num 1060 D.I.S.C. User Manual

NUM 1060

D.I.S.C.

(DIGITAL INTEGRATED

SERVO CONTROL)

INTEGRATION

MANUAL

0101938907/3

06-97 en-938907/3

Despite the care taken in the preparation of this document, NUM cannot guarantee the accuracy of the information it contains and cannot be held responsible for any errors therein, nor for any damage which might result from the use or application of the document.

The physical, technical and functional characteristics of the hardware and software products and the services described in this document are subject to modification and cannot under any circumstances be regarded as contractual.

The programming examples described in this manual are intended for guidance only. They must be specially adapted before they can be used in programs with an industrial application, according to the automated system used and the safety levels required.

All rights reserved. No part of this manual may be copied or reproduced in any form or by any means whatsoever, including photographic or magnetic processes. The transcription on an electronic machine of all or part of the contents is forbidden.

This software is the property of NUM. Each memorized copy of this software sold confers upon the purchaser a non-exclusive licence strictly limited to the use of the said copy. No copy or other form of duplication of this product is authorized.

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Table of Contents

1 General 1-1

1.1 General Description

1.2 Functional Description

1.3 System Architecture

2 Components 2-1

2.1 QVN Card

2.2 Measurement Cable

2.3 Compatible Axis Drives

3 Interconnections 3-1

3.1 Schematic Diagram

3.2 Servo-Drive Interconnections

3.3 Motor and Brake Power Supply

3.4 Measurement Cable Wiring Diagrams

3.5 Connection in Fibre-Optic Ring

3.6 Transmit Power Control

3.7 Setting of the Address Switch on the Serial Bus

3.8 Setting a Motor/Servo-Drive Association

4 Safecty Device Setting and Use

4.1 Messages Displayed at Power ON

4.2 Fault Detection and Processing of Safety Devices

4.3 Fault Diagnostic

4.4 QVN Information Pages

4.5 Reset After a Fault

5 Machine Parameters 5-1

5.1 General

5.2 Miscellaneous Parameters

5.3 Servo-Control Loop Gain Coefficient

5.4 Noisy Signal and Encoder Channel Complementarity Monitoring Declaration

5.5 Sampling Period

5.6 Card Mapping

5.7 Axes Controlled by QVN

5.8 Motor Direction of Rotation

5.9 Maximum Motor Speed

5.10 Block Diagram of the Speed Loop

5.11 Speed Servo-Loop Proportional Action Coefficient

5.12 Speed Servo-Loop Integral Action Cut-off Pulse

5.13 Speed Sensor Measurement Increment Average (Motor Sensor)

5.14 Speed Measurement Filter

5.15 Torque Reference Filter

5.16 Static Current Limiting

1-3 1-4 1-5

2-3 2-4 2-5

3-3 3-4

3-6 3-7 3-9

3-10 3-12

3-13

4-1 4-3

4-5 4-9

4-10 4-14

5-3

5-8 5-9

5-10 5-11 5-12 5-14 5-18 5-20 5-21

5-22 5-24 5-25

5-26 5-27 5-28

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5.17 Association of a Torque Slave with a Master

5.18 Direction of Rotation of a Torque Slave Application

5.19 Preload Current of a Master/Slave Pair

5-29 5-30

5-31

6 PLC Variables 6-1

6.1 Torque Enable

6.2 Speed Reference Enable

6.3 Programming Recommendations

6.4 Dynamic Current Limiting

6.5 Exchange Area

6-3 6-3 6-3 6-4 6-4

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Record of Revisions

Date Revision Pages revised Pages added Pages deleted

07 - 94 1 Complete revision

10 - 96 2 Complete revision

06 - 97 3 All pages issued in

Revision 3

REVISIONS OF THE DOCUMENTATION

Date Revision Reason for revision

08 - 93 0 Conforming to NUM 1060 software at index F.

07 - 94 1 Conforming to NUM 1060 software at index F2.

Miscellaneous corrections.

10 - 96 2 Conforming to NUM 1020, 1040 and 1060 software at index K.

