
4 Selection filter
2 4

Quick Start – Selection filter in addition to System
parameters
1 „New products“ are
• CMMS-ST, CMMP-AS, EMMS-
ST, EMMS-AS, EMGA, EGSA
1 2 Axis housing
2 For gantry axis, a dust protected

3 version (axis cover) is available.
3 Motor brake
2 Only with
.. is recommended if downhill-slope
4 gantries!! force is bigger than the friction of
the
axis = „Festo recommendation“
4
Selection/deselection is possible in
4 any case
Guide of gantry actuators
The most popular types of guide
are marked by default.
Cantilever axis have no different
Abteilung/Name Projektname guides and no dust protection.
30.03.23 30
Quick Start – First result overview
Sample: Cantilever
1 Available product technologies

Calculated without time restriction :
a = 0,01 m/s2
In this sample, all technologies offer
at least one solution
Travel time
2 Button „Calculate travel times“

1 2
3 Time ranges after simulation:
3 beside detailed motion profile, as
fast as possible!

Quick Start – Guide
1 Enter distances of load

Attention: take care about the
2 axis coordinate system!
3 Available product families,

calculated without time
restriction
2 4
3 Table of product families

4 suitable after calculation
1 without time restriction : a
= 0,01 m/s2

Quick Start – Guide load
Attention: Axis coordinate system!

Coordinate system of load is related to drive.
Gantry Cantilever
m m
Up or down
90° 90°
Sideways
m m

m
Result parts list
Help

Result parts list – Selection of a system
Result list shows
1 Optimum sizes
Suitable size plus next one
2
Technology description
without Festo designations
first sorting by product costs
3
Visual comparism of continous load
based on
1 3 fastest possible motion or
motion profile inputs
2 See advanced session
4
4
Report filter
allows additional selection of
specific sizes

Result parts list – Report
filter
Sample: Cantilever
1 „Freely selectable“
Specific required axis sizes can be
selected
1 Thus, defined solutions can be
determined for evaluation
2
2
Available diameters are displayed
in an additional check box.
Sizes beyond the 2 optimum sizes can
also be selected

Result parts list – Main components
Visual impression about main

components
1 • Images and designations
2 • Gear ratio and supply voltage
3
1
Performance data overview
3 • Application requirements
4
4 • Cycle time = travel + pause
2 Pause time set in menu „Settings“
Hints about impact on equipment

5
• Standard info: Maximum speed,
acceleration /deceleration
5 • Further hints about system
behaviour

Result parts list – Parts list
1 • Main components
• Mounting kits Axis – Motor
with DMES, EGSA and DNCE
1 Export functions for Excel

2 •Parts list table format
3 •Festo basket format
2 3
4
Reduction of order length
4 •in order to get a competable
size (length) of the applied
linear drive
•only with X – length axes
stroke reserve is reduced

Result parts list – Open
basket
www.festo.com
With this URL you will go to the

1
site of the country you selected
before.
2 Save it as a „favorite“
1
2 Select menu „Online Shop“,

„Shopping basket“

Result parts list – Import into Festo shop basket
1 Import PositioningDrives
parts list from file
2 Verify / complete order code

of set products
1
3 Select accessories if required

Project data
Descriptions about
1 • customer
2 • Project
1 2
Data are stored together with the
project

Result parts list – Project documentation
1 Select one or more project

document pages
2 Alternatively, select list of

possible solutions
3 Select the document type

1
• Preview
• Paper
2
• File
1
3
4
If a file only has to be stored,
4 deselect „Open file“

Save project
2 3 4
1 1 Save with button „Save“
2 Save with menu File | Save
3 Save with menu File | Save As
4 Last 4 project can be found

in menu „File“

m
Result parts list
Help

Selected Result information: Component load and Travel time
1 Axis feed force:

axis feed force required by applic. /
maximum feed force
2 Motor torque:
motor torque required by applic. /
maximum motor torque
3 Guide
Sum formula: see catalogue
4 Cycle time = travel time + pause time
4
+ 5 Hints for system behavior:
1 2 3 •downhill-slope force is bigger
than the friction of the axis (with
assembly positions > 0 °)
•Possible oscillating cantilevers with
load distances y, z > 0 mm
5
•External braking resistor (if needed)

