Denso SMT7 Instruction Manual

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Page 1

ROBOT

SMT7 CONTROLLER

INSTRUCTION MANUAL

(SUPPLEMENT)

Page 2

Specifications are subject to change without prior notice.

All products and company names mentioned in this book are trademarks or registered trademarks of their respective holders.

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Preface

Thank you for purchasing our SMT7 controller.

The SMT7 controller controls the positioning mechanism driven by an AC servomotor, e.g., X-Y table.

This manual is a supplement to the robot instruction manuals. Read through this manual in conjunction with manuals for robot systems configured with the RC7M controller, which are given on the next page.

Products covered by this manual: SMT7 controller and options

Controller System Configuration

SMT7 Configured with options given on pages 3 through 5.

Important

To ensure operator safety, be sure to read the precautions and instructions in "SAFETY PRECAUTIONS."

Cautions in handling and using the SMT7 controller

NOTES (1) If joint allocations are different between the SMT7 controller and

WINCAPSIII, transferring the arm data from WINCAPSIII to the controller may cause an error. If it happens, clear the error and transfer the data again.

(2) The SMT7 controller is customized for motors specified by each customer

in both hardware and software at the factory. The allowable combination of the controller's axes and motor types is printed in (2) SUBASSEMBLY on the "THE SETPRM LIST" labeled on the top of the controller.

According to the allowable combination, connect motors to the controller

correctly. Incorrect connection will result in a motor malfunction, controller overheat, motor overheat, and other problems.

(3) This product is not evaluated for EMC directive. When you export this

product to Europe, it needs to be compliant with EMC directive as a facility.

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How the documentation set is organized

The documentation set consists of the following books. If you are unfamiliar with this robot and option(s), please read all books and understand them fully before operating your robot and option(s).

SMT7 CONTROLLER INSTRUCTION MANUAL (SUPPLEMENT) -this book-

Describes the SMT7 controller designed for controlling the AC servomotor-driven positioning mechanism. Use this book in conjunction with other manuals.

GENERAL INFORMATION ABOUT ROBOT

Provides the packing list of the robot and outlines of the robot system, robot unit, and robot controller.

INSTALLATION & MAINTENANCE GUIDE

Provides instructions for installing the robot components and customizing your robot, and maintenance & inspection procedures.

STARTUP HANDBOOK

Introduces you to the DENSO robot system and guides you through connecting the robot unit and controller with each other, running the robot with the teach pendant, and making and verifying a program. This manual is a comprehensive guide to starting up your robot system.

SETTING-UP MANUAL

Describes how to set up or teach your robot with the teach pendant or mini-pendant. For the panel designer functions, refer to the Panel Designer User's Manual (SUPPLEMENT).

WINCAPSIII GUIDE

Provides instructions on how to use the programming support tool WINCAPSIII which runs on the PC connected to the robot controller for developing and managing programs.

PROGRAMMER'S MANUAL I, Program Design and Commands

Describes the PAC programming language, program development, and command specifications in PAC. This manual consists of two parts; Part 1 provides the basic programming knowledge, and Part 2, details of individual commands.

PROGRAMMER'S MANUAL II, PAC Library

Describes the program libraries that come with WINCAPSIII as standard.

RC7M CONTROLLER MANUAL

Provides the specifications, installation and maintenance of the RC7M controller. It also describes interfacing with external devices, system- and user-input/output signals, and I/O circuits.

ERROR CODE TABLES

List error codes that will appear on the teach pendant or mini-pendant if an error occurs in the robot system. These tables also provide detailed description and recovery ways.

OPTIONS MANUAL

Describes the specifications, installation, and use of optional devices. For the extension board "conveyer tracking board," refer to the OPTIONS MANUAL (SUPPLEMENT).

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SAFETY PRECAUTIONS

Be sure to observe all of the following safety precautions.

Strict observance of these warning and caution indications are a MUST for preventing accidents, which could result in bodily injury and substantial property damage. Make sure you fully understand all definitions of these terms and related symbols given below, before you proceed to the text itself.

WARNING

Alerts you to those conditions, which could result in serious bodily injury or death if the instructions are not followed correctly.

CAUTION

Alerts you to those conditions, which could result in minor bodily injury or substantial property damage if the instructions are not followed correctly.

Terminology and Definitions

Maximum space: Refers to the space which can be swept by the moving parts of the robot as defined by

the manufacturer, plus the space which can be swept by the end-effector and the workpiece. (Quoted from the ISO 10218-1:2006.)

Restricted space: Refers to the portion of the maximum space restricted by limiting devices (i.e., mechanical stops) that establish limits which will not be exceeded. (Quoted from the ISO 10218-1:2006.)

Motion space: Refers to the portion of the restricted space to which a robot is restricted by software motion limits. The maximum distance that the robot, end-effector, and workpiece can travel after the software motion limits are set defines the boundaries of the motion space of the robot. (The "motion space" is DENSO WAVE-proprietary terminology.)

Operating space: Refers to the portion of the restricted space that is actually used while performing all motions commanded by the task program. (Quoted from the ISO 10218-1:2006.)

Task program: Refers to a set of instructions for motion and auxiliary functions that define the specific intended task of the robot system. (Quoted from the ISO 10218-1:2006.)

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1. Introduction

This section provides safety precautions to be observed for the

robot system.

The installation shall be made by qualified personal and should confirm to all national and local codes.

The robot unit and controller have warning labels. These labels alert the user to the danger of the areas on which they are pasted. Be sure to observe the instructions printed on those labels.

Warning label Instructions printed on the label

Label (1)

Risk of injury.

Never enter the restricted space.

<HM>

Label (2)

For UL-Listed robot units only

Risk of injury.

This label alerts the user that pressing the brake release switch could drop the arm.

Label (3)

Risk of electrical shock.

Never open the controller cover when the power is on.

Never touch the inside of the controller for at least 3 minutes even after turning the power off and disconnecting the power cable.

2. Warning Labels

(Example: Location of labels)

Label (4)

Risk of injury.

Be sure to perform lockout/tagout before starting servicing.

Turning the power ON when a person is inside the safety fence may move the arm, causing injuries.

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SAFETY PRECAUTIONS

3. Installation Precautions

3.1 Insuring the proper installation environment

 For standard type and

cleanroom type

The standard and cleanroom types have not been designed to

withstand explosions, dust-proof, nor is it splash-proof. Therefore, it should not be installed in any environment where:

(1) there are flammable gases or liquids,

(2) there are any shavings from metal processing or other

conductive material flying about,

(3) there are any acidic, alkaline or other corrosive material,

(4) there is a mist,

(5) there are any large-sized inverters, high output/high

frequency transmitters, large contactors, welders, or other sources of electrical noise.

 For dust- & splash-proof

type

The dust- & splash-proof type has an IP54-equivalent structure,

but it has not been designed to withstand explosions. (The HM/HS-G-W and the wrist of the VM/VS-G-W are an IP65-equivalent dust- and splash-proof structure.)

Note that the robot controller is not a dust- or splash-proof structure. Therefore, when using the robot controller in an environment exposed to mist, put it in an optional protective box.

The dust- & splash-proof type should not be installed in any environment where:

(1) there are any flammable gases or liquids,

(2) there are any acidic, alkaline or other corrosive material,

(3) there are any large-sized inverters, high output/high

frequency transmitters, large contactors, welders, or other sources of electrical noise,

(4) it may likely be submerged in fluid,

(5) there are any grinding or machining chips or shavings,

(6) any machining oil not specified in this manual is in use, or

Note: Yushiron Oil No. 4C (non-soluble) is specified.

(7) there is sulfuric cutting or grinding oil mist.

3.2 Service space

The robot and peripheral equipment should be installed so that

sufficient service space is maintained for safe teaching, maintenance, and inspection.

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3.3 Control devices outside the robot's restricted space

The robot controller, teach pendant and mini-pendant should be

installed outside the robot's restricted space and in a place where you can observe all of the robot’s movements and operate the robot easily.

3.4 Positioning of gauges

Pressure gauges, oil pressure gauges and other gauges should

be installed in an easy-to-check location.

3.5 Protection of electrical wiring and hydraulic/pneumatic piping

If there is any possibility of the electrical wiring or

hydraulic/pneumatic piping being damaged, protect them with a cover or similar item.

3.6 Grounding resistance

The protective grounding resistance of the robot power supply

should not be more than 100Ω.

3.7 Positioning of emergency stop switches

Emergency stop switches should be provided in a position where

they can be reached easily should it be necessary to stop the robot immediately.

(1) The emergency stop switches should be red.

(2) Emergency stop switches should be designed so that they

will not be released after pressed, automatically or mistakenly by any other person.

(3) Emergency stop switches should be separate from the

power switch.

3.8 Positioning of operating status indicators

Operating status indicators should be positioned in such a way

where workers can easily see whether the robot is on a temporary halt or on an emergency or abnormal stop.

Note: The UL-Listed robot units have motor ON lamps on their robot arms.

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SAFETY PRECAUTIONS

3.9 Setting-up a safety fence

A safety fence should be set up so that no one can easily enter

the robot's restricted space.

(1) The fence should be constructed so that it cannot be easily

moved or removed.

(2) The fence should be constructed so that it cannot be easily

damaged or deformed through external force.

(3) Establish the exit/entrance to the fence. Construct the fence

so that no one can easily get past it by climbing over the fence.

(4) The fence should be constructed to ensure that it is not

possible for hands or any other parts of the body to get through it.

(5) Take any one of the following protections for the entrance/

exit of the fence:

1) Place a door, rope or chain across the entrance/exit of the fence, and fit it with an interlock that ensures the emergency stop device operates automatically if it is opened or removed.

2) Post a warning notice at the entrance/exit of the fence stating "In operation--Entry forbidden" or "Work in progress--Do not operate" and ensure that workers follow these instructions at all times.

When making a test run, before setting up the fence,

place an overseer in a position outside the robot’s restricted space and one in which he/she can see all of the robot’s movements. The overseer should prevent workers from entering the robot's restricted space and be devoted solely to that task.

3.10 Setting the robot's motion space

The area required for the robot to work is called the robot's

operating space.

If the robot’s motion space is greater than the operating space, it is recommended that you set a smaller motion space to prevent the robot from interfering or disrupting other equipment.

Refer to the INSTALLATION & MAINTENANCE GUIDE, Chapter

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3.11 No robot modification allowed

Never modify the robot unit, robot controller, teach pendant or

other devices.

3.12 Cleaning of tools

If your robot uses welding guns, paint spray nozzles, or other

end-effectors requiring cleaning, it is recommended that the cleaning process be carried out automatically.

3.13 Lighting

Sufficient illumination should be assured for safe robot

operation.

3.14 Protection from objects thrown by the end-effector

If there is any risk of workers being injured in the event that the

object being held by the end-effector is dropped or thrown by the end-effector, consider the size, weight, temperature and chemical nature of the object and take appropriate safeguards to ensure safety.

3.15 Affixing the warning label

Place the warning label packaged

with the robot on the exit/entrance of the safety fence or in a position where it is easy to see.

3.16 Posting the moving directions of all axes

Post a notice showing axes names and moving directions in a

visible location on the robot unit. The posted moving directions should match the actual directions.

No posting or wrong direction posting may result in bodily injuries or property damages due to incorrect operation.

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SAFETY PRECAUTIONS

4. Precautions

while Robot is Running

Warning

Touching the robot while it is in operation can lead to serious injury. Please ensure the following conditions are maintained and that the cautions listed from Section

4.1 and onwards are followed when any work is being performed.

1) Do not enter the robot's restricted space when the robot is in operation or when the motor power is on.

2) As a precaution against malfunction, ensure that an emergency stop device is activated to cut the power to the robot motor upon entry into the robot's restricted space.

3) When it is necessary to enter the robot's restricted space to perform teaching or maintenance work while the robot is running, ensure that the steps described in Section 4.3 "Ensuring safety of workers performing jobs within the robot's restricted space" are taken.

4.1 Creation of working regulations and assuring worker adherence

When entering the robot’s restricted space to perform teaching

or maintenance inspections, set "working regulations" for the following items and ensure workers adhere to them.

(1) Operating procedures required to run the robot.

(2) Robot speed when performing teaching.

(3) Signaling methods to be used when more than one worker is

to perform work.

(4) Steps that must be taken by the worker in the event of a

malfunction, according to the contents of the malfunction.

(5) The necessary steps for checking release and safety of the

malfunction status, in order to restart the robot after robot movement has been stopped due to activation of the emergency stop device

(6) Apart from the above, any steps below necessary to prevent

danger from unexpected robot movement or malfunction of the robot.

1) Display of the control panel (See Section 4.2 on the next page.)

2) Assuring the safety of workers performing jobs within the robot's restricted space (See Section 4.3 on the next page.)

3) Maintaining worker position and stance

Position and stance that enables the worker to confirm

normal robot operation and to take immediate refuge if a malfunction occurs.

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4) Implementation of measures for noise prevention

5) Signaling methods for workers of related equipment

6) Types of malfunctions and how to distinguish them

Please ensure "working regulations" are appropriate to the robot type, the place of installation and to the content of the work.

Be sure to consult the opinions of related workers, engineers at the equipment manufacturer and that of a labor safety consultant when creating these "working regulations".

4.2 Display of operation panel

To prevent anyone other than the worker from accessing the start

switch or the changeover switch by accident during operation, display something to indicate it is in operation on the operation panel or teach pendant. Take any other steps as appropriate, such as locking the cover.

4.3 Ensuring safety of workers performing jobs within the robot's restricted space

When performing jobs within the robot’s restricted space, take

any of the following steps to ensure that robot operation can be stopped immediately upon a malfunction.

(1) Ensure an overseer is placed in a position outside the

robot’s restricted space and one in which he/she can see all robot movements, and that he/she is devoted solely to that task.

An emergency stop device should be activated

immediately upon a malfunction.

d Do not permit anyone other than the worker engaged for

that job to enter the robot’s restricted space.

(2) Ensure a worker within the robot's restricted space carries

the portable emergency stop switch so he/she can press it (the emergency button on the teach pendant) immediately if it should be necessary to do so.

4.4 Inspections before commencing work such as teaching

Before starting work such as teaching, inspect the following

items, carry out any repairs immediately upon detection of a malfunction and perform any other necessary measures.

(1) Check for any damage to the sheath or cover of the external

wiring or to the external devices.

(2) Check that the robot is functioning normally or not (any

unusual noise or vibration during operation).

(3) Check the functioning of the emergency stop device.

(4) Check there is no leakage of air or oil from any pipes.

(5) Check there are no obstructive objects in or near the robot’s

restricted space.

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SAFETY PRECAUTIONS

4.5 Release of residual air pressure

Before disassembling or replacing pneumatic parts, first release

any residual air pressure in the drive cylinder.

4.6 Precautions for test runs

Whenever possible, have the worker stay outside of the robot's

restricted space when performing test runs.

4.7 Precautions for automatic operation

(1) At start-up

Stay out of the safeguarded space with a safety fence when

starting the robot; in particular, take extra caution in Internal automatic operation.

Before starting the robot, check the following items as well

as setting the signals to be used and perform signaling practice with all related workers.

1) Check that there is no one inside the safeguarded space (with a safety fence).

2) Check that the teach pendant and tools are in their designated places.

3) Check that no lamps indicating a malfunction on the robot or related equipment are lit.

(2) Check that the display lamp indicating automatic operation

is lit during automatic operation.