SETTool software at index E taken into account. Changes in servo-drives: transmit power and motor/servo-drive association settings on the front panel. Miscellaneous corrections.

06 - 97 3 Change in motor torques after measurements.

Miscellaneous corrections.

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6 en-938907/3

Structure of the NUM 1060 Documentation

User Documents

These documents are designed for the operator of the numerical control.

Preliminary

NUM

OPERATOR'S

MANUAL

M/W

938821

NUM

OPERATOR'S

MANUAL

T/G

938822

NUM

PROGRAMMING

MANUAL

938819

OEM Documents

These documents are designed for the OEM integrating the numerical control on a machine.

NUM 1060

INSTALLATION

AND

COMMISSIONING

MANUAL

NUM

PARAMETER

MANUAL

NUM

MACHINE

PROCESSOR

PROGRAMMING

MANUAL LADDER

LANGUAGE

NUM

PROGRAMMING

MANUAL

938820

NUM

D.I.S.C.

INTEGRATION

MANUAL

938816

938818

938846

938907

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List of NUM 1020 - 1040 - 1060 Utilities

A series of utilities are available for the NUM 1020 - 1040 - 1060 CNCs for integration and use of the systems. These utilities may be included in the basic version or available as options. Depending on the function performed by each utility, its use is described in the integration manual or operator manual. The table below lists the utilities and gives the references of the document describing them:

Utility Name Manual Chapter

UT 2 axis calibration installation and commissioning manuals 10

(938 816 or 938 938) UT 3 resident macros operator manuals (938 821 or 938 822) 8 UT5 parameter integration parameter manual (938 818) 12 UT 7 PLC programme debugging machine processor programming manual 18

ladder language (938 946) UT12 option locking operator manuals (938 821 or 938 822) 8 UT20 interaxis calibration installation and commissioning manual 1 1

(938 816 or 938 938) UT22 axis parameter integration SETTool manual (938 924) 8

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DISC (Digital Integrated Servo Control) Integration Manual

This manual is used for integrating the DISC components in the CNC.

Description of the axis and spindle DISC concepts

- General description,

- Functional description,

CHAPTER 1

GENERAL

CHAPTER 2

- System architecture.

Description of the DISC components

- Physical characteristics,

- Technical characteristics,

- List of DISC-compatible drives.

Preliminary

COMPONENTS

CHAPTER 3

INTERCONNECTIONS

CHAPTER 4

SAFETY DEVICE

SETTING AND

USE

Interconnections, adjustments and settings

- Fibre-optic ring,

- Transmit power setting,

- Address settings,

- Motor/servo-drive association settings,

- Schemas.

Faults and safety device processing

- Procedure for accessing the error display pages,

- Resetting procedures.

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List of machine parameters and axis and spindle configuration rules.

CHAPTER 5

MACHINE

PARAMETERS

List of PLC variables and programming rules.

CHAPTER 6

PLC

VARIABLES

Use of the DISC Integration Manual

Agencies

The list of NUM agencies is given at the end of the manual.

Questionnaire

To help us improve the quality of our documentation, we kindly request you to return the questionnaire at the end of the manual.

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General

1 General

1.1 General Description 1-3

1.2 Functional Description

1.3 System Architecture 1-5

1.3.1 NUM 1060 Series 2 System

1.3.1.1 1060 Series 2 with Two Processors

1.3.1.2 1060 Series 2 with UC SII Processor

1.3.2 NUM 1060 Series 1 System

1-4

1-5 1-5 1-6 1-7

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1 - 2 en-938907/3

General

1.1 General Description

The DISC (Digital Integrated Servo-Control) concept includes:

- QVN card (heart of the DISC concept),

- Current amplifier for the axes,

- Sensor integrated in the BMH motor,

- Fibre-optic digital link. The QVN card is built around a signal processor specially designed for servo-control (feedback) algorithms. It currently

operates on conventional axis speed and position control algorithms. This servo-control architecture is based on the following principles:

CNC

Digital servo-

drive

Fibre-optic link

400 VAC

current

amplifier

Digital sensor

BMH

motor

- Digital position and speed loops (in the CNC),

- Modular current amplifier directly connected to the European 400 VAC network,

- Two-way communication by optical fibre allowing transfers from the CNC to the amplifier (current reference, amplifier module control word) and from the amplifier to the CNC (module status word for processing the safety devices and diagnostic in the CNC),

- Dedicated sensor integrated in the motor,

- SETTool integration tool running on PC.