Selected Result information: Component Load
• Remember: without detailed motion profile

• motion as fast as possible with the given product properties
• Maximum possible load is ..
1. limited by one of the maximum component loads
• Axis: usable feed force for moving load
• Motor: motor torque < maximum torque at axis shaft
• Guide: distances of load (see page „Guide“)
2. limited by maximum component dynamic properties

• acceleration / deceleration
• e.g. toothbelt, axis size 25: Maximum feed force 260
N
• Required force = mass * maximum acceleration: 1 kg * 50 m /s2 = 50 N
  1/5 of maximum force is used
• Speed
3. See advanced session

Selected Result information – Result diagram values
1
Travel time
• with motion profile
usable length, no time limit
critical stroke
• with detailed motion profile
cycle time
3
see advanced session
2 Pause time
• with servo motors
4 • with profile „Usable length, no time
1 limit“
2
3
Values of current cursor position in
the diagram
4
Maximum values of
• complete motion profile or
• one selected step
Selected Result information – Result diagram operation
1
Context menu
• click the right mouse button to open
the options window
• select one specific profile step
with detailed • select all steps for display
motion profile • if required, modify the color of the
curves
Zoom
• mark area with mouse
• double click diagram to return
to 100 %
Selected Result information – Dynamic (calculated) data
1 Header shows main information about
selected solution
Calculated data
1 2 Axis
3 Motor
4 Mass moment of inertia
2 3
• Ratio is indicating controllability of
motor
JMotor + Jexternal
• Inertia ratio =
JMotor
4
• see advanced session
5
5 External braking resistor
• If internal resistor not able to match
braking energy loss use external
component
Selected Result information– Product data Axis
Displayed data
Axis: linear features

1 • catalogue data
2 • planning limits
3 Toothbelt / pinion:
1 rotary features of the axis

Selected Result information – Product data Motor
Displayed catalogue data
1 Motor
2 Controller
3 Gear
if part of system calculation

Selected Result information – Calculation relevant features
System data
1 Show order code explaination
2 Additional information
• hint „no brake“
• additional components
resulting from calculation
- axis: assembly kits
1 1 - motor: gear
3 Ambient temperature
2 • used for simulation
• input in Settings / user defined

m
Result parts list
Help

Help with maximum input values
1 For all selected axis technologies,
maximum product values are set
• Stroke, mass, force
3
• Speed, acceleration / deceleration
4
After input, value is compared with
maximum
2 If input value exceeds maximum

product value
2 • inputs marked is red coloured
1
3 • a message shows possible
measures
4
• a. o. message shows valid value
range
If combinations of inputs values fail

a messages appears, too.

Help with Motion profile
inputs
For all selected axis technologies,
maximum product values are set
• Stroke, mass, force
(system parameters)
• Speed, acceleration / deceleration
1 Input values are compared with

product or calculated maximum
2 If input value exceeds product or

calculated maximum value
1 • input marked in red
2 • a message shows maximum value
or reason
Calculated limit values


Help Menu
1 Internet link
1
2 INFO: Product range
2
3 3 Guided tour
4 (see next page)
4 Introduction: main
software functions

Help – Guided Tour
1
Guided tour shows
1 operation of the tool
Languages: ENGB and
DE
Menu: ? | Guided Tour
2
2
Proceed Guided Tour
with
button „next>>“
Currently available for

linear drives application

PositioningDrives Software - Advanced
m
Result parts list
Help

Topics:
Useful details
• Motion Profiles (Usable length/Critical stroke/Detailed)
• Guide integrated – a small tag with big effect
• Orientation of external force
• Profile Calculation Tool
Understanding and evaluating the results

• Range of suitable solutions
• Utilization (Axis / Motor / Guide)
• Information in Details page
Exercises

Useful details - Motion Profile
3 options for
Motion Profile
selectable
General Hint:
Pay attention to the Dynamic Help!
Important information is shown here.