(3) Steps to be taken when a malfunction occurs

Stop the robot's operation by activating the emergency stop

device when it is necessary to enter the safeguarded space with a safety fence to perform emergency maintenance in the case of malfunction of the robots or related equipment.

Take any necessary steps such as posting a notice on the

start switch to indicate work is in progress to prevent anyone from accessing the robot.

4.8 Precautions in repairs

(1) Do not perform repairs outside of the designated range.

(2) Under no circumstances should the interlock mechanism be

removed.

(3) When opening the robot controller's cover for battery

replacement or any other reasons, always turn the robot controller power off and disconnect the power cable.

(4) Use only spare tools specified in this manual.

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5. Daily and Periodical Inspections

(1) Be sure to perform daily and periodical inspections. Before

starting jobs, always check that there is no problem with the robot and related equipment. If any problems are found, take any necessary measures to correct them.

(2) When carrying out periodical inspections or any repairs,

maintain records and keep them for at least 3 years.

6. Management of Floppy Disks

(1) Carefully handle and store the "Initial settings" floppy disks

packaged with the robot, which store special data exclusively prepared for your robot.

(2) After finishing teaching or making any changes, always save

the programs and data onto floppy disks.

Making back-ups will help you recover if data stored in the

robot controller is lost due to the expired life of the back-up battery.

(3) Write the names of each of the floppy disks used for storing

task programs to prevent incorrect disks from loading into the robot controller.

(4) Store the floppy disks where they will not be exposed to dust,

humidity and magnetic field, which could corrupt the disks or data stored on them.

7. Safety Codes

The safety standards relating to robot systems are listed below.

As well as observing the safety precautions given in this manual, ensure compliance with all local and national safety and electrical codes for the installation and operation of the robot system.

Standards Title

ANSI/RIA R15.06-1999 Industrial Robots and Robot Systems--Safety Requirements

ANSI/UL1740: 1998 Safety for Robots and Robotic Equipment

CAN/CSA Z434-03 Industrial Robots and Robot Systems--General Safety Requirements

ISO10218-1: 2006 Robots for industrial environments--Safety requirements--Part 1: Robot

NFPA 79: 2002 Electrical Standard for Industrial Machinery

8. Battery Recycling

DENSO Robot uses lithium batteries.

Discard batteries according to your local and national recycling law.

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Contents

Preface

How the documentation set is organized

SAFETY PRECAUTIONS

Chapter 1 Overview.......................................................................................................................................................... 1

1.1 System Configuration............................................................................................................................................ 1

1.2 Standard Items Contained in the Package ............................................................................................................. 2

1.3 Optional Items ....................................................................................................................................................... 3

1.4 Controller Specification ........................................................................................................................................ 6

1.5 Outer Dimensions of the Controller ...................................................................................................................... 8

1.6 Names of the Controller Components ................................................................................................................... 9

1.7 Precautions for Safe Use of the Robot System.................................................................................................... 11

Chapter 2 Engineering Design of Servo Mechanism ................................................................................................... 12

2.1 Designing the Servo Mechanism......................................................................................................................... 12

2.1.1 Example of the Mechanism.................................................................................................................

2.1.2 Selection of the Drive System.............................................................................................................

2.1.3 Design Example (High-Speed Transfer Equipment)...........................................................................

2.1.4 Notes for Designing ............................................................................................................................

2.2 Knowledge Required for Selection of Servomotors............................................................................................ 22

Chapter 3 Choosing AC Servomotors ........................................................................................................................... 28

3.1 AC Servomotors.................................................................................................................................................. 28

3.1.1 List of AC Servomotors ......................................................................................................................28

3.1.2 Cable End Treatment of AC Servomotors When Shipped ..................................................................

3.1.3 Motor Characteristics Lists .................................................................................................................

3.1.4 Specification Details ...........................................................................................................................

3.2 External Dimensions of AC Servomotors ........................................................................................................... 35

Chapter 4 Configuring the Joint Parameters............................................................................................................... 41

4.1 Path Configuration Parameters............................................................................................................................ 41

4.2 Servo Configuration Parameters ......................................................................................................................... 44

4.3 Arm Configuration Parameters ........................................................................................................................... 47

4.3.1 Setting the Speed Reduction Rate in Manual Operation.....................................................................

4.4 Outputting a List of Joint Parameter Settings (Using WINCAPSIII).................................................................. 49

4.5 Detailed Description of Joint Parameter Setting ................................................................................................. 50

4.6 Configuring Motors as Robot Joints or Extended-Joints..................................................................................... 56

4.6.1 Robot Joints.........................................................................................................................................

4.6.2 Extended-Joints...................................................................................................................................

4.6.3 Usable Functions in Robot and Extended-Joint Motion (Examples) ..................................................

4.6.4 Configuring Robot Joints ....................................................................................................................

4.7 Gain Tuning of Each Joint................................................................................................................................... 59

4.7.1 Auto Gain Tuning................................................................................................................................

4.7.2 Manual Gain Tuning ...........................................................................................................................

4.8 Joint Exclusive Operations.................................................................................................................................. 71

4.8.1 Performing CALSET Operation on Each Joint...................................................................................

4.8.2 Releasing or locking brakes ................................................................................................................

4.8.3 Direct Teaching Mode.........................................................................................................................

4.8.4 Resetting Encoder ...............................................................................................................................

4.8.5 Operating Extended-Joints..................................................................................................................

4.8.6 Programmed Operation in SMT7 (Description of arm groups) ..........................................................

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4.9

Joint Parameter Configuration Commands ......................................................................................................... 83

4.9.1 Single-Joint Servo Data Monitor Commands (Library)......................................................................

4.9.2 Operation Termination Commands (Library)......................................................................................

4.9.3 Internal Servo Data Get Commands....................................................................................................

Chapter 5 Installation and Wiring ................................................................................................................................ 91

5.1 Installation of Controller ..................................................................................................................................... 91

5.1.1 Installation Site Conditions.................................................................................................................

5.1.2 Installing the Controller ......................................................................................................................

5.2 Wiring between Controller and Motor ................................................................................................................ 94

5.2.1 Connecting Motor Cable.....................................................................................................................

5.2.2 Connecting Encoder Cable..................................................................................................................

5.2.3 Encoder Backup Battery......................................................................................................................

5.2.4 Caution for Wiring ..............................................................................................................................

5.3 Wiring of Primary Power Source ........................................................................................................................ 98

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Chapter 1 Overview

1.1 System Configuration

The SMT7 is a controller that controls the positioning mechanism driven by an AC servomotor, e.g., X-Y table.

Shown below is a system configuration sample using the SMT7 controller.

First, move the X-Y table using the teach pendant to store the position into the controller memory. At the same time, store other conditions for synchronizing with external equipment (e.g., PLC).

After that, in an automatic operation, the controller drives the X-Y table as programmed, reading out the data stored in the memory.

System Configuration

(1) Notes in operating the SMT7

The SMT7 is functionally equivalent to robot controllers except the SMT7 cannot specify arm mechanisms. Using any of the following motions and commands in the SMT7, therefore, may cause an unexpected movement. It is dangerous.

CP motion (linear interpolation MOVE L or circular interpolation MOVE C)

TOOL movement ROTATE command Coordinate instruction movement (DRAW) PALT command APPROACH command DEPART command

(2) Drive capacity

The motor capacity that can be driven by the SMT7 is as listed below.

SMT7 controller Motor Capacity Total Drive Capacity Note

1st to 6th axes 1500 W max./axis 3000 W max.

3rd to 6th axes: Restricted to

1200 W or its equivalent

Note: Use AC servomotors specified in Chapter 3.

Note: The total drive capacity does not change even when optional extended-joints are in

use.

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Chapter 1 Overview

1.2 Standard Items Contained in the Package

The items listed in the table below are contained in the product package.

Standard Items

No. Item Qty.

(1) SMT7 controller (Note 1) 1

(2) Power supply cable (5m) 1

(3) Instruction manuals (Manual pack CD) 1 set

(4)

NetwoRC CD (containing WINCAPSIII beta version)

(5) Spare fuse for controller 3

(6) Pendantless connector (Dummy connector) 1

(7) Spare output IC for controller 1

(8) Short socket for controller 2

Note 1: When shipped from the factory, the controller has a built-in IPM board

suited for AC servomotors to be connected. When ordering the controller, therefore, also order AC servomotors.

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Chapter 1 Overview

1.3 Optional Items

The table below lists the optional items.

Optional Items (1)

No. Item Remarks Part No.

AC servomotor (Standard type, 50W, Without brake) SGMAH-A5A1A-DH1* 410627-0210

AC servomotor (Standard type, 50W, With brake) SGMAH-A5A1A-DH2* 410627-0160

AC servomotor (Standard type, 100W, Without brake) SGMAH-01A1A-DH1* 410627-0220

AC servomotor (Standard type, 100W, With brake) SGMAH-01A1A-DH2* 410627-0170

AC servomotor (Standard type, 200W, Without brake) SGMAH-02A1A-DH1* 410627-0230

AC servomotor (Standard type, 200W, With brake) SGMAH-02A1A-DH2* 410627-0180

AC servomotor (Standard type, 400W, Without brake) SGMAH-04A1A-DH1* 410627-0240

AC servomotor (Standard type, 400W, With brake) SGMAH-04A1A-DH2* 410627-0190

AC servomotor (Standard type, 750W, Without brake) SGMAH-08A1A-DH1* 410627-0250

AC servomotor (Standard type, 750W, With brake) SGMAH-08A1A-DH2* 410627-0200

AC servomotor (Flat type, 100W, Without brake) SGMPH-01A1A-DH1* 410627-0310

AC servomotor (Flat type, 100W, With brake) SGMPH-01A1A-DH2* 410627-0260

AC servomotor (Flat type, 200W, Without brake) SGMPH-02A1A-DH1* 410627-0320

AC servomotor (Flat type, 200W, With brake) SGMPH-02A1A-DH2* 410627-0270

AC servomotor (Flat type, 400W, Without brake) SGMPH-04A1A-DH1* 410627-0330

AC servomotor (Flat type, 400W, With brake) SGMPH-04A1A-DH2* 410627-0280

AC servomotor (Flat type, 750W, Without brake) SGMPH-08A1A-DH1* 410627-0340

AC servomotor (Flat type, 750W, With brake) SGMPH-08A1A-DH2* 410627-0290

AC servomotor (Flat type, 1500W, Without brake) SGMPH-15A1A-DH1* 410627-0350

AC servomotor (Flat type, 1500W, With brake) SGMPH-15A1A-DH2* 410627-0300

Encoder branch cable (for 4 axes) 410141-4050

Encoder branch cable (for 6 axes)

Between controller and encoder cable

410141-4060

Motor branch cable (for 4 axes) 410141-4030

Motor branch cable (for 6 axes)

Between controller and motor cable

410141-4040

Encoder cable (4 m) 410141-4130

Encoder cable (6 m) 410141-4140

Encoder cable (12 m)

1 cable per a motor

410141-4150

Motor cable (Connected to 750W or less motor, 4 m) 410141-4100

Motor cable (Connected to 750W or less motor, 6 m) 410141-4110

Motor cable (Connected to 750W or less motor, 12 m) 410141-4120

Motor cable (Connected to 1500w motor, 4 m) 410141-4070

Motor cable (Connected to 1500w motor, 6 m) 410141-4080

Motor cable (Connected to 1500w motor, 12 m)

1 cable per a motor

410141-4090

Page 20

Chapter 1 Overview

Optional Items (2)

No. Item Remarks Part No.

6 Encoder backup battery 1 unit per a motor 410611-0030

(8 m) Includes Nos. 7-1 and 7-2. 410149-0940

7 Standard I/O cable set

(15 m) Includes Nos. 7-1 and 7-2 410149-0950

(8 m) 410141-2700

7-1 I/O cable for "Mini I/O" (68-pin)

(15 m) 410141-2710

(8 m) 410141-1740

7-2 I/O cable for "HAND I/O"

(15 m) 410141-1750

(8 m) 410141-3050

I/O cable for "Parallel I/O board" (96-pin)

(15 m) 410141-3060

(8 m) 410141-3580

I/O cable for "SAFETY I/O" (36-pin) (Only for global type)

(15 m) 410141-3590

(4 m) With cable 410100-1570

(8 m) With cable 410100-1580

10 Teach pendant

(15 m) With cable 410100-1590

Japanese version 410109-0390

(4 m)

English version 410109-0400

Japanese version 410109-0410

(8 m)

English version 410109-0420

Japanese version 410109-0430

Mini-pendant kit (Incl. cable and WINCAPSIII Light)

(12 m)

English version 410109-0440

(4 m) For TP, MP 410141-3710

12 Pendant extension cable

(8 m) For TP, MP 410141-3720

13 WINCAPSIII

CD-ROM (common to the languages--Japanese, English, German, Korean, and Chinese)

410090-0980

NPN 410010-3320

Shipped as installed on the controller

PNP 410010-3330

NPN 410010-3340

Parallel I/O board

Shipped as individual boards (supply part)

PNP 410010-3350

For Slave station 410010-3370

For Master station 410010-3380

Shipped as installed on the controller

For Master & slave station 410010-3390

For Slave station 410010-3400

For Master station 410010-3410

DeviceNet board

Shipped as individual boards (supply part)

For Master & slave station 410010-3480

Page 21

Chapter 1 Overview

Optional Items (3)

No. Item Remarks Part No.

Shipped as installed on the controller 410010-3430

16 CC-Link board

Shipped as individual boards (supply part) 410010-3440

Shipped as installed on the controller 410010-3460

17 Conveyor tracking board

Shipped as individual boards (supply part) 410010-3470

Shipped after integrated in the controller 410006-0260

Optional function for RS-232C board

Board manufacturer: CONTEC CO., LTD. Model: COM-2P(PCI)H

Added when the board is purchased as a spare part

410006-0270

Shipped after integrated in the controller 410006-0280

Optional function for S-LINK V board

Board manufacturer: SUNX CO., LTD Model: SL-VPCI

Added when the board is purchased as a spare part

410006-0290

Shipped after integrated in the controller 410006-0300

Optional function for PROFIBUS-DP slave board

Board manufacturer: Hilscher GmbH Model: CIF50-DPS

\DENSO

Added when the board is purchased as a spare part

410006-0310

Shipped after integrated in the controller 410006-0800

EtherNet/IP function

Board manufacturer: Hilscher GmbH

Model: CIFX 50-RE\DENSO

Added when the board is purchased as a spare part

410006-0810

22 Optional function for memory extension

Extension only upon controller shipment (3.25 to 5.5 MB)

410006-0320

23 Controller protection box 410181-0090

24 I/O conversion box For interchangeability with RC5 controller 410181-0100

For the part numbers of extended-joint options, refer to the Supplement for Extended-Joints Support.

Page 22

Chapter 1 Overview

1.4 Controller Specification

The table below lists the specifications of the SMT7 controller.

Specifications of SMT7 Controller (1)

Item Specifications

Applicable motor

AC servomotors specified in Section 1.3. (For details, see Chapter 3.)