Several high-level diagnostic devices are included in the CNC for remote diagnostic from the CNC operator panel. The SETTool integration tool with sophisticated ergonomics, running on a PC, is used to optimise the servo-control

parameters. SETTool includes an oscilloscope function and automatic setting procedures (machine parameters) allowing rapid and reliable integration.

Since the speed servo-loop is fully digitised, any offset that could bias the following error has been completely eliminated, making the servo-control more accurate and the axes more stable.

Both DISC and conventional axes and spindles can be controlled by the same CNC (for the conventional axes, a +/-10 V speed reference is used by each axis card).

Two sensor configurations are possible for an axis controlled by QVN:

- A single speed and position measurement sensor (motor sensor) connected to the QVN card,

- A speed measurement sensor (motor sensor) connected to the QVN card and a position measurement sensor (on the moving assembly) connected to the same QVN card or to an axis encoder card.

A QVN sensor input can receive data from a spindle sensor, a handwheel (with complemented channels) or a position sensor for an axis that is only measured.

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Maximum Axis Speed

Considering an internal resolution of one micron (one ten-thousandth of a degree for rotary axes), the maximum speeds are as follows:

Axis speed Axis speed

(without additional sensor) (with additional sensor)

Motor speed Linear axis Rotary axis Linear axis Rotary axis (rpm) (m/min) (rpm) (m/min) (x1000 °/rpm)

2000 36 100 360 100 3000 54 150 360 100 4000 72 200 360 100

1.2 Functional Description

When connected to the CNC system bus, the QVN (digital drive) card:

- Handles transfers with the current amplifier and interfaces with the motor sensors; if an additional sensor is placed on the axis, it can provide the interfacing,

- Handles feedback with position and speed control,

- Manages the safety devices specific to the axis.

Machine

E_CNPRET

SETTOOL

parameter

integration tool

The SETTool software is used for:

- Setting the machine parameters,

- Testing of the servo-control responses to a typical signal (indicial response for the speed loop),

- Display of the response by the oscilloscope function.

safety

device

Interpo-

lation

Safety device processing

Position

control

QVN card

QVN card or axes

Speed control

CNC

Current

Measu-

rement

Measu-

rement

control

Amplifier

safety

devices

Power

stage

Current

amplifier

BMH

motor

Motor

sensor

Axis

sensor

1 - 4 en-938907/3

1.3 System Architecture

1.3.1 NUM 1060 Series 2 System

1.3.1.1 1060 Series 2 with Two Processors

General

Operator panel

Compact panel ∗

System Bus

CNC/graphic

processor

Memory

QVN Axes

Axes

Dedicated interfaces

Digital bus

Optional keyboard

To current amplifier Measurement

Origin switch

Anamogue speed reference Measurement Origin switch

Inputs

Outputs

Machine

processor

Serial Bus

Serial

bus/fibre-optic

adapter

Interrupts Analogue inputs/outputs Serial interfaces

∗ The use of the compact panel precludes the use of a machine panel.

Machine

panel

Machine

panel extension

(I/O)

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1.3.1.2 1060 Series 2 with UC SII Processor

Graphic function

Operator panel

Compact panel ∗

U C

System Bus

Serial Bus

Memory

CNC

function

PLC

function

Serial

bus/fibre-optic

adapter

Inputs

Outputs

Optional keyboard

RS 232 serial interfaces

Interrupt

Analogue inputs/outputs

Machine

panel

Machine

panel

extension (I/O)

Digital bus

QVN Axes

Axes

Dedicated

interfaces

To current amplifier Measurement

Origin switch

Speed reference Measurement Origin switch

∗ The use of the compact panel precludes the use of a machine panel.