• Usable length, no time restriction … means
+ Calculation of full stroke in positive direction as fast as possible
+ Optimization of speed and acceleration for time optimal movement
 Different travelling times for the resulting drive systems Full Stroke
+ For servo motors a pause time is used – default is 0.2 s *)
• Detailed Motion Profile … means

+ Motion Profile can be defined in detail (many options, separate page)
+ For a well-defined motion(e.g. with speed & acceleration) this profile is calculated
+ If profile is ambiguous (e.g. only speed given), time optimal movement is calculated
• Critical Stroke … means

+ Calculation of given stroke as fast as possible (Optimization like 1.)
+ Only systems faster and equal the demanded travel time are results.
+ For servo motors a minimum duty ratio is required – default is 25% *) Any
Distance
*) Value can be changed in Settings/Uses defines

When to use which Motion Profile Option?

1 2 3
Fast overview which systems come into question generally? 1
Fast overview over possible positioning times for a certain stroke ? 2
Certain travel time (movement time) for full stroke required? 2
Certain cycle time (travel time plus dwell time for operating) required? 3
Certain constant speed required? 3
Comparison of the utilization (motor, guide, axis load) of different drive systems? 3
Calculation of movements with varying mass or external force? 3
Useful details - Guide integrated – a small tag with big effect
Option ‘Guide integrated’ checked means:

• Only actuators with integrated guiding systems taken into account , i.e.:
Gantry axis: DGE-ZR-KF, DGE-SP-KF, DGE-ZR-RF, DMES-KF, DMES-GF
Cantilever axis: DGEA, EGSA, HME, SLTE, DNCE with FENG
• Additional page ‘Guide’ to put in the load arrangement (lever arms for mass and force)
• Guide load is calculated and if o.k. (i.e. < 100%) displayed as utilization in the result list
• In case of time optimization, eventually reduced acceleration not to overload guide
Option ‘Guide integrated’ not checked means:

• Only drives without guiding systems:
Gantry axis: DGE-ZR without KF, DGE-SP without KF, DMES without KF or GF
Cantilever axis: DNCE without FENG
• No guide load calculation  Lateral forces and torques must be carried by external guide

Everything clear, but where is the big effect??
Email form somewhere:
REF: Error in PositioningDrives ?
Hi TSHQ
We have an application to move 15 kg over 500 mm and want to use a DNCE-BS but do no get
any solution with PositioningDrives tool. The crazy thing is, if I calculate the same vertical
there are results even with DNCE-40. Do you have an explanation for this?
 The calculation was done with ‘Guide integrated’ selected and the FENG guide of DNCE
is the limiting factor in this case. With an external guide it is no problem with DNCE-40.

Useful details - Orientation of external force
For the Motion Profiles ‚ Usable length‘ and ‚Critical stroke‘
Movement calculation is always done in positive direction indicated by the small black arrow.
‘Accelerating’ means a force in the direction of the arrow and ‘Decelerating’ against.
Accelerating force
Decelerating force
Horizontal (0°) Vertical up(90°) Vertical down(270°)

Useful details - Orientation of external force
In case of ‘Detailed Motion Profile’ :
Value of force can differ from step to step and direction is given via the sign:
Decelerating force
Accelerating force
Accelerating force
Decelerating force
Sign Rule: Positive forces act in positive direction of movement.

Negative forces act in negative direction of movement.
 If force has the same sign as movement direction we have an accelerating force

Useful details - Profile Calculation Tool
This tool helps you to fill out the motion

profile with correct parameter values.

Three phases of a motion:

1. acceleration
2. constant speed *)
1. 2. 3.
3. deceleration
*) constant speed phase may not exist for

short strokes and/or low acceleration
because maximum speed is not reached.