Controller model

RC7M-SMT6AA :NPN I/O RC7M-SMT6AA-P :PNP I/O RC7M-SMT6AA-BN :NPN I/O, Global type with safety board RC7M-SMT6AA-BP :PNP I/O, Global type with safety board RC7M-SMT6AA-CN :NPN I/O, Global type with safety box RC7M-SMT6AA-CP :PNP I/O, Global type with safety box

Number of controllable axes

Max. 8 axes (incl. optional extended-joints)

Control system

PTP, CP 3-dimensional linear, 3-dimensional circular

Drive system All axes: Full-digital AC servo

Language used

DENSO robot language (conforming to SLIM)

Memory capacity

3.25 MB (equivalent to 10,000 steps, 30,000 points)

Teaching system

1) Remote teaching 2) Numerical input (MDI) 3) Direct teaching

Mini I/O

Input signals: 8 user open points + 11 fixed system points Output signals: 8 user open points + 14 fixed system points Note: In global type, some fixed system points are not used.

Standard I/O

HAND I/O

Input signals: 8 user open points Output signals: 8 user open points

SAFETY I/O

(Only for Global type)

Input signals: 6 fixed system points Output signals: 5 fixed system points

2 boards

Input signals: Additional 80 user open points Output signals: Additional 96 user open points

Parallel I/O

board

(Option)

1 board

Input signals: Additional 40 user open points Output signals: Additional 48 user open points

Master & slave

Input signals: 1024 points (Master) + 256 points (Slave) Output signals: 1024 points (Master) + 256 points (Slave)

Master

Input signals: 1024 points Output signals: 1024 points

DeviceNet

board

(Option)

Slave

Input signals: 256 points Output signals: 256 points

External

signals

(I/O)

CC-Link board

(option)

Slave

Input signals: 384 points Output signals: 384 points (including remote registers RWw and RWr)

External

communication

RS-232C: 1 line Ethernet: 1 line USB: 2 lines

Extension slot 3 (For an optional board)

Self-diagnosis function Overrun, servo error, memory error, input error, etc.

Timer function 0.02 to 10 sec. (in units of 1/60 sec.)

Error display

Error codes will be outputted on the external I/O. Error messages will be displayed in English on the teach pendant (option). Error codes will be displayed on the mini pendant (option).

Page 23

Chapter 1 Overview

Specifications of SMT7 Controller (2)

Item Specifications

Motor cable, encoder cable (option)

4 m, 6 m, 12 m (Connected to the controller via the branch cable.)

I/O cable (option)

8 m, 15 m (For Mini I/O, HAND I/O, Optional board for parallel I/O and SAFETY I/O)

Cables

Power supply cable

5 m

Environmental conditions

(in operation)

Temperature: 0 to 40C Humidity: 90% RH or less (no condensation allowed)

Power source

（at full IPM boards）

Three-phase, 200 VAC-15% to 230 VAC+10%, 50/60 Hz, 3.3KVA

Single-phase, 230 VAC-10% to 230 VAC+10%, 50/60 Hz, 3.3KVA

External power source

A 24 VDC ±10% should be supplied from external equipment.

I/O power source

Internal power source

A 24 VDC ±10% should be supplied internally in the controller.

Note: Refer to the RC7M CONTROLLER MANUAL, sections

4.2.1 and 5.2.1 "Setting up Mini I/O Power Supply."

Safety category

With safety board: Compliant with safety category 3 With safety box: Compliant with safety category 4

Degree of protection

IP20

Weight (at full IPM boards)

Approx. 22 kg (49 lbs)

Controller Handling Notes

WARNING

DO NOT touch fins. Their hot surfaces may cause severe burns. DO NOT insert fingers or foreign objects into openings. Doing so may cause

bodily injury.

Before opening the controller cover and accessing the inside of the controller

for maintenance, be sure to turn off the power switch, disconnect the power cable, and wait 3 minutes or more. This is for protecting you from electric shock.

DO NOT connect or disconnect connectors to/from the controller when the AC

power or the 24 VDC power for I/O is being supplied. Doing so may cause electric shock or controller failure.

CAUTION IN INSTALLATION

This controller is not designed to be dust-proof, splash-proof, or

explosion-proof.

Read operation manuals before installation. Do not place anything on the controller.

CAUTION

The controller connectors are of a screw-lock type or ring-lock type. Lock the

connectors securely. If even one of the connectors is not locked, weak contact may result thereby causing an error.

Be sure to turn the controller OFF before connecting/ disconnecting the power

connector or motor connector. Otherwise, the internal circuits of the controller may be damaged.

Page 24

Chapter 1 Overview

1.5 Outer Dimensions of the Controller

The figure below shows the outer dimensions of the SMT7.

Outer dimensions

Page 25

Chapter 1 Overview

1.6 Names of the Controller Components

The following figures show the names of the SMT7 components.

Front Panel

Connector No. Marking Name

CN1 RS-232C Serial interface connector CN2 USB USB connector (2 lines) CN3 PENDANT Teach pendant connector CN4 LAN Ethernet connector CN5 Mini I/O User/system I/O connector CN6 INPUT AC Power supply connector CN7 MOTOR Motor connector CN8 ENCODER Encoder connector CN9 HAND I/O Hand I/O connector CN10 SAFETY I/O Safety I/O connector

(only on the global type)

Names of SMT7 Components

Rear side (air exhaust)

Front panel

ir intake filters

Page 26

Chapter 1 Overview

"THE SETPRM LIST" of the SMT7

The SMT7 is customized for motors specified by each customer in both hardware and software at the factory. The allowable combination of the controller's axes and motor types is printed in (2) SUBASSEMBLY on the "THE SETPRM LIST" labeled on the top of the controller.

According to the allowable combination, connect motors to the controller correctly. Incorrect connection will result in a motor malfunction, controller overheat, motor overheat, and other problems.

Note: When shipped from the factory, IPM boards suited to AC servomotors to be connected will

be built into the controller for 1 to 6 axes.

Motor capacity 50 W 100 W 200 W 400 W 750 W 1.5 kW

IPM board type SS SS S S M LL

SETPRM LIST

Page 27

Chapter 1 Overview

1.7 Precautions for Safe Use of the Robot System

NOTE: This section provides safety precautions to be taken when you configure the robot system with

the SMT7 controller. For details, refer to the ISO 10218-1:2006, Safety Requirements.

[1] For the mechanism to be driven

(1) If the mechanism involves a risk of bodily injury to workers, set up a safety fence

to prevent danger.

(2) When the joint(s) in the mechanism has the largest motion range in all joints,

prepare mechanical stops with sufficient rigidity.

(3) When the joint(s) in the mechanism has the 2nd or 3rd largest motion range in all

joints, prepare joint limiters with sufficient rigidity.

(4) If the mechanism involves a risk of bodily injury to workers when the brakes are

released, use warning labels to alert workers to danger.

(5) If it is not easy to carry the mechanism, prepare any measures for hoisting it.

(6) Provide markings (e.g. labels) on the driven mechanisms to show which axis

corresponds to which mechanism.

[2] When connecting motors

(1) When connecting the motors using cables, protect those cables from electrical

noise.

[3] When mounting motors

(1) If the motor surface gets hot and the workers are at risk of touching the heated

surface, attach a warning label, alerting them to the high temperature.

[4] For providing data to the user

(1) When the motion range of the joint in the mechanism is 3rd largest or below in all

joints, provide the user with the maximum stop time and distance of that joint, using instruction manuals, etc.

Page 28

Chapter 2 Engineering Design of Servo Mechanism

2.1 Designing the Servo Mechanism

2.1.1 Example of the Mechanism

The mechanism is classified into a linear movement section and a revolving arm section as shown

in Fig. 2-1.

(a) Linear movement section (b) Revolving arm

Fig. 2-1 Example of the mechanism

2.1.2 Selection of the Drive System

An appropriate control cannot be performed if a rapid torque fluctuation occurs due to stick slip or the like. Typical appropriate and inappropriate examples of the drive system are as shown below:

 Ball screw Grinding Backlash small  Rolling Backlash large (Control instable)   Gear Grinding Accuracy grade 1 or higher Backlash small  Cutting Accuracy grade 3 or higher Backlash medium  Accuracy grade 4 or lower Backlash large



 Screw shaft Friction large



 Harmonic drive Friction large 

(Care for selection)  Slide section bearing linear motion bearing  LM guide  Slide bearing



 Seal, packing Friction: 20% or less of the rated torque in conversion

into the motor shaft's  Friction: More than 20% of the rated torque in conversion into the motor shaft's



 denotes "Appropriate"  denotes "Conditionally appropriate"

 denotes "Inappropriate"

Ball screw, etc.

Load

Moto

Coupling

Load

Gea

Motor

Arm

Friction large

Page 29

Chapter 2 Engineering Design of Servo Mechanism

2.1.3 Design Example (High-Speed Transfer Equipment)

Fig. 2-2. High-speed transfer equipment

[Designing conditions]

1) Table design specification Table weight : WA = 40 kg Transferred object weight : W

= 20 kg (Max)

Max. stroke : S

max

= 700 mm

Fast feed speed : S

max

= 1000 mm/sec (60 m/min) Positioning accuracy : ±0.10/700 mm (0.01 mm /pulse) Repeat accuracy : ±0.010 mm Required life : L

= 25000 hr (5 years)

Slide surface (rolling) :

 = 0.01 (Friction factor)

Drive motor : AC motor (Nmax = 3000 rpm)

2) Operation conditions

Fig. 2-3. Operation conditions

[Items to be decided]

1) Selection of screw shaft dia., lead and nut

2) Selection of accuracy and clearance

An explanation is given to these items as follows.

Sliding resistance

t = 3.5 sec/cycle

1 sec  2 times

Reciprocation

Page 30

Chapter 2 Engineering Design of Servo Mechanism

[Selection of screw shaft dia., lead and nut]

1) Selection of lead (l) From the max. speed of DC motor



max

1000 60

20 (mm)

3000

Select from among accuracy large lead products of 20 mm or longer lead.

2) Temporary selection of thread length Ls = max. stroke + nut length + shaft end allowance = 700 + 100 + 100 + 900 (mm)

3) Selection of screw shaft dia. Select the shaft dia. by checking the allowable speed with a high speed feed. The bearing

support construction shall be of the most general fixing-support one.

Dangerous speed

Fig. 2-4. Selection of thread length

An examination is required for the ball screw speed not to resonate with the intrinsic number of

vibrations of the screw shaft. The allowable speed shall be 80% or less of this dangerous speed.

LEIA

  





(rpm)

········································································· (1)

where a: Safety factor (a = 0.8) E: Modulus of longitudinal elasticity (E = 2.06

× 10

kPa)

I: Minimum secondary moment of the screw shaft cross section

Idr



(mm )

dr: Screw shaft minor dia. (mm) <See Dimension Table> r: Specific weight of the material (r = 7.8

× 10

-6

kg/mm3)

A: Screw shaft cross-sectional area (A =



dr2/4 mm2)

L: Distance between mounting points (mm) f,



: Factor fixed by the mounting method of the ball screw

Support – support f = 9.7 (



)

Fixing – support f = 15.1 (



3.927 )

Fixing – fixing f = 21.9 (



4.730 )

Fixing – freedom f = 3.4 (



1.875 )

Page 31

Chapter 2 Engineering Design of Servo Mechanism

Therefore, from equation (1)

≧





27

10 (mm)

where L = Max. stroke + Nut length/2 + Shaft end allowance = 700 + 50 + 100 = 850 (mm) f = 15.1 dr = 14.4 (mm)

dmn value

Allowable speed is also regulated by dm



n value which shows peripheral speed (dm: center circle

dia. of steel ball mm n: speed rpm).

Generally

For precision (Accuracy grade C7 or higher) dm



n  70,000

For general industry (Accuracy grade C10) dm



n  50,000

Therefore,

dmn≦

70000

= 23.3 (mm)

Primary selection: Shaft dia. 20 (mm)

Lead 20 (mm)

4) Life forecast

(When accelerating

)

1 

mas

025.

4 (m / sec )







()()WWgWWa

AL AL1







0016098604 245.. .9 (N)

 

3000

1500 (rpm)





2

tt 0.75 (sec)

(At constant speed

)







(). ..WWg

001 60 98 59 (N)

 3000 (rpm)





2

tt0.65 (sec)

(When decelerating

)













()()WWg WWa

12 123

234 (N)

 1500 (rpm)





2

tt0.75 (sec)

············ Equation (2)

Page 32

Chapter 2 Engineering Design of Servo Mechanism

4-1) Average load Fm, Average rpm N

When shaft direction load is changed, find the average load which may give the life equal to the

fatigue life under changing load conditions, and calculate the life.

(a) When load and rpm are divided step-by-step (Fig. 2-5)

Shaft direction load

(kgf)

Speed (rpm) Time in use or rate of

time in use

Average load F

can be achieved by the following equation.

Average load Fm

  

  

 



 



Fnt Fnt Fnt

nt nt nt

nnn

1311 2322

11 2 2

13/

·············Equation (3)

And the average rpm can be achieved by the following equation.

ntnt nt

tt t











 

11 2 2

·································································Equation (4)

(b) When load is changed almost linearly (Fig. 2-6)

Average load F

can be approximately achieved by the following equation.

FFF



2()

min max

················································································Equation (5)

Fig. 2-5. Step-by-step fluctuation load Fig. 2-6. Monotonous fluctuation load

Page 33

Chapter 2 Engineering Design of Servo Mechanism

Average load F

can be approximately achieved by the following equation.

Fig. 6 In case of (a) Fm≒0.65F

max

In case of (b) F

≒0.75F

max

Fig. 2-7. Sine-curvedly changing load

Therefore, from equation (3), (4)

FNt FNtFNt

Nt Nt N t

abc



 

  

 



 





131232

123

13/



195 (N)

Nt Nt Nt

abc



 



123



1200 (rpm)

4-2) Life calculation

Fatigue life is generally shown by total rpm. Sometimes it is shown by total rotation time or

total running distance. Fatigue life can be achieved by the following equation.

Fa f





 



 





······························································································ (7)

n60

············································································································· (8)

LsLl



············································································································· (9)

Where L: Rated fatigue life (rev)

Lt: Life time (hr)

Ls: Running distance life (km)

Ca: Basic dynamic load rating (N)

Fa: Shaft direction load (N)

n: Speed (rpm)

l: Lead (mm)

: Load coefficient (coefficient by operating condition)

Smooth running without shock 1.0 - 1.2 Normal running 1.2 - 1.5 Running with shock/vibration 1.5 - 3.0

··············································· (6)

Page 34

Chapter 2 Engineering Design of Servo Mechanism

When selecting a ball screw, it is not economical to make its fatigue life uselessly long because the ball

screw must be so much big. For reference, general target value of fatigue life is shown bellow.