1 - 6 en-938907/3

1.3.2 NUM 1060 Series 1 System

General

System Bus

Graphic

processor

Memory

CNC

processor

QVN Axes

Axes

Digital bus

Operator panel

Serial interfaces

To current amplifier Measurement

Origin switch

Speed reference Measurement Origin switch

Compact panel ∗

Optional keyboard

Remote

inputs

Dedicated interfaces

Machine

processor

Serial Bus

Interrupts Analogue inputs/outputs Serial interfaces

Serial

bus/fibre-optic

adapter

Inputs

Outputs

∗ The use of the compact panel precludes the use of a machine panel.

Remote

outputs

Machine

panel

Machine

panel extension

(I/O)

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1 - 8 en-938907/3

Components

2 Components

2.1 QVN Card 2-3

2.2 Measurement Cable

2.3 Compatible Axis Drives 2-5

2.3.1 Motor Characteristics

2.3.2 Current Amplifier Module

2.3.2.1 Characteristics

2.3.2.2 Overall Dimensions and Mounting Dimensions

2.3.3 BMH Axis Motor

2-4

2-5 2-8 2-9

2-10 2-10

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2 - 2 en-938907/3

Components

2.1 QVN Card

The QVN card is in double Eurocard format. It plugs into the system bus of the CNC rack. The interconnections are made on the front using four 26-contact Sub.D (high density) connectors for the sensors and one fibre-optic transmit/ receive connector.

CAUTION

The QVN cards (P/N 204 202 069) must be connected to the system bus just to the left of

the memory card.

Power consumption 1.25 A (+ 0.18 A per DISC sensor) Location in the continuity of the CNC cards Switch contact one 24 V input per axis

C A P T 3

The QVN card includes four measurement inputs and is able to drive up to four axes. The built-in sensors on the axis motors controlled by the QVN card are connected in

priority to the measurement inputs. Any additional axis, spindle and handwheel sensors can be connected to the remaining inputs, to another QVN card or to an axis encoder card.

C A P T 2

C A P T 1

C A P T 0

V A R

R E C

QVN

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2.2 Measurement Cable

Protective earth

This cable interconnects the QVN card with:

- The motor sensor,

- An encoder or a rule,

- A handwheel.

Solder side

1 2

Cable Assembly Part Number

1 - Cable assembly (see P/N) including:

2 - Connector supplied with the motor to be wired (see Sec. 3.4)

BMH Q 50 M xx

To switch and

24 V power suppl

- One 26-contact male Sub.D (high density) connector

- One typical sensor and thermal probe cable (length 6, 10, 15, 20, 25, 30 or 40 m)

- One typical FM2R switch cable (length 1.5 m)

Length in m

If the switch cable is not used

When the switch cable is not used, the shielding and two conductors must mandatorily be connected to the protective earth to prevent interference.

2 - 4 en-938907/3

Components

2.3 Compatible Axis Drives

The axis drives compatible with DISC consist of BMH axis motors equipped with a dedicated sensor and 400 VAC modular current amplifiers.

REMARK All spindle drives with UAC servo-drive are compatible with DISC.