Meaning of the symbols as shown in the tool:

t traveling time
d positioning stroke (distance)
v maximum or constant speed
dv distance in constant speed phase
a1 acceleration
a2 deceleration
ta1 duration of acceleration phase
ta2 duration of deceleration phase
ta2 duration of constant speed phase
Motion profile can be defined by few inputs and other parameters can be calculated.
 Profile Calculation Tool makes this calculation easy
1 2 3
3 different options (cases) for input parameter:
t–d–v : time / stroke / speed
t–d–a : time / stroke / acceleration and deceleration
d – v – dv: stroke / speed / distance in constant speed phase

Sample:
>>> Given is the following details <<<

Critical stroke: 240 mm
Positioning time: 250 ms
max. acceleration: 24 m/s²
Which option for input parameter?
t–d–v : time / stroke / speed

t–d–a : time / stroke / acceleration and deceleration
d – v – dv: stroke / speed / distance in constant speed phase


>>> Questions you can answer now <<<
What is the necessary maximum velocity ?

What is the acceleration time ?
What is the time for the constant speed phase ?
Which stroke is traveled during the constant speed phase ?
What is the smallest stroke to reach the maximum velocity?
 Profile Calculation Tool is helpful for working

with motion profiles!

Understanding the results - Range of suitable solutions
Result list:

Which systems occur in the result list and which not?
 Possible systems, i.e. they fulfill the demands put in by the user
 Observe Filter settings! Default: Selection filter – no HD, no GV; Report filter – Optimum sizes (=2)
 Selection is based on list of possible systems , i.e. more combinations than in catalogue,
e.g. DNCE-63 + MTR-AC-70-..GB, DNCE-LS/DMES with AC servo but still no DNCE-BS/DGE-SP +

MTR-DCI
 New stepper motors EMMS-ST only with 48 V supply and Encoder (Limitation of current version)
 U-mounting of motor not implemented for DGE-SP and DMES (Limitation of current version)

Is a certain system really suitable ? Some topics to check.
• Is the machine frame stable enough to bear the dynamic loads?
• Observe warning hints in case of non horizontal drives without brake or …
for cantilever axis if center of gravity has distance to drive axis

• In case of MTR-DCI and DMES: Is the calculated service life sufficient?
 Settings/service life: number of cycles and shifts (MTR-DCI: 3000h DMES: 100 km )

• In case of servo motors (MTR-AC, EMMS-AS, HME, DC motors in SLTE or MTR-DCI ):
Cycle time = Travel time + Pause time (to be observed especially in ‘High Speed Applications’)
What is the pause time in case of stepper motors? Zero pause time / 100% duty cycle
Servomotors can deliver more than the nominal torque for a
limited time.
To avoid overheating the effective torque

Meff (RMS torque) must be lower than the nominal torque
curve.
Short Time Operation Range
M eff 
 M  t i
2
i
!
 M nom n 
 t i
Periods with low load like pause times 

More utilization of peak torque range 
Higher accelerations, i.e. shorter travel time
Observe correct pause time or duty cycle for calculation of servomotors and for direct drive HME
 additionally the maximum ambient temperature!

Understanding the results - Utilization of Axis, Motor and Guide
• Utilization bar indicates which component is the limiting factor of the drive system
• Definition of utilization:
Axis Maximum feed force in application / Nominal feed force of axis ( Fxmax,app/ Fxmax )
Motor Servo: Meff,app / Mnom(nmax,app) [app = calculated value of the application]
Stepper: Mmax,app / Mnom(nmax,app) [nmax,app = max. speed of application]

Guide Formula must be less than 1.0
Sample Application:

 Motor EMMS-AS-100-S is the limiting factor in combination with DGE-40-ZR-KF, i.e. Meff = Mnom
Same axis with stronger motor EMMS-AS-100-M instead of EMMS-AS-100-S

 Now the tooth-belt axis DGE-40-ZR-KF is the limiting factor, i.e. Fx max,app = Fxmax
Same motor but with DGE-40-ZR-…-RF

 Now the roller bearing is the limiting factor, i.e. =1
Same application with spindle drive selected leads to:
Why is no component fully utilized? (motion profile is still ‚Usable Length‘)

 Additional limitation is the maximum acceleration (6 m/s² for DGE-…-SP)
Still the same application, now with toothbelt- and spindle drive selected:
Which solution has the most reserve for a certain application?
Not possible to answer with this result list!