Machine tool 20,000 hours

Industrial machine 10,000 hours

Automatic controller 15,000 hours

Measuring instrument 15,000 hours

Therefore, from equation (7), (8) (T clearance Ca = 7056 kgf)

Ff N

mw m





 



 





≒380000  25000 (hr)

[Selection of accuracy and clearance]

(a) Accuracy grade

Positioning accuracy ± 0.10/700 (mm)

From Table 2-1

Accuracy grade: C5

E = ± 0.040/1000 (mm)

e = 0.027 (mm)

Table 2-1. Allowance of accumulated main lead error (±E) and fluctuation (e)

Unit: m

Accuracy grade C0 C1 C2 C3 C5

more than or less ±E e ±E e ±E e ±E e ±E e

– 100 3 3 3.5 5 5 7 8 8 18 18 100 200 3.5 3 4.5 5 7 7 10 8 20 18 200 315 4 3.5 6 5 8 7 12 8 23 18 315 400 5 3.5 7 5 9 7 13 10 25 20 400 500 6 4 8 5 10 7 15 10 27 20 500 630 6 4 9 6 11 8 16 12 30 23 630 800 7 5 10 7 13 9 18 13 35 25 800 1000 8 6 11 8 15 10 21 15 40 27

1000 1250 9 6 13 9 18 11 24 16 46 30 1250 1600 11 7 15 10 21 13 29 18 54 35 1600 2000 – – 18 11 25 15 35 21 65 40 2000 2500 – – 22 13 30 18 41 24 77 46 2500 3150 – – 26 15 36 21 50 29 93 54 3150 4000 – – 30 18 44 25 60 35 115 65 4000 5000 – – – – 52 30 72 41 140 77 5000 6300 – – – – 65 36 90 50 170 93 6300 8000 – – – – – – 110 60 210 115 8000 10000 – – – – – – – – 260 140

Screw part

effective

length

(mm)

10000 12500 – – – – – – – – 320 170

Source : NSK catalog

Page 35

Chapter 2 Engineering Design of Servo Mechanism

(b) Shaft direction clearance

Repeat positioning accuracy: ± 0.010 (mm)

Min. resolution: 0.01 mm/pulse

From the above,

Shaft direction clearance: T clearance 0.005 (mm) or less

Table 2-2. Combination of accuracy grade and shaft direction clearance

Unit: mm

Z T S N L

Shaft direction

clearance

Accuracy grade

(Pre-load)

0.005

or less

0.020

or less

0.050

or less

0.3

or less

C0 C0Z C0T – – –

C1 C1Z C1T – – –

C2 C2Z C2T – – –

C3 C3Z C3T C3S – –

C5 C5Z C5T C5S C5N –

C7 – – C7S C7N C7L

[Results]

Use the following spec. ball screw.

Shaft dia. 20 (mm), lead 20 (mm)

Screw length (temporary) 800 mm

Accuracy grade C5 shaft direction clearance T (0.005 mm or less)

Page 36

Chapter 2 Engineering Design of Servo Mechanism

2.1.4 Notes for Designing

The sliding resistance of the mechanism controlled by the SMT7 should be as follows.

Sliding resistance (torque conversion)  0.2

× motor rated torque (T )

[ 1 ] Sliding resistance of ball screw

Fig. 2-8 Sliding resistance of ball screw

1) Friction torque by external load

Fa l





2



: Friction torque by external load (Nm)

Fa: Shaft direction load (N)

Fa = F +



F: External load (N)

W: Workpiece weight + Table weight (N)



: Friction coefficient of slide surface (0.003 - 0.004)

l: Lead (m)



: Effectiveness (0.9)…Ball screw

(1.0)…LM guide

2) Friction torque by pre-load

Fao l







: Friction torque by pre-load (Nm)

Fao: Pre-load (5% of Ca) (N)

l: Lead (N)

k: Internal friction coefficient of pre-load nut (0.1 - 0.3)

Ca: Basic load rating (N)

F (External load)

Wor

kpi

ece

weight

Table weight

Screw shaft

Nut Gear B Gear A Motor

Page 37

Chapter 2 Engineering Design of Servo Mechanism

3) Motor rated torque (TR)

Refer to motor catalog.

4) Evaluation

() .TT

PD R



 



 





02≦

: Friction torque by external load (Nm)

: Friction torque by pre-load (Nm)

: Motor rated torque (Nm)

: The number of gear A teeth

: The number of gear B teeth

5) Others

It is recommended to use the grinding ball screw. Rolling ball screw has so large backlash that it

may not move properly.

[ 2 ] Gear sliding resistance

Table 2-3 shows gear transmission efficiency

Use gear of which transmission efficiency is 98% or more except for skew gears. In this case,

sliding resistance of gear (friction torque) can be disregarded.

Table 2-3. Classification and type of gear

Classification of gear Type of gear Efficiency (%) Spur gear Rack

Parallel axis Internal gear 98.0 - 99.5

Helical gear Helical rack Double helical gear Straight bevel gear

Intersecting axis Spiral bevel type gear 98.0 - 99.0

Zerol bevel gear

Skew axis Cylindrical worm gear 30.0 - 90.0

Crossed helical gear 70.0 - 95.0

Page 38

Chapter 2 Engineering Design of Servo Mechanism

2.2 Knowledge Required for Selection of Servomotors

This section describes basic knowledge required for selecting an optimal servomotor output and reduction gear ratio in designing of servo mechanism drive including robots.

Calculation of load drive torque (T) (conversion into the motor shaft's)

Drive torque = Inertia + Friction + Particular T (Nm) = (I





) + (N٠Ki + TFM + TFD) + (Tg + Ts) ٠٠٠٠٠٠٠٠٠٠٠٠٠٠٠٠٠٠٠٠٠٠٠٠٠٠٠٠ (1)

Where I = Total inertia moment in conversion into the motor shaft's (Nms2)





= Motor shaft angle acceleration (rad/s2)

N = Motor usage rpm (rpm)

Ki = Braking constant (see motor catalog) (Nm/rpm)

= Motor static friction torque (see motor catalog) (Nm)

= Friction torque of transmission system, etc.

(conversion into the motor shaft's) (Nm)

Tg = Gravity holding torque (conversion into the motor shaft's)(Nm)

Ts = Interference torque, centrifugal force, coriolis force, etc.

(conversion into the motor shaft's) (Nm)

Calculation of motor max. occurrence torque (TM) (conversion into the motor shaft's)

(kgcm) = IR٠Kt

Where IR = Max. current value which can be applied to motor (Ao٠p) Kt = Torque constant (See motor catalog) (Nm/Ao٠p)

Or this is shown by the "Instantaneous max. torque" in the motor catalog.

[Note] T

> T shall be formed.

However, drive torque T shall be designed within 2.5 times of motor rated torque as SMT7.

٠٠٠٠٠(2)

Page 39

Chapter 2 Engineering Design of Servo Mechanism

Calculation and evaluation of effective torque

When the servomotor moves like fig. 2-10 pattern, the effective torque (T

) of 1 cycle is achieved by the

following equation.

(Nm)(



1

)

However,

Speed diagram

Torque diagram

Fig. 2-10 Evaluation of effective torque

(a) Evaluation of motor unit

< TR (Rated torque in the motor catalog) shall be formed.

Use the motor within 80% of motor rated torque because of encoder circuit thermal limit (70℃).

When the effective torque is 80% or more of motor rated torque, measure the temperature of encoder

circuit to check it is within the limit.

·············································································(3)

}····· Drive torque (T in equation (1)) (Nm)

}····· Deceleration torque (subtract friction torque from T in equation (1)) (Nm) }····· Friction torque + particular torque (Nm)

······· Time of

(sec)

······· Cycle time (sec)

Speed

Page 40

Chapter 2 Engineering Design of Servo Mechanism

Calculation of total inertia moment (I) (conversion into the motor shaft's) (a) Revolving arm (Fig. 2-11). I (Nms

) = (IL + IA + IG4) × (RG1 × RG2)2··············· (Deceleration 2 step part)

+ (I

+ IG2) × (RG1)2 ······················· (Deceleration 1 step part)

+ (I

+ IC + IM + IE + IB) ····················(No deceleration part) ················ Equation (4)

Where

IL : Inertia moment of load W arm revolution shaft (Nms2)

: Inertia moment of arm revolution shaft (Nms2)

: 1st step pinion inertia moment (Nms2)

: 1st step gear inertia moment (Nms2)

: 2nd step pinion inertia moment (Nms2)

: 2nd step gear inertia moment (Nms2)

: Coupling inertia moment (Nms2)

: Motor armature inertia moment (Nms2)

: Encoder inertia moment (Nms2)

: Built-in brake inertia moment (Nms2)

RG1 : First step gear ratio (1/n)

RG2 : Second step gear ratio (1/n)

Fig. 2-11 Revolving arm

(b) Linear movement arm (Fig. 2-12)

IWW RG

(Nms )2

 



 









()

··············(Deceleration 2 step part)

+ (I

+ IG2) × (RG1)2·····································(Deceleration 1 step part)

+ I

+ IC + IM + IE + IB·································(No deceleration part)··················· Equation (5)

Where

WL : Load weight (kg)

: Arm weight (kg)

: Inertia moment of ball screw (Nms2)

l : Lead of ball screw (m/rev.)

Fig. 2-12 Linear movement arm

Motor

Ball screw etc.

Arm

Arm revolving shaft

Motor

Page 41

Chapter 2 Engineering Design of Servo Mechanism

(Nms ) D d h







()

····································································· Equation (6)

Where D : Outer diameter (m)

d : Inner diameter (m)

h : Thickness (m)



: Specific gravity (kg/m3)

* When inertia is expressed by GD

divide it by 4  g.

Fig. 2-13 Rotor

(d) Calculation of complex shape unit inertia moment (I2) (Fig. 2-14) Inertia moment of complex shape unit can not be achieved by the equation. Therefore, divide the unit

into parts and achieve the inertia moment by each part and add such moments.

IWy

ii2

(Nms

)( ) 



························································································· Equation (7)

Where

= Divided part weight (kg)

= Distance from center of revolution

to center of divided part (m)

Fig. 2-14 Complex shape unit

Calculation of motor shaft angular acceleration (ω)

(a) Revolving arm  (rad / s

) = ٠2 / 360٠t٠RG ··············································································· Equation (8)

(b) Linear movement  (rad / s

) = V٠2 / l٠t٠RG ···················································································· Equation (9)

Where

t = Acceleration time (sec.)



= Arm revolving speed ( /s)

V = Linear speed (m/s)

RG = Total deceleration ratio

(

)

l =

Fig. 2-15 Angular acceleration

Ball screw, Rack & Pinion

}

Lead (m/rev.)

Time

Speed

Page 42

Chapter 2 Engineering Design of Servo Mechanism

Friction torque of transmission system, etc. (TFD)

Divide the friction torque of the slide part, seal, speed reducer, etc. by deceleration ratio to make the

quotient as the friction torque in conversion into the motor shaft. Especially be sure to know that the

transmission mechanism friction torque before deceleration is directly applied to the motor.

Gravity holding torque (Tg)

When the gravity needs to be held, divide the holding unit weight by gear ratio to make the quotient as

the gravity torque in conversion into the motor shaft's. When taking gravity balance by air cylinder or

counter weight, the gravity holding torque is "0". Be sure to check, however, the slide resistance of air

cylinder and the addition of inertia moment.

Particular load torque (Ts)

When the degree of freedom is 2 or more, sometimes interference torque or centrifugal force or corioli's

force is applied by other shaft movement. Achieve the sum of these forces by mechanism construction

or motion speed and divide it by gear ratio to make the quotient as the torque in conversion into the motor

shaft's.

(a) Example of interference torque

(i) On two joint arm, second arm drive torque (T

) is applied to first arm. (Fig. 2-16)

(ii) Also in combination of linear movement and revolving shaft movement, acceleration () of linear

shaft is applied to the offset load (W) of the revolving shaft and torque (Tr) of the revolving shaft

which is in proportion to the offset distance (r) occurs. (Fig. 2-17)

JT 





(g: Gravitational acceleration 9.8 m/s2)

Fig. 2-16 Interference torque i Fig. 2-17 Interference torque ii

(b) Example of centrifugal force (FT)

On an object (W) on the revolving shaft, centrifugal force

) occurs from center to outside in proportion to the square

of revolving shaft angular speed (



) and the revolving

radius (r) (Fig. 2-18)







On fig. 2-18, linear shaft supports centrifugal force.

Fig. 2-18 Centrifugal force

First arm

Second arm

Revolving shaft

Linear shaft

Page 43

Chapter 2 Engineering Design of Servo Mechanism

speed, corioli's force (Fc) which is in proportion

to the double of the product of W, revolving shaft angular speed (





) and speed (VW) occurs in the vertical

direction to V

on the object (W). (Fig. 2-19)

  2





On Fig. 2-19, a torque which is the multiplication of corioli's force (Fc) by radius (r) occurs on the

revolving shaft, and a friction resistance which is the multiplication of corioli's force (Fc) by slide part friction coefficient occurs on the linear shaft.

Fig. 2-19 Corioli's force

Linear shaft

Revolving shaft

Page 44

Chapter 3 Choosing AC Servomotors

There are 20 types of AC servomotors available to the SMT7 controller. This chapter provides the reference data for motor selection.

3.1 AC Servomotors

3.1.1 List of AC Servomotors

The table below lists AC servomotors available to the SMT7.

When placing an order for the SMT7, order AC servomotors selected at the same time. This is because the SMT7 is shipped from the factory with a built-in IPM board suited for AC servomotors.

List of AC Servomotors Available for the SMT7

Motor type Motor capacity Brake Model Parts No.

Without SGMAH-A5A1A-DH1* 410627-0210

50 W

With SGMAH-A5A1A-DH2* 410627-0160

Without SGMAH-01A1A-DH1* 410627-0220

100 W

With SGMAH-01A1A-DH2* 410627-0170

Without SGMAH-02A1A-DH1* 410627-0230

200 W

With SGMAH-02A1A-DH2* 410627-0180

Without SGMAH-04A1A-DH1* 410627-0240

400 W

With SGMAH-04A1A-DH2* 410627-0190

Without SGMAH-08A1A-DH1* 410627-0250

Standard type

(For the system

requiring torque with

small inertia)

750 W

With SGMAH-08A1A-DH2* 410627-0200

Without SGMPH-01A1A-DH1* 410627-0310

100 W

With SGMPH-01A1A-DH2* 410627-0260

Without SGMPH-02A1A-DH1* 410627-0320

200 W

With SGMPH-02A1A-DH2* 410627-0270

Without SGMPH-04A1A-DH1* 410627-0330

400 W

With SGMPH-04A1A-DH2* 410627-0280

Without SGMPH-08A1A-DH1* 410627-0340

750 W

With SGMPH-08A1A-DH2* 410627-0290

Without SGMPH-15A1A-DH1* 410627-0350

Flat type

(For limited motor

space)

1500 W

With SGMPH-15A1A-DH2* 410627-0300

Page 45

Chapter 3 Choosing AC Servomotors

3.1.2 Cable End Treatment of AC Servomotors When Shipped

When shipped, the cable ends of an AC servomotor are treated with connector housings as shown below.

Cable End Treatment of AC Servomotor Shipped

Page 46

Chapter 3 Choosing AC Servomotors

3.1.3 Motor Characteristics Lists

The main characteristics of each motor are listed below.

(1) Motor characteristics of standard type

Motor model

SGMAH-A5A SGMAH-01A SGMAH-02A SGMAH-04A SGMAH-08A

Rated output W 50 100 200 400 750 Rated revolving speed r/min 3000 Maximum revolving speed r/min 5000 Rated torque Nm 0.159 0.318 0.637 1.27 2.39 Instantaneous max. torque Nm 0.477 0.955 1.91 3.82 7.16

Rotor inertia (10

－

kgm2)

0.0220 0.0364 0.106 0.173 0.672

Allowable load inertia

(Max. n times of rotor inertia)

Max. 30 times Max. 20 times

Rated current Arms

(RMS value)

0.64 0.91 2.1 2.8 4.4

Torque constant Nm/Arms

(RMS value)

0.268 0.378 0.327 0.498 0.590

Weight (without brake) kg 0.4 0.5 1.1 1.7 3.4 Weight (with brake) kg 0.7 0.8 1.6 2.2 4.3

Holding torque Nm 0.159 0.318 0.637 1.27 2.39 Inertia at revolving part,

typical (10

-4

kgm2)

0.0085 0.058 0.14

Exiting voltage DC, V

24 ±10%

Brake

Exciting current DC, A (at 20C)

0.25 0.25 0.29 0.29 0.32

Motor characteristic curve (Torque-revolving speed)

SGMAH-A5A SGMAH-01A SGMAH-02A

SGMAH-04A SGMAH-08A

(Note)

A: Continuous operating area B: Peak loading area

Page 47

Chapter 3 Choosing AC Servomotors

(2) Motor characteristics of flat type

Motor model

SGMPH-01A SGMPH-02A SGMPH-04A SGMPH-08A SGMPH-15A

Rated output W 100 200 400 750 1500 Rated revolving speed r/min 3000 Maximum revolving speed r/min 5000 Rated torque Nm 0.318 0.637 1.27 2.39 4.77 Instantaneous max. torque Nm 0.955 1.91 3.82 7.16 14.3

Rotor inertia (10

－

kgm2)

0.0491 0.193 0.331 2.10 4.02

Allowable load inertia

(Max. n times of rotor inertia)

Max. 25 times Max. 15 times Max. 7 times Max. 5 times

Rated current Arms

(RMS value)

0.89 2.0 2.6 4.1 7.5

Torque constant Nm/Arms

(RMS value)

0.392 0.349 0.535 0.641 0.687

Weight (without brake) kg 0.7 1.4 2.1 4.2 6.6 Weight (with brake) kg 0.9 1.9 2.6 5.7 8.1

Holding torque Nm 0.318 0.637 1.27 2.39 4.77 Inertia at revolving part,

typical (10

-4

kgm2)

0.029 0.109 0.875

Exiting voltage DC, V 24±10%

Brake

Exciting current DC, A (at 20C)

0.32 0.32 0.32 0.31 0.42

Motor characteristic curve (Torque-revolving speed)

SGMPH-01A SGMPH-02A SGMPH-04A

SGMPH-08A SGMPH-15A

(Note)

A: Continuous operating area B: Peak loading area

Page 48

Chapter 3 Choosing AC Servomotors

3.1.4 Specification Details

(1) Performance

Item Specifications

Heat resistance

Allowable ambient temperature Running: 0C to +40C

In storage: -20C to +80C

Dampproof

Allowable ambient humidity 20% to 80% RH (No dew condensation allowed)

Insulation resistance

10 M or more (when cooled), measured by 500 VDC megger (Motor part: Between frame and lead wire)

Withstand voltage

To resist 1500 VAC for one minute (at motor) To resist 1200 VAC for one second (at brake)

Instantaneous maximum revolving speed

100% of maximum rotation speed

Vibration resistance

49 m/s2 max. (In each of X, Y, and Z axes)

Enclosure

Fully-enclosed, non-ventilated IP55 (except the motor shaft penetrating section)

(2) Assembly accuracy

The assembly accuracy is specified in external dimension drawings given in Section 3.2.

- The motor shaft deviation should be measured in the lateral direction.

- The perpendicularity of the flange face to the shaft and the eccentricity of the spigot joint should be measured in the shaft upper direction.

The end play (Shaft direction backlash) should be 0.3 mm or less.

(3) Mounting to the equipment

When mounting the motor shaft to the equipment, use a flexible joint.

If a rigid joint is used, even a slight runout of the center applies an excessive force to the

shaft, resulting in a shaft break.

If it is not avoidable to use a rigid joint, confirm the mounting accuracy and strength of the

motor shaft.

The motor has a built-in positioning transducer. When mounting the motor to the equipment,

take special care not to apply an excessive force to the shaft; otherwise, the positioning transducer may be broken.

Do not pull motor lead wires. Do not allow them to be bent repeatedly.

Page 49

Chapter 3 Choosing AC Servomotors

(4) Allowable shaft load

Motor

Part No. Model Capacity

Radial load

(F1)

Thrust load

(F2)

410627-0210 SGMAH-A5A1A-DH1* 50W 68N 54N

410627-0160 SGMAH-A5A1A-DH2* 50W 68N 54N

410627-0220 SGMAH-01A1A-DH1* 100W 78N 54N

410627-0170 SGMAH-01A1A-DH2* 100W 78N 54N

410627-0230 SGMAH-02A1A-DH1* 200W 245N 74N

410627-0180 SGMAH-02A1A-DH2* 200W 245N 74N

410627-0240 SGMAH-04A1A-DH1* 400W 245N 74N

410627-0190 SGMAH-04A1A-DH2* 400W 245N 74N

410627-0250 SGMAH-08A1A-DH1* 750W 392N 147N

410627-0200 SGMAH-08A1A-DH2* 750W 392N 147N

410627-0310 SGMPH-01A1A-DH1* 100W 78N 49N

410627-0260 SGMPH-01A1A-DH2* 100W 78N 49N

410627-0320 SGMPH-02A1A-DH1* 200W 245N 68N

410627-0270 SGMPH-02A1A-DH2* 200W 245N 68N

410627-0330 SGMPH-04A1A-DH1* 400W 245N 68N

410627-0280 SGMPH-04A1A-DH2* 400W 245N 68N

410627-0340 SGMPH-08A1A-DH1* 750W 392N 147N

410627-0290 SGMPH-08A1A-DH2* 750W 392N 147N

410627-0350 SGMPH-15A1A-DH1* 1500W 490N 147N

410627-0300 SGMPH-15A1A-DH2* 1500W 490N 147N

Page 50

Chapter 3 Choosing AC Servomotors

(5) Lead wire colors and signals

Motor lead wires

Motor side Name

Red

White

Blue

Green/Yellow

U V

E (FG)

Brake lead wires

Brake side Name

Black Black

Brake Brake

Encoder lead wires

Encoder side Name Remarks

Orange BAT

White /Orange COMMON

Twisted pair wires

Sky blue PS

White /Sky blue

Twisted pair wires

Red +5 V

Black 0 V

Twisted pair wires

Shielding wire Shield

Page 51

Chapter 3 Choosing AC Servomotors

3.2 External Dimensions of AC Servomotors

■Standard type without brake [50W or 100W]

Part No.

Motor model

SGMAH -

Rated

output

L LL LM S Tap QK U W T

Approx

weight

Remarks

410627-0210 A5A1A - DH1* 50W 102.0 77.0 44.0 6 Dia. 2.5, Depth 5 14 1.2 2 2 0.4 kg 410627-0220 01A1A - DH1* 100W 119.5 94.5 61.5 8 Dia. 3, Depth 6 14 1.8 3 3 0.5 kg

(Unit: mm)

(1) Assembly accuracy conforms to Japan

Machine Tool Builder's Association standard (MAS402-1981). (TIR value)

a) Shaft end deflection 0.03 (Shaft projection center) b) Squareness of flange face against

shaft 0.08 (45)

c) Eccentricity of

flange-fitting-outside diameter against shaft (Spigot joint portion center)

(2) Flange fixing bolt:

Use hexagon socket head bolt.

(3) Motor cable / Encoder cable length:

300 mm

Page 52

Chapter 3 Choosing AC Servomotors

■Standard type with brake [50W or 100W]

Part No.

Motor model

SGMAH -

Rated output

L LL LM S Tap QK U W T

Approx weight

Remarks

410627-0160 A5A1A - DH2* 50W 133.5 108.5 44.0 6 Dia. 2.5, Depth 5 14 1.2 2 2 0.7 kg 410627-0170 01A1A - DH2* 100W 160.0 135.0 61.5 8 Dia. 3, Depth 6 14 1.8 3 3 0.8 kg

(Unit: mm)

(1) Assembly accuracy conforms to Japan

Machine Tool Builder's Association standard (MAS402-1981). (TIR value)

a) Shaft end deflection 0.03 (Shaft projection center) b) Squareness of flange face against

shaft 0.08 (45)

c) Eccentricity of

flange-fitting-outside diameter against shaft (Spigot joint portion center)

(2) Flange fixing bolt:

Use hexagon socket head bolt.

(3) Motor cable / Encoder cable length:

300 mm

Page 53

Chapter 3 Choosing AC Servomotors

■Standard type without brake [200W, 400W or 750W]

Part No.

Motor model

SGMAH-

Rated

output

L LL LM LR

LELGLCL

LZ S LB Tap

Q K

UW T

Approx

weight

Remarks

410627-0230 02A1A–DH1* 200W 126.5 96.5 62.5 30 3 6 60 70 5.5 14 50 Dia. 5, Depth 8 20 3 5 5 1.1 kg 410627-0240 04A1A–DH1* 400W 154.5 124.5 90.5 30 3 6 60 70 5.5 14 50 Dia. 5, Depth 8 20 3 5 5 1.7 kg 410627-0250 08A1A-DH1* 750W 185 145 111 40 3 8 80 90 7 16 70 Dia. 5, Depth 8 20 3 5 5 3.4kg

(Unit: mm)

(1) Assembly accuracy

conforms to Japan Machine Tool Builder's Association standard (MAS402-1981). (TIR value)

a) Shaft end deflection

0.03 (Shaft projection center)

b) Squareness of flange

face against shaft 0.08 (45)

c) Eccentricity of

flange-fitting-outside diameter against shaft (Spigot joint portion center)

(2) Flange fixing bolt:

Use hexagon socket head bolt.

(3) Motor cable / Encoder cable

length: 300 mm

Page 54

Chapter 3 Choosing AC Servomotors

■Standard type with brake [200W, 400W or 750W]

Part No.

Motor model

SGMAH-

Rated

output

L LL LM LR LE LG LC LA LZ S LB Tap QK U W T

Approx

weight

Remarks

410627-0180 02A1A–DH2* 200W 166.0 136. 0 62. 5 30 3 6 60 70 5.5 14 50 Dia. 5, Depth 8 20 3 5 5 1.6 kg 410627-0190 04A1A–DH2* 400W 194.0 164. 0 90. 5 30 3 6 60 70 5.5 14 50 Dia. 5, Depth 8 20 3 5 5 2.2 kg 410627-0200 08A1A-DH2* 750W 229.5 189.5 111 40 3 8 80 90 7 16 70 Dia. 5, Depth 8 20 3 5 5 4.3kg

(Unit: mm)

(1) Assembly accuracy

conforms to Japan Machine Tool Builder's Association standard (MAS402-1981). (TIR value) a) Shaft end deflection

0.03 (Shaft projection center)

b) Squareness of flange

face against shaft 0.08 (45)

c) Eccentricity of

flange-fitting-outside diameter against shaft (Spigot joint portion center)

(2) Flange fixing bolt:

Use hexagon socket head bolt.

(3) Motor cable / Encoder cable

length: 300 mm

Page 55

Chapter 3 Choosing AC Servomotors

■Flat type without brake [100W, 200W, 400W, 750W or 1.5kW]

Part No.

Motor model

SGMPH-

Rated

output

L LL LM LR LE LG LF LC LA LZ S LB LH Tap QK U W T

Approx

weight

Remarks

410627-0310 01A1A–DH1* 100W 87.0 62.0 42.5 25 3 6 12. 5 60 70 5.5 8 50 10.55 Dia. 3, Depth 6 14 1.8 3 3 0.7 kg 410627-0320 02A1A–DH1* 200W 97.0 67.0 48.1 30 3 8 11.9 80 90 7 14 70 8.25 Dia. 5, Depth 8 16 3 5 5 1.4 kg 410627-0330 04A1A–DH1* 400W 117.0 87.0 68.1 30 3 8 11.9 80 90 7 14 70 8. 25 Di a. 5, Depth 8 16 3 5 5 2.1 kg 410627-0340 08A1A-DH1* 750W 126.5 86.5 66.7 40 3.5 10 12. 8 120 145 10 16 110 10.5 Dia. 5, Depth 8 22 3 5 5 4.2kg 410627-0350 15A1A-DH1* 1.5kW 154.5 114.5 94.7 40 3.5 10 12.8 120 145 10 19 110 10.5 Dia. 6, Depth 10 22 3.5 6 6 6.6kg

(Unit: mm)

(1) Assembly accuracy conforms to Japan Machine Tool Builder's Association standard (MAS402-1981). (TIR value)

a) Shaft end deflection: 0.03 (Shaft projection center) b) Squareness of flange face against shaft 0.08 (45) c) Eccentricity of flange-fitting-outsid e diameter against shaft (Spigot joint portion center)

(2) Flange fixing bolt: Use hexagon socket head bolt.

(3) Motor cable / Encoder cable length: 300 mm

Page 56

Chapter 3 Choosing AC Servomotors

■Flat type with brake [100W, 200W, 400W, 750W or 1.5kW]

Part No.

Motor model

SGMPH-

Rated

output

L LL LM LR LE LG LF LC LA LZ S LB LH Tap QK U W T

Approx

weight

Remarks

410627-0260 01A1A–DH2* 100W 116.0 91.0 42.5 25 3 6 12.5 60 70 5.5 8 50 10.55 Dia. 3, Depth 6 14 1. 8 3 3 0.9 kg 410627-0270 02A1A–DH2* 200W 128.5 98.5 48.1 30 3 8 11.9 80 90 7 14 70 8.25 Dia. 5, Depth 8 16 3 5 5 1.9 kg 410627-0280 04A1A–DH2* 400W 148.5 118.5 68.1 30 3 8 11.9 80 90 7 14 70 8.25 Dia. 5, Depth 8 16 3 5 5 2.6 kg 410627-0290 08A1A–DH2* 750W 163.0 123. 0 66.7 40 3.5 10 12.8 120 145 10 16 110 10.5 Dia. 5, Depth 8 22 3 5 5 5.7kg 410627-0300 15A1A–DH2* 1.5kW 188.0 148.0 94. 7 40 3.5 10 12.8 120 145 10 19 110 10.5 Dia. 6, Depth 10 22 3.5 6 6 8.1kg

(Unit: mm)

(1) Assembly

accuracy conforms to Japan Machine Tool Builder's Association standard (MAS402-1981). (TIR value)

(2) Flange fixing bolt: Use hexagon socket head bolt.

(3) Motor cable / Encoder cable length: 300 mm

Page 57

Chapter 4 Configuring the Joint Parameters

To use joints, you need to configure joint parameters beforehand. There are three types of joint parameters as described below, which can be configured by using the teach pendant.

(1) Path configuration parameters, which are provided for motion definitions

(including speed, acceleration, and range of motion) of joints.

(2) Servo configuration parameters, which are provided for setting the gain and

others of joint servo system.

(3) Arm configuration parameters, which are provided for performing CP motions

with joints being collaborated.

4.1 Path Configuration Parameters

(1) Call up the "Maintenance Functions (Arm)" window.

Access: Top Screen—[F2 Arm]—[F12 Maint.]

(2) Press [F7 Joints]. The Joint Settings window appears.

Page 58

Chapter 4 Configuring the Joint Parameters

(3) Press [F7 Path]. The path configuration window appears as shown below.

(4) Select the target joint (J1 in this example) by using the cursor keys or jog dial.

Press [OK]. The path configuration parameters window appears as shown below. Change the path configuration parameters and press [OK].

Note: For the detailed procedure, refer to Section 4.5 "Detailed Description of

Joint Parameter Setting."

The path configuration parameters are listed in the table on the next page.

Note: Some parameters will take effect after the controller is restarted.

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Chapter 4 Configuring the Joint Parameters

List of Path Configuration Parameters

Parameter name Entry range

Factory

default

Unit Description Remarks

Controller

restart

Boundless rotation

(0: Limited, 1: Boundless)

0 or 1 0

To rotate the motor 32768 times or more in the same direction, set this parameter to 1.

Setting this parameter to "1: Boundless" requires the Motion limit detection parameter to be set to "0: Invalid."

Needed

Joint structure

(0: Sliding, 1: Rotary)

0 or 1 1 If your optional mechanism

to be connected to the specified motor has a sliding joint, then set 0; if a rotary joint, set 1.

Needed

Motor rotation direction

(0: CCW, 1: CW)

0 or 1 0 To convert the CCW

rotation of the specified motor (when viewed from the load side) to the positive direction movement of the connected mechanism, set 0; to convert it to the negative one, set 1.

Needed

Motor max. speed (rpm)

1 to 5000 3000 rpm Set the maximum speed of

the specified motor.

Needed

Motor acceleration time (ms)

1 min. 200 ms Set the motor acceleration

time required for the specified motor to reach the maximum speed.

Needed

Gear ratio or lead (mm/r)

0.00001 min.

100

For lead: mm/r

For rotary joints, set the deceleration ratio (motor rotation/joint rotation).

For sliding joints, set the lead (movement) per motor rotation.

Up to 100,000 may be set. But if a large value is set, the entered value may be different from the displayed one due to overflow.

Needed

Motion limit detection

(0: Invalid, 1: Valid)

0 or 1 1

To make the controller check the motion limit and issue an error if the specified joint is out of the range, set 1.

Setting the Boundless rotation parameter to "1: Boundless" requires this parameter to be set to "0: Invalid."

Needed

Positive motion limit

(deg.) (mm)

360

For rotary joints: degrees

For sliding joints: mm

Set the positive motion limit.

Not needed

Negative motion limit

(deg.) (mm)

-360

For rotary joints: degrees

For sliding joints: mm

Set the negative motion limit.

Not needed

CALSET position 0

For rotary joints: degrees

For sliding joints: mm

Set the CALSET reference position.

Not needed

Radius of gyration (mm)

0 to 100000 1000 mm

For rotary joints, set the maximum radius of rotation.

For sliding joints, no setting is required.

Needed

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Chapter 4 Configuring the Joint Parameters

4.2 Servo Configuration Parameters

(1) Call up the Joint Settings window.

Access: Top Screen—[F2 Arm]—[F12 Maint.]—[F7 Joints]

(2) On the Joint Settings window shown above, press [F8 Servo]. The servo

configuration window appears as shown below. Select the target joint (J1 in this example) by using the cursor keys or jog dial.

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Chapter 4 Configuring the Joint Parameters

(3) Press [OK]. The servo configuration parameters window appears as shown

below. Change the servo configuration parameters and press [OK].

Note: For the detailed procedure, refer to "Detailed Description of Joint

Parameter Setting."

The servo configuration parameters are listed in the table below.

Note: Some parameters will take effect after the controller is restarted.

List of Servo Configuration Parameters (1)

Parameter name

Entry

range

Factory

default

Unit Description Remarks

Controller

restart

Joint motion

(0: Invalid, 1: Valid, 2: Encoder)

0 to 2 To connect and drive a

specified motor, set 1; to use the encoder only, set 2.

If "2: Encoder" is selected, turning the motor on will release the brake.

CAUTION: If any unbalanced load is applied, the joint will move towards the load.

Needed

Torque limit in auto mode (Motor rating ratio %)

0 to 400 300 % Set the torque limit value to

be applied in auto mode.

Not needed

Torque limit in manual mode (Motor rating ratio %)

0 to 400 150 % Set the torque limit value to

be applied in manual mode.

Not needed

Brake relay number 0 to 8 Displays the motor brake

relay number.

No change allowed.

Encoder axis number

1 to 8 Displays the encoder axis

number.

No change allowed.

Power module slot number

1 to 8 Displays the power module

slot number.

No change allowed.

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Chapter 4 Configuring the Joint Parameters

List of Servo Configuration Parameters (2)

Parameter name

Entry

range

Factory

default

Unit Description Remarks

Controller

restart

Positional loop gain 1 min. 64 Set the response of the

position control system. Increasing the value will decrease the positioning time.

The positioning loop gain can be converted in unit by Formula 4.7-1 given in Section 4.7.

Not needed

Positional loop feed forward gain (%)

0 to 100 0 % Set the loop forward gain of

the position control system. Increasing the value will decrease a positioning error and increase the response, but overshoot will easily occur.

Not needed

Positioning error allowance (pulse)

1 min. 30000 Set the allowable value of

positioning error. If a positioning error exceeding this allowable value occurs, an error will result.

Set the value that meets Formula

4.7-2 given in Section 4.7.

Not needed

Speed loop proportional gain

1 min. 200 (for

400 W or less)

400 (for 750 W or greater)

Set the response of the

speed control system. Increasing the value will enable you to set a higher value of the positional loop gain.

The speed loop proportional gain can be converted to the speed response frequency in Hz by Formula 4.7-3 given in Section 4.7.

Not needed

Speed integral gain 0 min. 5 Set the integral

compensation gain of the speed control system. Increasing the value will converge the speed deviation at the time of stop faster.

The speed loop integral gain can be converted to the time constant by Formula 4.7-4 given in Section 4.7.

Not needed

Filter parameter 0 to 15 10 Set the primary delay filter

band in the torque instruction section. Increasing the value will decrease the time constant of the low-pass filter.

Not needed

Torque offset setting (Motor rating ratio %)

0 to 100 0 % Set the torque offset value

of the torque instruction value.

If the motor undergoes any unbalanced load (movement towards the load), this offset will compensate it.

If you enable the gravity offset in auto gain tuning, the torque offset value will be automatically set.

Not needed

Motor capacity (SGMAH

50W: 1, 100W: 2, 200W: 3, 400W: 4, 750W: 5

SGMPH

100W: 12, 200W: 13, 400W: 14, 750W: 15, 1500W: 16)

1 to 16 Display the connected motor

capacity

No change allowed.

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4.3 Arm Configuration Parameters

(1) Call up the Joint Settings window.

Access: Top Screen—[F2 Arm]—[F12 Maint.]—[F7 Joints]

(2) Press [F2 ArmSet]. The ArmSet window appears as shown below.

List of Arm Configuration Parameters

Parameter name Entry range

Factory

default

Unit Description Remarks

Controller

restart

Speed reduction rate in manual operation

1 to 10 10 %

Limit the manual operation speed to 10 % or below of the automatic operation one.

Needed

Maximum translation speed

1 min. 800 mm/s

Set the maximum translation speed in CP motion.

Needed

Maximum translation acceleration

1 min. 2000 mm/s

Set the maximum translation acceleration in CP motion.

Needed

Maximum rotation speed

1 min. 360 deg/s

Set the maximum rotation speed in CP motion.

Needed

Maximum rotation acceleration

1 min. 900 deg/s

Set the maximum rotation acceleration in CP motion.

Needed

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4.3.1 Setting the Speed Reduction Rate in Manual Operation

The speed reduction rate in manual operation can be limited to 10% or below of that in automatic operation.

This section provides the reduction rate calculation procedure using the maximum composite tool-end speed and the target speed in manual operation.

NOTE: For details, refer to the ISO 10218-1:2006, Safety Requirements.

The example below uses a 3-joint mechanism configured with Cartesian coordinates and limits the tool-end speed in manual operation to 250 mm/s or below.

(1) Check the specifications of the 3-joint mechanism and calculate the maximum

speed of each joint.

3-joint mechanism X-joint: Max. speed 2000 mm/s Y-joint: Max. speed 2000 mm/s Z-joint: Max. speed 1000 mm/s

Calculating the maximum speed Assuming:

Lead/rev.: 40 mm Maximum motor rotation: 3000 rpm,

Then:

]/[2000

]/[40

][3000

smm

revmm

rpm





(2) Calculate the maximum composite tool-end speed.

Calculation example

]/[3000)1000()2000()2000(

222222

smmzyx 

(3) Calculate the speed reduction rate in manual operation to limit the tool-end

speed to 250 mm/s or below.

Calculation example

8100

]/[3000

]/[250



smm

(%) (Truncate the decimal places.)

(4) Enter the calculation result into the "Speed reducing rate in manual operation"

field in the ArmSet window shown on the previous page.

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Chapter 4 Configuring the Joint Parameters

4.4 Outputting a List of Joint Parameter Settings (Using

WINCAPSIII)

WINCAPSIII can display a list of joint parameter settings on the PC screen and output it in CSV format.

If you log on to WINCAPSIII as Programmer or higher level, you can configure the following parameters in the Joint Setting window.

- Joint setting table tab

Path settings

Servo settings

Arm settings

- Arm group tab

- Link info tab

- Disable arm tab

- Selecting Robot Joint tab

(1) Calling up the "Joint setting" window Access: Project | Joint Setting Table

"Joint setting table" Window

(2) Outputting the joint setting table data in CSV format Access: Export button in the Joint setting window

Pressing the [Export] button displays the file selection dialog box where you

select a file to save the data in CSV format.

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Chapter 4 Configuring the Joint Parameters

4.5 Detailed Description of Joint Parameter Setting

The path configuration parameters and servo configuration parameters should be configured with joints being connected to motors.

(1) Resetting the encoder

The encoder is not connected with a backup battery at the time of shipment, so the error message "J* encoder system down" or "J* encoder speed exceeded" will appear.

If this happens, reset the encoder (refer to Section 4.8.3) and restart the controller.

(2) Setting the path configuration parameters

For the calling-up procedure of the path configuration parameters window, refer to Section 4.1.

(2-1) Boundless rotation

The boundless rotation function suppresses errors that could occur if a joint keeps on rotation in the same direction. (This function applies to J5 or later.) You need to set the boundless rotation parameter to [1: Boundless] in the path configuration parameters window.

Notes for allowing boundless rotation

(1) When a joint is used as a rotary joint, an absolute motion command (DRIVEA or

MOVE with EXA option) can drive it within the range of ±360°. When it is used as a sliding joint, the allowable motion range is ±32768 in the number of motor rotations from the reference position (CALSET position).

(2) If a movement of a rotary joint exceeding the range of ±360° is commanded, the

joint rotates the specified angle and then it automatically returns to the position within the range of ±360°. This correction operation changes the reference position (CALSET position). Therefore, the Step Back function cannot return the program control back to the steps preceding the change of the reference position.

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Chapter 4 Configuring the Joint Parameters

(3) When a joint keeps on rotating in the same direction, the current value might

jump (overflow) suddenly and greatly. Performing an absolute motion in this state moves the joint to the position different from the specified one.

(4) In a boundless rotation motion command, the effective number of digits is 7. If a

value exceeding 7 digits is specified, the actual rotation amount will differ from the specified one.

For example

If DR I VE (5, 11111115555) is specified, 11111115555 will be internally interpreted

as 1.111111* E +10 so t h at 5555 will be trimmed due to the definition of a single precision floating point number.

(5) If a large value is specified as the amount of movement at one time in boundless

rotation, then the "Out of range" error will occur. The quantum of movement depends on the gear ratio.

(6) When a joint is used as a rotary joint requiring positioning, e.g., index table,

observe the following instructions.

- For the reduction gear, enter an integer multiple. Entering a non-integer multiple will result in a positioning error after a lot of rotations.

- If a relative motion command specifies a motion amount using a decimal, the joint could reach the position slightly different from the specified one. Using such a relative motion command repeatedly will result in a positioning error after a lot of rotations.

To avoid such a positioning error, correct the difference from the specified

position, for example, using an absolute motion command or MoveIndexHome library after completion of one rotation to return the joint to the home position.

(7) Rotating a joint exceeding ±32768 in the number of motor rotations from the

reference position (CALSET position) with the controller power being off will require CALSET operation when the controller is powered on at the next time.

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Chapter 4 Configuring the Joint Parameters

(2-2) Setting the motion conditions

Set the motion-relation parameters--sliding/rotary joint structure, motor rotation direction, motor maximum speed, motor acceleration time, gear ratio or lead, motion limit detection, positive motion limit, negative motion limit, and CALSET reference position.

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Chapter 4 Configuring the Joint Parameters

(3) Setting the servo configuration parameters

For the calling-up procedure of the servo configuration parameters window, refer to Section 4.2.

(3-1) Setting the joint motion

Set the joint motion to "1: Valid."

(3-2) Setting the torque limits

Set the torque limits in each of Auto and Manual modes.

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Chapter 4 Configuring the Joint Parameters

(3-3) Checking the encoder axis number, power module slot number, and motor

capacity

Checks that the encoder axis number and power module slot number match the joint number. Also, check that the motor capacity is selected correctly.

After completion of steps (1) to (3), restart the controller.

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Chapter 4 Configuring the Joint Parameters

(4) Checking the wiring

(4-1) Checking the brake wiring

If the motor has a brake, release the brake and check that the brake of all joints will be released. For the brake releasing procedure, refer to Section 4.8.2 "Releasing or locking brakes."

(4-2) Checking the encoder wiring

After releasing the brake of the motor, apply external force to the motor and check that the data of the joint corresponding to the motor will change in the Current Robot Position window of the teach pendant.

(4-3) Checking the motor wiring

Turn the motor on, set the motor speed at SP10, and check that you may drive the joint manually in Joint mode.

If the motor vibrates abnormally or stops due to any error, check the wiring of the motor. If the wiring is correct, gradually decrease the positional loop gain and speed proportional gain of the servo configuration parameters.

(5) Executing CALSET

Release the brake of the motor and move the optional mechanism connected to the motor to the CALSET reference position. Then execute CALSET in the CALSET reference position, referring to Section 4.8.1 "Performing CALSET Operation on Each Joint."

NOTE: Take care not to perform CALSET on any robot joint

. Performing it on

a robot joint will change the reference angle of the robot..

(6) Checking the motion of the mechanism connected to the joint motor

Run the mechanism connected to the motor manually in Joint mode and check that an error will be detected if the mechanism exceeds the positive or negative motion limit.

Also check that the actual movement amount matches the values displayed in the Current Robot Position window of the teach pendant. If not, check the gear ratio and lead.

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Chapter 4 Configuring the Joint Parameters

4.6 Configuring Motors as Robot Joints or Extended-Joints

The motors connected to the controller can be configured as robot joints or extended-joints. Any or all of joints 1 to 4 can be configured as robot joints. (In version 2.7 or earlier, all of four joints J1 to J4 are fixed as robot joints.)

Robot joints can be driven by robot motion commands enabling CP motion (linear and circular). To enable those robot motion commands, however, joints J1 to J4 should be configured as predetermined.

All joints except robot joints are used as extended-joints.

For details about operations of robot joints and extended-joints, refer to the Supplement for Extended-Joints Support.

4.6.1 Robot Joints

Configuring robot joints J1 to J4 in Cartesian coordinates as shown below enables you to drive those joints with robot motion commands enabling CP motion (linear and circular).

Example of joint configuration with Cartesian coordinates realized in robot motion

NOTE: To drive joints correctly in a CP motion (linear or circular), the configuration

and the motion directions of J1 to J4 must match the Cartesian coordinates (coordinates for RIGHTY) shown above. In a different configuration of J1 to J4, commanding a CP motion causes an unexpected motion. It is dangerous. Use a PTP motion instead of a CP motion.

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Chapter 4 Configuring the Joint Parameters

4.6.2 Extended-Joints

A single extended-joint is configured as shown below. It can execute only PTP motion. A MOVE command is not available for extended-joints, so use DRIVEA and DRIVE commands to drive extended-joints.

Example of configuration realized in extended-joint motion

4.6.3 Usable Functions in Robot and Extended-Joint Motion (Examples)

Usable functions in robot motion

Usable functions in

extended-joint motion

Position variables Joint, Position, and Double-precision

variables

Floating-point variables

Motion control All commands used in the robot,

including MOVE, APPROACH, DEPART, CURJNT, and CURPOS. *

DRIVE, DRIVEA (only in PTP motion)

Manual motion mode

Joint, X-Y, and Tool modes (Cartesian coordinate type only)

Joint mode only

NOTE: The CP motion (linear or circular) of robot joints is available depending on

the configuration of J1 to J4. For details, see the illustration given in "Robot Joints."

* These commands take effect only for joints configured as robot joints and

they are invalid for other joints.

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Chapter 4 Configuring the Joint Parameters

4.6.4 Configuring Robot Joints

The SMT7 controller is capable of controlling a maximum of eight joints (incl. optional extended-joints) that can be configured as robot joints or extended-joints.

Up to four joints can be selectively configured as robot joints using the teach pendant or in WINCAPSIII with the following procedures.

Joints not configured as robot joints are regarded as extended-joints.

Note: Modifying the robot joint configuration initializes the arm group and link

information settings.

 Configuring using the teach pendant

Access: [F2 Arm]--[F12 Maint.]--[F7 Joints]--[F1 ArmGroup]--[F6 RobotJoints]

Select joints to be configured as robot joints and press OK.

 Configuring in WINCAPSIII

Access: Project | Joint Setting Table (This displays the Joint setting window.)

Choose the Selecting Robot Joint tab. Select joints to be configured as robot joints and press OK.

Choose Connect | Transfer data to display the Transfer data window. In the WINCAPSIII pane, select Parameters | Arm parameters and then press Send to transfer the data to the robot controller.

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Chapter 4 Configuring the Joint Parameters

4.7 Gain Tuning of Each Joint

In Section 4.5, you have set the motion conditions of each joint and checked the motion of the mechanism connected to each joint motor in manual mode. After that, proceed to the gain tuning for the servo system.

Tune the servo system according to the following two types of tuning methods:

(1) Auto gain tuning

The controller performs acceleration/deceleration operation of each joint according to the default pattern preset in the controller. Based on the motion of each joint in that operation, the controller will estimate the inertia of payload and set the appropriate gain automatically.

(2) Manual gain tuning

The monitor function of the single-joint servo data monitors the motor speed control value, current motor speed, motor angle deviation, and torque control value. According to the monitored results, you can adjust the gain and torque control filter parameters for optimizing the motion of each joint.

Follow the next flowchart to tune the servo system.

Start

Do auto gain tuning?

Motion of the joint OK?

Abnormal end during auto gain tuning?

Auto gain tuning

Manual gain tuning

Motion of the joint OK?

djust the torque control filte

Set the positioning error allowance

End of tuning

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Chapter 4 Configuring the Joint Parameters

4.7.1 Auto Gain Tuning

To implement auto gain tuning, the mechanism to be connected to the joint motor should satisfy the requirements given in Section 4.7.1.1 below. Otherwise, some errors may occur and the auto gain tuning process may be interrupted. If such happens, implement manual gain tuning.

4.7.1.1 Requirements for implementing auto gain tuning

(1) The inertia of payload should be within 15 times that of the motor and should not

deviate greatly.

(2) The rigidity of the torque transmission mechanism (including motor and coupling)

to be connected to each joint motor should be high.

(3) The backlash in the torque transmission mechanism should be minimized.

(4) Rotating the motor in CCW and CW directions alternately two times each

direction should result in no problem.

4.7.1.2 Auto gain tuning procedure

(1) Turn the motor power on and perform CAL.

NOTE: If the controller is in Auto mode or Teach check mode, switch to Manual

mode.

(2) Get out of the motion range so that there will be no problem even if the motor

rotates in CCW and CW directions alternately two times each direction.

(3) On the teach pendant, call up the Joint Settings window.

Access: Top Screen―[F2 Arm]―[F12 Maint.]―[F7 Joints]

(4) Press [F5 Auto Gain] to call up the Auto Gain Tuning window as shown below.

Choose the joint number that should undergo auto gain tuning and the motor rotation direction.

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Chapter 4 Configuring the Joint Parameters

(5) Select the mechanical rigidity, referring to the rigidity reference values listed

below.

Types of Torque Transmission Mechanisms Mechanical Rigidity

Ball screw direct connection 4 to 8

Ball screw with transmission mechanism 3 to 7

Timing belt 3 to 6

Gear or rack & pinion 2 to 6

Other mechanism with low rigidity 1 to 3

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Chapter 4 Configuring the Joint Parameters

(6) Select whether the gravity offset torque should be enabled or disabled.

If an unbalanced load applies to the motor, be sure to enable the gravity offset

torque.

NOTE: If you disable gravity offset torque when the motor undergoes any

unbalanced load, then the joint will drop in the gravity direction, causing an error. To implement auto gain tuning when an unbalanced load applies to the motor, be sure to enable the gravity offset torque.

If you enable the gravity offset torque for auto gain tuning, the controller will

automatically calculate the torque offset included in servo configuration parameters. On the Joint Settings window, press [F8 Servo] to call up the servo configuration parameters window and then press OK to save the calculated torque offset value.

NOTE: If you turn the controller power off without saving the calculated torque

offset value, then the value will be lost and the previous value will resume.

(7) Hold down either one of the deadman switches through all processes of auto

gain tuning. Releasing it will interrupt auto gain tuning.

NOTE: During auto gain tuning, do not press any key on the teach pendant

except for the deadman switches. Doing so will interrupt auto gain tuning.

NOTE: If the joint motion has been set to [2:Encoder] on the servo

configuration parameters window, then the error message "Not executable" will appear during auto gain tuning.

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Chapter 4 Configuring the Joint Parameters

(8) In the dialog box shown below, confirm the conditions and press OK. In the

confirmation window, press OK. Then auto gain tuning will start.

The motor rotates in CCW and CW directions alternately two times each

direction in two sequences to calculate a temporary servo loop gain.

After that, the motor will repeat the sequence up to 8 times to fine-tune the gain.

If the gain is fixed within the eight sequences, auto gain tuning will complete.

Caution: For a boundless rotation joint, CALSET needs to be performed

after each auto gain tuning, which deletes CALSET values.

(9) After eight sequences of the above fine tuning operation, any of the following

messages may display:

"Auto gain tuning warning 1": Overshoot found at the end of motion.

"Auto gain tuning warning 2": Slow settlement found at the end of motion.

"Auto gain tuning warning 3": Low-level oscillation found during motion.

If any of the above messages displays but there is no problem with the joint

motion, then finish the gain tuning. If any abnormal noise or vibration is noted and there are some problems with the motion, then change the mechanical rigidity. After that, retry auto gain tuning or proceed to manual gain tuning.

(10) If you set higher mechanical rigidity for transmission mechanism having lower

rigidity and vise versa, then an error may occur during auto gain tuning. Change the mechanical rigidity setting and retry auto gain tuning.

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Chapter 4 Configuring the Joint Parameters

4.7.2 Manual Gain Tuning

You can manage the following parameters for manual gain tuning:

(1) Positioning loop gain

(2) Positioning loop feed forward gain

(3) Positioning error allowance

(4) Speed linear gain

(5) Speed loop integral gain

(6) Torque control filter

(7) Torque offset

The block diagram for the servo system is shown below.

An electric servo loop system consists of the three feed back systems--positioning loop, speed control loop, and drive current loop. The inner the loop is, the quicker response required. If the response of an inner loop is not sufficiently high for an outer loop, then the overall system response degrades and vibrations or oscillations may occur in the joint support system.

In this system, the innermost loop is the drive current loop and the outermost loop, the positioning loop.

You need to do gain tuning for the positioning loop and speed control loop. The drive current loop is designed to have sufficiently high response for all applications allowable to the joint support system.

Positioning path generator

Position control value

Pos. loop gain

Speed control value

Pos. loop FF gain

Encoder count

Motor rpm

Speed controlle

Speed loop linear gain

Speed loop integral gain

Torque control filter

Drive current control

Power converter

Encode

Moto

Speed detection

Torque offset

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Chapter 4 Configuring the Joint Parameters

4.7.2.1 Parameter details

(1) Positioning loop gain

Set the response of the positioning loop. The positioning loop gain is a dimensionless number, so it may be converted to the (1/s) unit according to the following formula:

Positioning loop gain x 125/256 (1/s) (Formula 4.7-1)

For example, positioning loop gain 32 is equivalent to 15.625 (1/s).

Increasing the positioning loop gain will reduce the positioning time. However, increasing the gain exceeding the natural oscillation frequency of the connected mechanism will easily bring vibration or overshoot. If the natural oscillation frequency is 20 Hz, for instance, set the positioning loop gain to 20 (1/s), that is, approx. 41.

(2) Positioning loop feed forward gain

Set the speed feeding forward value of the positioning loop. Increasing the value will reduce the positioning error and increase the system response. Setting 100 may reduce the positioning error to almost 0 in constant speed operation. However, setting an excessively high value may easily cause vibration or overshoot in the system.

(3) Positioning error allowance

Set the positioning error allowance. If the actual positioning error exceeds the specified allowance, an error will occur. The positioning error allowance should satisfy the following formula:

[Positioning error allowance] > [Maximum motor speed (rpm)] x (1.0-[Positioning loop forward gain (%)] x 0.01)/[Positioning loop gain] x 524288/1875

(Formula 4.7-2)

(4) Speed control linear gain

Set the response of the speed control system. Increasing the value will make it possible to set a high value to the positioning loop gain, thereby increasing the system response. The speed control linear gain to be set may be converted to the speed response frequency (in Hz) according to the following formula:

Speed response frequency (Hz) = [Speed control linear gain] / [Motor rotor inertia (kgm

) + Load inertia converted at motor joint (kgm2)] x [Drive current loop gain] / (2)

(Formula 4.7-3)

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The drive current system gain is as listed below.

Motor Model Motor rated output Drive Current System Gain

SGMAH-A5A1A 50W 1.852E-05

SGMAH-01A1A 100W 3.004E-05

SGMAH-02A1A 200W 7.144E-05

SGMAH-04A1A 400W 1.093E-04

SGMAH-08A1A 750W 1.979E-04

SGMPH-01A1A 100W 3.421E-05

SGMPH-02A1A 200W 7.845E-05

SGMPH-04A1A 400W 1.209E-04

SGMPH-08A1A 750W 2.150E-04

SGMPH-15A1A 1500W 5.819E-04

(5) Speed control integral gain

Set the integral compensation gain of the speed control system. You may convert the integral gain of the speed control loop into integral speed loop gain time constant (ms) according to the following formula:

Integral speed loop gain time constant (ms) =

0.25 x [Speed control linear gain] / [Speed loop integral gain]

(Formula 4.7-4)

Increasing the value will decrease the integral time constant, making the speed error converge faster at the end of joint motion. However, increasing the value for the connected transmission mechanism having lower rigidity will decrease the convergence of residual oscillation at the end of joint motion.

(6) Torque control filter

This value sets the band of the linear delay component for the torque control filter. The table below lists the relationship between the value and the band.

Filter Set Value 3 4 5 6 7 8 9 10 11 12 13 14 15

Band (Hz) 2450 1080 843 682 559 460 377 305 241 184 133 85 41

(7) Torque offset

This value gives an offset to the torque control value of joint support system. If the motor undergoes any unbalanced load due to the force of gravity, setting this value will compensate the torque caused by the unbalanced load. The maximum offset value you can set is equal to the rated output torque of the motor.

If you set a large torque offset at once, the connected mechanism may move in the preset direction immediately after the motor power is turned on. Gradually change the torque offset while confirming the current torque value and positioning error waveform in the next item "4.7.2.2 Monitor of single-joint servo data."

As described in Section 4.7.1 "Auto Gain Tuning," the torque offset value will be automatically set if you enable the gravity offset torque in auto gain tuning.

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4.7.2.2 Monitor of single-joint servo data

This function allows you to monitor a specified joint servo data currently set in the controller with graphs in real-time.

(1) Monitoring capability

This function is capable of handling up to 1,250 samples of data at once. If the sampling interval is set to 1ms, then you may monitor the servo data for 1.25 seconds. If 8ms, you may monitor it for 10 seconds.

The following five types of data may be monitored, two types at a time:

1) Motor speed control value (rpm)

Shows the sampled control value of motor speed.

2) Current motor speed (rpm)

Shows the sampled current motor speed.

3) Motor angle deviation (pulse)

Shows the deviation between the actual motor angle and motor control angle.

4) Torque control value (%)

Shows the substantial torque control value; that is, (Torque control value – the

Torque offset value). The unit is a ratio to the rated motor torque (%).

5) Motor current (%)

Shows the currently maximal motor drive current between the 3-phase driving lines. The unit is a ratio to the motor rated current.

(2) Defining the monitoring terms

To define the monitoring terms, call the single-joint servo data monitor definition

library SetMonitorCond in your program. For details, refer to "SetMonitorCond" in Section 4.9.

Once monitoring starts, the monitoring terms already defined cannot be changed

until the monitoring cycle has completed. Define all necessary monitoring terms before starting a monitoring cycle.

(3) Starting and stopping the monitoring cycle

To start monitoring, run the library StartSrvMonitor. To end it, run the library

StopSrvMonitor. To clear the data collected in the monitoring cycle, run the library ClearSrvMonitor. For details, refer to StartSrvMonitor, StopSrvMonitor, and ClearSrvMonitor in Section 4.9.

If the total number of data samples monitored in a monitoring cycle is 1250 or less,

all data may be monitored. If it exceeds 1250 samples, the last 1250 data samples before the end of the cycle may be monitored and other data will be discarded.

If any error occurs and the motor being monitored is turned OFF during monitoring,

then a maximum of 850 samples before the OFF and 400 samples after that may be monitored.

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(4) Graphing the monitored data

The single joint servo log function in WINCAPSIII can graph the monitored data on

a PC screen.

(4.1) Read monitored data

To receive single joint servo log data from the controller, use the data transfer

function in WINCAPSIII as follows.

Choose Connect | Transfer data to display the Transfer data window.

In the Controller pane, select Log | Single joint control log and then press Receive.

This operation transfers the single joint servo log data held in the controller to the

current project in WINCAPSIII.

(4.2) Plot the graph of monitored data

Choose View | Log View | Servo data to plot the graph of the single joint servo log

data of the project in WINCAPSIII.

Adjust the scale and offset of the graph and check the graphed data.

(5) Saving the monitored data into a file

WINCAPSIII can save the monitored data into a CSV file.

Choose File | Export to display the Export window.

Specify the destination folder, select Single Joint Servo Log (Log_Srv.csv) in Log,

and then press Export.

This operation saves the data into the specified folder in CSV format.

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4.7.2.3 Operating procedure for manual gain tuning

(1) Initializing positioning loop gain

First set the positioning loop gain to almost the same value of that calculated from

natural frequency of the connected mechanism.

If the natural frequency is 20 Hz, set the positioning loop gain to 41 which equals to

20  256/125 as calculated by Formula 4.7-1. If the natural frequency is unknown, use the default value 64.

(2) Tuning torque

If almost constant, unbalanced load (e.g., force of gravity) applies to the motor,

then set the torque offset calculated from the load.

(3) Obtaining the limit of speed linear loop gain

While increasing the speed linear loop gain gradually, find the upper limit of the

loop gain at which the connected mechanism will start producing abnormal noises or oscillations.

(4) Checking the effect of the torque control filter setting

First set the torque control filter parameter to "0" and find the upper limit of speed

linear loop gain again. If the speed linear loop gain obtained here is lower than the previous one obtained in step (3), reset it to 8 (default).

(5) Determining the appropriate speed linear loop gain

Apply 80% of the limit obtained in steps (3) and (4) to the speed linear loop on the

connected mechanism.

(6) Tuning the speed Integral loop gain

Gradually increase the speed integral loop gain so that the positioning time and

peaks of overshoot and undershoot will be minimized to optimize the connected mechanism.

(7) Tuning the positioning loop gain

If the connected mechanism is still oscillatory after carrying out the procedure in

step (6), then decrease the positioning loop gain.

If you decrease the positioning time further after tuning in steps (3) through (6),

then gradually increase the positioning loop gain to the extent that no noise or oscillation will be produced.

(8) Tuning the positioning loop feed forward gain

If you further decrease the positioning time of the connected mechanism, gradually

increase the positioning loop feed forward gain to extend that no oscillation will be produced.

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(9) Checking operations of the connected mechanism in full motion range and in

full speed range

Run the connected mechanism in the full motion range while changing the speed gradually. If any abnormal noises or vibrations occur at some particular points, then check whether the mechanism slides evenly.

If any abnormal noise occurs in some particular speed, tune the torque control filter parameter again and check whether the abnormal noise decreases.

If tuning-up of the mechanism and torque control filter parameter cannot suppress abnormal noises, then decrease the speed linear loop gain and speed integral loop gain in the same proportion. (It is convenient to use the quick tuning function for the speed control system gain described in the next item [ 4 ].)

If any vibration occurs in some particular speed, decrease the speed integral loop gain, positioning loop gain, and/or positioning loop feed forward gain.

NOTE: Servomotors recommended earlier in this manual will issue torque ripple 4 times per rotation. The torque transmission mechanism may also issue torque ripple specific times per rotation at its output shaft.

Therefore, the frequency of the torque ripple may vary according to the speed so as to become equal to the natural frequency of the connected mechanism.

If vibrations are large in some specific speed, decrease the speed integral loop gain, positioning loop gain and/or positioning loop feed forward gain as well as stated above.

4.7.2.4 Quick tuning function for speed control system gain

As expressed in Formula 4.7-4, the ratio of the speed linear loop gain to speed integral loop gain makes the integral speed loop gain time constant. For fine-tuning of the speed control system gain, therefore, change the speed linear loop gain and speed integral loop gain in the same proportion. This simultaneous and proportional adjustment of those gains is "Quick tuning function for speed control system gain." You may use this function with the teach pendant.

(1) Calling up the Quick Loop Gain Tuning screen using the teach pendant

Access: Top Screen―[F2 Arm]―[F6 Aux.]―[F7 Config.]―[F3 Jump To]

Select #59.

(2) Setting a value to "Gain Decreasing Ratio (J*)" for the joint (J*) to be tuned

The gain decreasing ratio is called Tuning Ratio. The controller automatically

modifies the current speed linear loop gain and speed integral loop gain by the number of "Tuning Ratio" times.

The relationship between the value to be set and the tuning ratio is listed below.

Set Value -5 -4 -3 -2 -1 0 1 2 3 4 5

Tuning Ratio 1.5 1.4 1.3 1.2 1.1 1 0.9 0.8 0.7 0.6 0.5

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4.8 Joint Exclusive Operations

4.8.1 Performing CALSET Operation on Each Joint

■ From the teach pendant

(1) Call up the Maintenance Functions (Arm) window.

Access: Top Screen―[F2 Arm]―[F12 Maint.]―[F6 CALSET]

Select a joint to be CALSET and press [OK]. CALSET on the selected joint will start.

■ From the mini-pendant

Access: [AUX]—[ArmAux]—[CalSet]

(1) The CALSET joint selection window appears.

(2) Enter a joint number to be CALSET.

NOTE: Selecting 0 performs CALSET on all joints.

(3) Press [OK] to start CALSET on the selected joint.

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4.8.2 Releasing or locking brakes

■ From the teach pendant

(1) Call up the Brake Release Settings window.

Access: Top Screen―[F2 Arm]―[F12 Maint.]―[F3 Brake]

(2) Select the target brake.

(3) Press [F5 ON/OFF], and the indicator color of the selected brake will change

from black to green if locked or from green to black if released.

Black: Brake locked, Green: Brake released

To lock all axes' brakes, press [F4 CanclAll]; to release them, press [F6 SelctAll].

(4) Check the brake status, and then press the OK button to make the new entry

take effect.

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■ From the mini-pendant

(1) Press [BRAKE] to call up the "BrakeSetting" window shown below.

(2) Choose an arbitrary joint with the up and down cursor keys. (You can vertically

scroll the screen with those keys.)

Then press [OK]. Either of the following windows will appear.

(3) To switch the selected joint brake between Release and Lock status, press [OK].

To abort brake setting and return to the previous screen, press [CANCEL].

(4) If the selected brake is released or locked successfully as specified, the following

message will display.

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4.8.3 Direct Teaching Mode

This section describes the direct teaching mode in the SMT7. The direct teaching mode allows you to move the joint by hand (without using the teach pendant) with the motor OFF and teach the current position to a joint variable, position variable, or homogeneous transform matrix variable. (Usual teaching requires the motor to be turned ON.)

Note 1: In the SMT7, the system has no air balance cylinder on the Z-axis, so the operation procedure for the direct teaching mode differs from that of the conventional 4-axis robots.

Note 2: In the SMT7, the brake is not released in the direct teaching mode.

■ From the teach pendant

Access: Top Screen―[F2 Arm]―[F12 Maint.]―[F3 Brake]

(1) In the Auxiliary Functions (Arm) window, press [F3 Direct.].

The following message will appear. Press the OK button.

Caution: The system message "The specified brake(s) will be

released by pressing the brake release button." appears. But the SMT7 series, the brake is not released.

(2) The system message "The direct mode is started." appears.

If pressing the OK button, the direct teaching mode will be started.

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■ From the mini-pendant (Starting/ending the direct teaching mode)

Access: [AUX]―[Arm Aux.]―[Direct.]

(1) Select [Direct] and press [OK].

(2) A confirmation screen whether "Direct Mode Start OK?" or "Direct Mode end OK?"

appears.

(3) Press [OK]. The direct teaching mode starts or ends.

NOTE: In the direct teaching mode, the "D" appears at the left end of the status

bar.

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4.8.4 Resetting Encoder

You need to reset encoders and perform CALSET if:

- Error 6411 or 6422 occurs due to first use of AC servomotors, or run-down

encoder backup batteries, or

- Error 6771 or 6772 occurs due to a great impact applied to the robot when

the power is off.

This section describes how to reset encoders using the teach pendant.

■ From the teach pendant

(1) Call up the Encoder reset window.

Access: Top Screen―[F2 Arm]―[F12 Maint.]―[F11 ENC rst]

Pressing [F11 ENC rst] in the Maintenance Functions (Arm) window will display the Encoder reset window as shown below.

(2) Enter the axis number whose encoder is to be reset, and press [OK]. System Message appears.

(3) Pressing [OK] resets the encoder on the selected axis.

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■ From the mini-pendant

Access: [AUX]—[ArmAux]—[EncRst]

(1) The "Select Joint" screen appears, prompting you to choose the joint to reset the

related encoder.

(2) Select the target joint.

(3) Press [OK] to start resetting the encoder on the target joint.

4.8.5 Operating Extended-Joints

For the operating procedures for the manual operation of extended-joints, for taking position data into variables, and for moving a joint with a variable in an extended-joint motion, refer to the Supplement for Extended-Joints Support.

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4.8.6 Programmed Operation in SMT7 (Description of arm groups)

■ Concept of an arm group

An arm group is a set of semaphores for joints to be driven. Specifying an arm group using a TAKEARM command allows a task to get arm semaphores and execute motion commands. Using an arm group prevents more than one task from executing a motion command to the same joint at the same time.

A motion command is executable only to those joints contained in the arm group held in the task.

Robot joints are regarded as a single linked joint so that they cannot individually take arm semaphores. On the contrary, extended-joints can individually take arm semaphores and the individual settings constitute an arm group.

Up to 32 arm groups are available.

Example: When an extended-joint motion is specified, a task holding Group 1 obtains permissions to drive joints 1 and 2 (robot joints) and joint 5.

Extended-joint motion setting

■ Getting an arm group

To make tasks get an arm group, give a TAKEARM command an arm group number as an argument as shown below.

PROGRAM PRO1

TAKEARM 1

END

 PRO1 gets Arm Group 1 by TAKEARM command with an

argument set to 1.

For the TAKEARM syntax and KEEP options, refer to the Programmer's Manual I, Section 14.3 "Arm Semaphore."

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■ Releasing the currently held arm group

To release the currently held arm group, execute a GIVEARM command.

An occurrence of an error or program termination automatically releases the currently held arm group.

For details about the GIVEARM, refer to the Programmer's Manual I, Section 14.3 "Arm Semaphore."

Example: Halt or Step Stop does not release the currently held arm group.

■ Restrictions on the application of arm groups

Two or more programs can run concurrently as long as their arm groups specified do not hold the same joint(s).

If their arm groups hold the same joint(s), only one program can run and arm group related lines in other programs cannot execute during execution of the currently running program.

Example: In an extended-joint motion During execution of codes

in PRO0, codes in PRO1 cannot execute, but

codes

in PRO2 can execute concurrently.

Example: Extended-joint motion setting

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■ Motion commands requiring an arm group

The following commands require an arm group.

If a task holding no arm group attempts to execute any of the following motion commands, an error will occur. Before execution of those commands, get an arm group by using the TAKEARM command.

Commands

HOME, TOOL, WORK, APPROACH, DEPART, DRAW, GOHOME,

MOVE, ROTATEH, ROTATE, CHANGETOOL, CHANGEWORK,

DRIVE, DRIVEA, SPEED, JSPEED, ACCEL, JACCEL,

DECEL, JDECEL, INTERRU

T, LETENV, POSCLR, Motion

optimization library, Arm motion library

■ Defining a new configuration of an arm group

To drive both J5 and J6 in an extended-joint motion

Usually arm groups are configured by default as shown on the previous page; that is, Arm Group 1 contains J5, and Arm Group 2, J6.

Making a single program to hold more than one arm group (Arm Groups 1 and 2) will result in an error as shown below.

Example: PROGRAM PRO2

TAKEARM 1 . . TAKEARM 2 'Impossible to get Arm Group 2 'after getting Arm Group 1 'Resulting in an error

To drive both J5 and J6 in a single task in an extended-joint motion, you need to define a new configuration of an arm group (e.g. Arm Group 3) to contain both joints using the procedure given on the next page. Then make the task get the newly configured arm group as shown below.

Such configuration allows only the PTP motion with DRIVE and DRIVEA commands.

Example: PROGRAM PRO1

TAKEARM 3 'When changing the configuration of Arm . 'Group 3 to contain J5 and J6 . . DRIVE (5,20.5),(6,150.33) 'Drive J5 and J6 concurrently

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Note: A program can get the same arm group repeatedly.

Example: PROGRAM PRO1

TAKEARM 1 . . TAKEARM 1 'Possible to get Arm Group 1 'even after getting it on the earlier 'line

■ From the teach pendant

(1) Call up the "ArmGroup Settings" window.

Access: Top Screen—[F2 Arm]—[F12 Maint.]—[F7 Joints]—[F1 ArmGroup]

(2) Choose the arm group to be changed and press [F5 Change].

(3) Select or deselect joints with  or , respectively, and then press [OK].

Example: Making Arm Group 3 contain J5 and J6

Note 1: New configuration settings will go into effect when the controller is turned

off and then on after the change.

Note 2: Arm Group 0 cannot be accessed.

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■ Notes for command execution from the specified line

The specifications about command execution from the specified line are detailed in the Setting-up Manual, Section 3.3, "Teach Check Mode (TP/MP), [ 4 ]."

(1) Making effective the arm group previously obtained by TAKEARM

If a command on the specified program line is executed, an arm group obtained

by a TAKEARM command on the earlier line will automatically take effect.

Example

PROGRAM PRO1 TAKEARM 1  Get Arm Group 1 I0=3  Step stop at this line MOVE P，P0 MOVE P，P1  If this line is specified, Arm Group 1 automatically goes into effect again. END

(2) Notes when using more than one arm group in a single task

Example

PROGRAM PRO1 TAKEARM 1  Get Arm Group 1 I0=3  Step stop at this line DRIVE (7,10) GIVEARM TAKEARM 2 DRIVE (8,23)  If this line is specified, Arm Group 0

obtained by the earlier TAKEARM 1 automatically goes into effect again. DRIVE command requires Arm Group 2, so an

error will occur. END

(3) Checking an active arm group currently held by a task

You can check an active arm group by displaying the task.

Example: This program has got Arm Group 0.

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4.9 Joint Parameter Configuration Commands

4.9.1 Single-Joint Servo Data Monitor Commands (Library)

SetMonitorCond

Function

Sets the monitoring conditions for single-joint servo data monitor.

Syntax

SetMonitorCond(<JntNumber>,<MonitorData1>,<MonitorData2>, <SampInterval>)

Description

SetMonitorCond sets the joint number to be monitored, monitor data (up to 2 types allowed per command), and sampling interval in ms as monitoring conditions.

The following five types of data may be monitored, two types at a time, by specifying <MonitorData1> and <MonitorData2>:

Data to be monitored

0 Motor speed control value in rpm

1 Current motor speed (Actual speed) in rpm

2 Motor torque control value (excluding torque offset) in ratio

(%) to the rated value

3 Motor rotation angle error (Motor angle control value -

Actual motor angle value) in pulses

4 Motor current absolute value (Maximum value out of three

absolute values detected from all 3 phases of the motor.) in ratio (%) to the rated value

<SampInterval> must be set in ms as an integer between 1 and 8.

Macro definition

Not needed.

Related commands

ClearSrvMonitor, StartSrvMonitor, and StopSrvMonitor

Notes

(1) If this library executes following the monitor start library

StartSrvMonitor, the error "6001: Not executable" will result. Be sure to set the monitoring conditions before starting monitor.

(2) If any of the joint number, data types, and sampling interval entered is

wrong, the error message "The entered value is out of the range." will result. Correct those monitoring conditions you entered.

Example

CALL SetMonitorCond(7,0,3,4) 'For getting speed control value and 'motor angle error of J7 every 4 ms. CALL StartSrvMonitor 'Start monitoring data.

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StartSrvMonitor

Function

Starts monitoring single-joint servo data.

Syntax

StartSrvMonitor

Description

StartSrvMonitor fetches a maximum of 1250 samples of single-joint servo data until StopSrvMonitor executes.

Macro definition

Not needed.

Related commands

ClearSrvMonitor, SetMonitorCond, and StopSrvMonitor

Notes

(1) If the total number of data samples monitored in a monitoring cycle is 1250

or less, all data may be monitored. If it exceeds 1250 samples, the last 1250 data samples before the end of the cycle may be monitored and other data will be discarded.

(2) If any error occurs and the motor being monitored is turned OFF during

monitoring, then a maximum of 850 samples before the OFF and 400 samples after that may be monitored.

(3) No data may be monitored when the target motor is off. Execute this

command with the motor power on.

Example

CALL SetMonitorCond(7,0,3,4) 'For getting speed control value and 'motor angle error of J7 every 4 ms.

CALL StartSrvMonitor 'Start monitoring data.