2.3.1 Motor Characteristics

BMH..D Motor Cn 60 ∗ In 60 ∗ rated Pn 60 ∗ rated Nominal Amplifier Cmax Cmax

torque current A rms power kW dim speed rpm MDL D...Q /Cn Nm

• 075 1 N 1.1 1.9 0.35 3000 007 2.45 2.7

014 4.73 5.2

1 V 1.1 2.6 0.46 4000 014 3.55 3.9

• 2 N 1.8 2.3 0.63 3000 014 4.17 7.5

2 V 1.8 3 0.84 4000 014 3.28 5.9

• 4 N 3.1 3 1.07 3000 014 3.55 11

• 095 2 N 3.3 2.9 1.16 3000 014 3.33 11

2 V 3.3 5 1.55 4000 021 3.03 10

3.3 5 1.55 4000 034 4.24 14

• 3 N 4.6 4.5 1.6 3000 021 3.48 16

3 V 4.6 8.8 2.14 4000 034 3.04 14

050 4.13 19

• 5 N 7.1 4.9 2.45 3000 021 3.1 22

034 4.37 31

• 115 2 N 5.7 4.7 1.98 3000 021 2.81 16

034 3.68 21

2 V 5.7 8.9 2.64 4000 034 2.46 14

050 3.16 18

3 K 8.1 4.5 1.86 2000 021 2.96 24

• 3 N 8.1 7.8 2.79 3000 034 2.72 22

050 3.58 29

3 V 8.1 10.7 3.73 4000 034 2.22 18

050 2.96 24 075 3.7 30

• 4 K 10.2 5.3 2.37 2000 021 2.65 27

034 3.73 38

4 N 10.2 8.6 3.55 3000 034 2.65 27

050 3.43 35

4 V 10.2 15 4.73 4000 050 2.25 23

075 3.14 32 100 3.82 39

6 N 14.4 10.2 5.02 3000 034 2.29 33

050 3.13 45

∗ :∆T = 60 K.

• : Preferred motor type.

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BMH..D Motor Cn 60 ∗ In 60 ∗ rated Pn 60 ∗ rated Nominal Amplifier Cmax Cmax

torque current A rms power kW dim speed rpm MDL D...Q /Cn Nm

142 2 K 9.2 5.1 2.09 2000 021 2.39 22

034 3.15 29

• 2 N 9.2 8.8 3.14 3000 034 2.17 20

050 2.93 27

2 R 9.2 9.8 4.19 4000 034 2.07 19

050 2.72 25

3 K 13.1 8.1 2.93 2000 034 2.52 33

050 3.28 43

• 3 N 13.1 9.9 4.4 3000 034 2.14 28

050 2.82 37

3 R 13.1 14.4 5.86 4000 050 2.14 28

075 2.90 38 100 3.44 45

• 4 K 16.9 8.8 3.98 2000 034 2.43 41

050 3.25 55

4 N 16.9 13.3 5.97 3000 034 1.72 29

050 2.43 41 075 3.25 55

4 R 16.9 17.7 7.95 4000 075 2.66 45

100 3.25 55

7 N 27 20.6 9.42 3000 050 1.85 50

075 2.63 71 100 3.33 90

∗ :∆T = 60 K.

• : Preferred motor type.

2 - 6 en-938907/3

Components

BMH..D Motor Cn 60 ∗ In 60 ∗ rated Pn 60 ∗ rated Nominal Amplifier Cmax Cmax

torque current A rms power kW dim speed rpm MDL D...Q /Cn Nm

• 190 2 K 19.3 14.1 4. 4 2000 034 1.55 30

050 2.07 40

2 N 19.3 16.9 6.59 3000 050 1.81 35

075 2.38 46

2 R 19.3 24.8 8.79 4000 075 1.87 36

100 2.23 43

3 K 27.7 16.7 6.49 2000 050 1.88 52

075 2.45 68

• 3 N 27.7 23.6 9.73 3000 075 1.95 54

100 2.38 66

4 K 37 17.5 8.16 2000 050 1.84 68

075 2.43 90 100 2.84 105

4 N 37 25.8 12.25 3000 075 1.86 69

100 2.3 85

5 H 43.1 17 7.54 1500 050 1.9 82

075 2.53 109 100 2.95 127

• 5 L 43.1 26.7 12.56 2500 075 1.83 79

100 2.27 98 150 2.9 125

7 K 57.8 23.7 13.4 2000 075 2.08 120

100 2.56 148

A K 77 37.4 17.79 2000 100 1.88 145

150 2.60 200

∗ :∆T = 60 K.

• : Preferred motor type.