 Due to time optimization the different solutions have different travel times
(different acceleration values different loads for axis, motor and guide) ≠
 To compare the load on a common base, calculate with fixed motion profile
=
Same calculation with completely defined motion profile …
… leads to same travel time for all solutions:
Same motion profile is a common base for a comparison.

=
Understanding the results - Important information in Details page
Detail page shows additional information of selected drive system:

Dynamic data – Axis:
Required usable force *):

Maximum value of the available feed force - normally
in acceleration phase
Required torque:
Max. torque at the drive shaft of the axis to accelerate
and overcome internal friction and external forces
including gravitation.
*)
Maximum jerk:
Usable force is the force at the front end of the axis Calculated limitation of the jerk to take into account the
available to accelerate the user mass load and act time delayed accelera-tion of the real drive
against gravitational and external forces. The limit of (approximately).
the usable force can be found in ‘Product data axis’
Dynamic data – Explanation of the jerk:
Jerk is the change of acceleration. A real drive needs a certain time to reach its acceleration.
This is taken into account by using a - load and drive type depended - maximum jerk value.
Sample: DGE-ZR with 10 kg: amax=50 m/s², j=4840 m/s³, i.e. amax is reached after 10.3 ms
Stroke 500 mm Stroke 15 mm

Travel time 259 ms Travel time 48 ms
The limited jerk increases the travel time a bit (in above case less than 15 ms)
Only relevant for high speed motions (short time & high accelerations)

Dynamic data – Mass Moment of Inertia:
Jtrans
Jrot
Jext Gear: JG
RJ
Coupling: JC
Jtrans = ( jL · m + JW)/ i2 Motor: JM

m
J0 + j H · H
Jrot = ( J0 + jH · H + JC )/i2 + JG
Jext = Jtrans + Jrot Slide: JW
J ext  J M
RJ  Load: jL·m
JM
The moment of inertia ratio RJ is an important criteria for controllability of a drive system.
J  JM Applications with a higher RJ are more difficult to control

RJ  ext (hard to tune / oscillations / overshoot / loss of steps)
JM
Typical upper limits for the moment of inertia ratio RJ
16 For CMMP-AS with servo motors EMMS-AS
11 For SEC-AC with servo motors MTR-AC
8 For CMMS-ST with stepper motors EMMS-ST
6 For SEC-ST with stepper motors MTR-ST
1.2 For MTR-DCI with custom axis or rotary application
This criteria leads to an additional limitation of the mass!

For HME, SLTE, MTR-DCI with DMES the mass limitations are part of the catalogue data.

Dynamic data – Motor:
Acceleration torque:
Maximum value of the required motor torque - normally
in acceleration phase
Load torque:
Required motor torque during constant speed phase –
needed to overcome friction, external force and
gravitation
Root mean square torque:

Effective torque Meff
Any difference between the required torque axis and the load torque of the motor without gear?
The load torque of the motor is higher because the motor inertia has to be accelerated as well.

Electric Drives Technical Training for
Pneumatic Sales Engineers
End of Part 6

Electric Drives Technical Training For Pneumatic Sales Engineers

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KP = Position Loop Gain

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Motor Coupling or Gearbox - Load

Load and motor in motion

Motor reaches target position and stops

Backlash reverses and the load inertia jerks the system

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Result parts list

Selected result information Extended by advanced session

Drive selection exercises Extended by advanced session

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Main product filter inputs

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6 2 Maximum moving mass

6 Motion profile description

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See advanced session

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2 Pause time for servo motors at

4 Project values different from settings

See advanced session

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Main product selection

3 Axis technology list

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2 For gantry axis, a dust protected

1 Available product technologies

2 Button „Calculate travel times“

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1 Enter distances of load

3 Available product families,

3 Table of product families

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Attention: Axis coordinate system!

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Result parts list

Selected result information Extended by advanced session

Drive selection exercises Extended by advanced session

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