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2.3.2 Current Amplifier Module

PA and PB

for size 2

PA PB 1-L1 3-L2 5-L3

J400J400J400

12 13

1 - Ribbon cable connector 9 - Torque enable connector 2 - Plug-in terminal board for source I / O 10 - Microswitches for setting the 3 - Plug-in terminal board for serial interface (not used) motor / servo-drive associations 4 - LEDs 11 - Address microswitch 5 - Power cable connector (power lines L1, L2, L3) 12 - Optical output power setting 6 - Terminals for dissipation resistor (PA - PB) microswitch 7 - Connectors for monitor power supplies 13 - Fibre-optic connector (transmit) 8 - Plug-in connector (except on size 4) for motor 14 - Fibre-optic connector (receive)

power supply (U, V, W, earth) 15 - Connector cap

2 - 8 en-938907/3

Components

2.3.2.1 Characteristics

Amplifier Module

Module Size Pitch Rated Peak Rated Nominal Weight

(mm) current current power dissipation (kg)

(A rms) (A) (kW) (W)

MDL D2 007 Q 1 50 2 7 20 4.6 MDL D2 014 Q 4 14 35 MDL D2 021 Q 7 21 50

MDL D2 034 Q 2 80 14 34 150 6.9 MDL D2 050 Q 20 50 170

MDL D2 075 Q 3 110 35 75 200 9.2 MDL D2 100 Q 4 140 45 100 400 10.5

MDL D2 150 Q 60 150 460

Power Supply Module

Module Size Pitch Rated Peak Rated Nominal Weight

(mm) current current power dissipation (kg)

(A rms) (A) (kW) (W)

MDL L1 008 Q 2 80 14 8 50 8.1 MDL L1 015 Q 21 12 80 8.5

MDL L1 030 Q 4 140 53 30 170 10.5 Operating temperature range: 0 to +40 °C

Relative humidity: Maximum 75 percent noncondensing, nondripping Protection class: IP20

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2.3.2.2 Overall Dimensions and Mounting Dimensions

285

100

355

380

140

70 40

110 80 50

Install the components vertically, placing the amplifier modules to the right of the power supply modules.

Keep the assembly away from heat-generating components. Provide a clearance of 100 mm at the top and bottom and 50 mm on the left and right of the assembly for ventilation. Provide a clearance of 40 mm in front for the cables. Use M6 attaching screws.

2.3.3 BMH Axis Motor

The overall dimensions are the same as those of standard BMH motors. The internal sensor is specific to DISC.

Example of a DISC-Compatible Motor Reference

BMH 142 2 N 1 D F 1 L

DISC sensor

2 - 10 en-938907/3

Interconnections

3 Interconnections

3.1 Schematic Diagram 3-3

3.2 Servo-Drive Interconnections

3.2.1 Connection of Axis Amplifier Power Supply

3.2.2 Wiring of the Torque Enable Connector

3.3 Motor and Brake Power Supply

3.3.1 Motor and Brake Power Supply with Terminal Box

3.3.2 Motor and Brake Power Supply with Power Connector on Motor

3.4 Measurement Cable Wiring Diagrams

3.4.1 Motor Sensor - QVN Connecting Cable

3.4.2 Encoder or Rule - QVN Connecting Cable

3.4.3 Handwheel - QVN Connecting Cable

3.5 Connection in Fibre-Optic Ring

3.6 Transmit Power Control 3-10

3.6.1 Control on QVN Card

3.6.2 Setting on the Current Amplifier

3.7 Setting of the Address Switch on the Serial Bus 3-12

3.8 Setting a Motor/Servo-Drive Association

3.8.1 BMH075 Motor

3.8.2 BMH095 Motor

3.8.3 BMH115 Motor

3.8.4 BMH142 Motor

3.8.5 BMH190 Motor

3-4 3-4

3-5 3-6

3-6 3-6

3-7 3-7

3-8 3-8

3-9

3-10 3-11

3-13 3-13 3-14 3-15 3-16 3-17

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3 - 2 en-938907/3

+ 67 hidden pages

num 1060 D.I.S.C. User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual