Siemens Sinumerik 840D Series, Simodrive 611 digital, SINUMERIK 840DiE, SINUMERIK 840D, SINUMERIK 840DE Function Manual

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Description of Functions 10/2003 Edition

sinumerik

& simodrive

HLA Module SINUMERIK 840D SIMODRIVE 611 digital

General 1 Configuration 2 Installation and Start-Up 3 Firmware Drive Functions 4

SINUMERIK 840D SIMODRIVE 611 digital

HLA module

Description of Functions

Hardware Drive Functions 5 Hydraulics Diagnostics 6 Peripherals/Accessories 7 Service 8

Valid for

Control Software Version

SINUMERIK 840D 5, 6 SINUMERIK 840DE (export version) 5, 6 SINUMERIK 840Di 2 SINUMERIK 840DiE (export version) 2

10.03 Edition

Hydraulics A Abbreviations B Definition of Terms C References D

EC Declaration of

Conformity E Index F

O Printed in Germany

3ls

SINUMERIK Documentation

Revision history

Brief details of this edition and previous editions are listed below. The status of each edition is indicated by the code in the “Remarks” column. Status code in the “Remarks” column:

A New documentation. . . . . .

B Unmodified reprint with new order number . . . . .

C Revised version with new edition status. . . . . .

If the technical subject matter shown on the page has changed compared to the previous edition status, this is indicated by the changed edition status in the header of the respective page.

Edition Order no. Remarks 02/99 6SN1197-0AB60-0BP0 A 08/99 6SN1197-0AB60-0BP1 C 04/00 6SN1197-0AB60-0BP2 C 10/03 6SN1197-0AB60-0BP3 C

This manual is supplied as part of the CD-ROM documentation (DOCONCD) Edition Order no. Remarks 03/04 6FC5 298-7CA00-0BG3 C

Trademarks SIMATICr, SIMATIC HMIr, SIMATIC NETr, SIROTECr, SINUMERIKr, SIMODRIVEr and MOTION-CONNECTr are registered trademarks of Siemens AG. Other names in this publication might be trademarks whose use by a third party for his own purposes may violate the rights of the registered holder.

More information is available on the Internet at: http://www.siemens.com/motioncontrol

This document was created with Interleaf V 7

The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration or a utility model or design, are reserved.

Other functions not described in this documentation might be executable in the control. This does not, however, represent an obligation to supply such functions with a new control or when servicing.

We have checked that the contents of this document correspond to the hardware and software described. Nevertheless, differences might exist and therefore we cannot guarantee that they are completely identical. The information given in this publication is reviewed at regular intervals and any corrections that might be necessary are made in subsequent editions. We welcome all recommendations and suggestions.

Subject to change without prior notice

rder no. 6SN1197-0AB60-0BP3

Siemens Aktiengesellschaft.

Preface

Notes for the Reader

Structure of the documentation

Target group

The documentation for SIMODRIVE 611/SINUMERIK 840D is organized on the following levels:

S General Documentation S Manufacturer/Service Documentation S Electronic Documentation

The description of functions of the HLA module is part of the SIMODRIVE/SINUMERIK documentation.

For further information about the publications listed in the documentation overview and other available SIMODRIVE/SINUMERIK publications, please contact your local Siemens sales office.

This Description of Functions does not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be met in connection with installation, operation or maintenance.

The contents of this document shall neither become part of nor modify any prior or existing agreement, commitment or relationship. The Sales Contract contains the entire obligations of Siemens. The warranty contained in the contract between the parties is the sole warranty of Siemens. Any statements contained herein do not create new warranties or modify the existing warranty.

This documentation is intended for use by machine manufacturers and servicing personnel who use the “HLA modules”.

Objective

This Description of Functions provides the information required to configure and start up the hydraulic drive module.

S Chapter 2 describes the procedures for configuring the electric and hydraulic

components.

S Chapter 3 shows how the hydraulic drive is started up with the support of a

menu-driven user interface.

S The firmware and the HLA module hardware functionality are explained in

Chapters 4 and 5.

S Chapter 6 explains how to check and interpret status displays and alarms

(hydraulic diagnostics).

S Chapter 7 describes the accessories required, e.g. measuring systems and

cables.

S Appendix A contains general information and an explanation of the hydraulic

system functionality.

Note

Preface

Hydraulics In this document, information about specific hydraulic functions refers to functions provided by Bosch Rexroth AG.

10.03

How to use this manual

Definition of qualified persons

The following guide information is provided to help you reference information in this Description of Functions:

S General table of contents S Header (as orientation aid):

- The top line of the header is the main section number

- The second line of the header is the subsection number

S Appendix with

- abbreviations, terms and references

- Glossary (index)

For the purpose of this manual and product labels, a “qualified person” is one who is familiar with the installation, mounting, start-up and operation of the equipment and the hazards involved.

S Training or instruction/permit for connecting electric circuits and devices in

accordance with safety technology standards.

S Training and instruction in maintenance and use of adequate safety equip-

ment according to safety regulations.

S Trained in rendering first aid.

Software version

The SW versions specified in this documentation refer to the SINUMERIK 840D control system and the HLA module.

The Description of Functions applies only to the software versions specified. When a new software version is released, the Description of Functions for that version must be ordered.

SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

10.03

Preface

Explanation of symbols

The following danger and warning concept is used in this document:

Danger

This symbol appears whenever death, severe physical injury or substantial material damage

will occur if appropriate precautions are not taken.

Warning

This symbol appears whenever death, severe physical injury or substantial material damage

may occur if appropriate precautions are not taken.

Caution

This symbol appears whenever minor physical injury or material damage may occur if appropriate precautions are not taken.

Caution

This warning (without warning triangle) indicates that material damage may occur if appropriate precautions are not taken.

Notice

This warning indicates that an undesirable result or an undesirable state may occur if the information is ignored.

Note

In the context of this document, it is advisable to take note of the warning information.

vii

Hotline

Preface

10.03

The hotline phone numbers appear in Chapter 8. Should you have any questions about the documentation (suggestions, correc-

tions), please fax them to:

Fax: +49 (9131) 98-2176

Fax form: See the reply form at the end of the brochure

viii

SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

10.03

Preface

Danger and warning notices

Danger

Commissioning should not start until you have ensured that the machine in which the components described here are to be installed complies with Directive 98/37/EC.

Only appropriately qualified personnel may commission/start-up this equipment.

The personnel must take into account the information provided in the technical customer documentation for the product, and be familiar with and observe the specified danger and warning notices.

When electrical devices are operated, the electrical circuits automatically conduct a dangerous voltage.

Dangerous mechanical movements may occur in the system during operation. All work on the electrical system must be carried out when the system has

been disconnected from the power supply.

Warning

Proper transportation, expert storage, installation and mounting, as well as careful operation and maintenance are essential for this device to operate correctly and reliably.

In addition to the danger and warning information provided in the technical customer documentation, applicable national, local, and system-specific regulations must be taken into account.

The information given in catalogs and quotations applies additionally to special versions of machines and equipment.

Caution

When attaching the connecting cables, you must ensure that:

S They must not be damaged S They must not be stressed S They cannot come into contact with rotating parts

Caution

As part of routine tests, the devices undergo a voltage test in accordance with EN 50178. During voltage testing of electrical equipment on industrial machines in accordance with EN 60204-1, Section 19.4, all SIMODRIVE device connections must be disconnected/removed. This is necessary in order to avoid damaging the SIMODRIVE devices.

10.03

Preface

ESD notices

Electrostatic Sensitive Devices

Components which can be destroyed by electrostatic discharge are individual components, integrated circuits or boards which, when handled, tested or transported, could be destroyed by electrostatic fields or electrostatic discharge. These components are designated as ESDS (ElectroStatic Discharge Sensitive Devices).

Handling of modules containing devices sensitive to electrostatic discharge:

S When handling components which can be destroyed by electrostatic

discharge, it must be ensured that personnel, the workstation and packaging are well grounded,.

S As a general principle, electronic modules should only be touched if this is

absolutely unavoidable (owing to repair work, etc.).

S Touch components only if

- you are constantly grounded by an antistatic armband,

- you are wearing ESD boots or ESD boots with grounding strips in conjunction with ESD flooring.

S Modules may be placed only on electrically conductive surfaces (table with

ESD top, conductive ESD foam plastic, ESD packing bags, ESD transport containers).

S Keep modules away from visual display units, monitors or TV sets

(minimum distance from screen > 10 cm).

S Do not bring ESD-sensitive modules into contact with chargeable and

highly-insulating materials, such as plastic, insulating table tops or clothing made of synthetic materials.

S Measurements on modules are allowed only if

- the measuring instrument is properly grounded (e.g. equipment grounding conductor), or

- before measuring, with an isolated measuring instrument, the measuring head is briefly discharged (e.g. touching a bare metal control housing).

S Closed-loop control modules, option modules and memory submodules

may only be held by the front plate or on the board edges.

SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

1 General 1-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Typical applications 1-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Comparison of electric and hydraulic drive systems 1-16. . . . . . . . . . . . .

1.3 Structure of an electro-hydraulically-controlled drive axis 1-18. . . . . . . .

1.3.1 Machine guideway 1-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.2 Cylinder 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.3 Servo solenoid valve 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.4 Valve amplifier 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.5 Shutoff valve 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.6 Position measuring system 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.7 SINUMERIK 840D/SIMODRIVE 611 digital 1-20. . . . . . . . . . . . . . . . . . . .

1.3.8 Hydraulic power unit 1-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Configuration 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Configuring steps 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 Procedure for configuring electrical components 2-21. . . . . . . . . . . . . . .

2.1.2 Procedure for configuring hydraulic components 2-22. . . . . . . . . . . . . . .

2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital 2-24. . . . . . . .

2.2.1 System overview 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.2 Required FW packages 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.3 Hardware requirements 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Configuring the hydraulic drive 2-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.1 Cylinder selection 2-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.2 Selection of servo solenoid valves 2-32. . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.3 Selection of shutoff valves 2-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.4 Natural frequency of the hydraulic drive 2-42. . . . . . . . . . . . . . . . . . . . . . .

2.3.5 Hydraulic power unit 2-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Connection 2-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1 Internal power supply 2-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.2 External power supply 2-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.3 Grounding concept/Electromagnetic compatibility (EMC) 2-48. . . . . . . .

3 Installation and Start-Up 3-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Overview of start-up process 3-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Drive configuration 3-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Modify drive machine data 3-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Valve selection 3-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 Cylinder selection 3-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 Mounting/supply data 3-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 Measuring system data 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 Modifying data 3-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 Fine adjustment and optimization 3-62. . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.1 Control direction, travel direction 3-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents

3.9.2 Offset adjustment 3-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.3 Velocity adjustment 3-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.4 Referencing data for HLA 3-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.5 Controller optimization 3-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.6 Controller adaptation 3-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.7 Hydraulic/electrical interpolation 3-74. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 File functions 3-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11 Start-up functions 3-76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.1 Measurement function 3-77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.2 Function generator 3-84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.3 Circularity test 3-88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.4 Servo trace 3-88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.5 DAC parameter settings 3-89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12 User views 3-90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.13 Display options 3-91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.14 Configuring an OEM valve list 3-92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.03

3.15 System variables 3-94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Firmware Drive Functions 4-95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Block diagram of closed-loop control 4-95. . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Functions 4-97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 Overview of functions 4-97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.2 Parameter set changeover 4-98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Closed-loop velocity control 4-99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.1 Velocity adaptation/feedforward control 4-99. . . . . . . . . . . . . . . . . . . . . . .

4.3.2 Velocity controller 4-106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.3 Dynamic stiffness control (DSC) 4-114. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Closed-loop force control 4-115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.1 Force limitation 4-117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.2 Static friction injection 4-118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.3 Force controller 4-119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Manipulated voltage output 4-124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.1 Characteristic compensation 4-124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.2 Control output filter 4-130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.3 Manipulated voltage limitation 4-132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 Supply unit data 4-133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 Valve 4-134. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 Cylinder drive 4-136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9 Drive data 4-137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10 Position measuring system 4-140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.11 Pressure sensing system 4-145. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.12 Terminals 4-146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.13 Monitoring functions 4-152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

xii

SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

10.03

Contents

4.13.1 Alarms 4-152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.13.2 Variable signaling functions 4-154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.14 Service functions 4-159. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.14.1 Min/max display 4-159. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.14.2 Monitor 4-160. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.14.3 Diagnostic machine data 4-161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.15 Parameters table 4-165. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Hardware Drive Functions 5-175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Interface overview 5-175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 Measuring system 5-178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.2 Pressure sensor system 5-179. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.3 Servo solenoid valve 5-180. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.4 Terminals 5-181. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.5 Test sockets (diagnostics) 5-182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.6 Bus interfaces 5-183. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 System environment 5-184. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Notes 5-185. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1 Climatic and mechanical environmental conditions in operation 5-185. . .

5.3.2 Transport and storage conditions 5-186. . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.3 Stress caused by contaminants 5-187. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Hydraulics Diagnostics 6-189. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Peripherals/Accessories 7-219. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 Measuring systems 7-219. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.1 Encoders, linear scales 7-219. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.2 Connection diagrams 7-222. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 BERO (X432) 7-226. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 Pressure sensor 7-227. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3.1 Sensor equipment 7-227. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3.2 Connection diagrams 7-231. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 Connection diagrams for servo solenoid valves 7-232. . . . . . . . . . . . . . . .

8 Service 8-237. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 Areas of responsibility at Siemens/Bosch Rexroth 8-237. . . . . . . . . . . . . .

8.2 Hotline and contacts 8-238. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A Hydraulics A-239. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1 Servo solenoid valves A-239. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1.1 General A-239. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1.2 Directly-controlled servo solenoid valves, sizes 6 and 10 A-247. . . . . . . .

A.1.3 Pilot-controlled servo solenoid valves, sizes 10 and 16 A-249. . . . . . . . . .

A.1.4 HR servo solenoid valves A-252. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2 Cylinder A-254. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

xiii

B Abbreviations B-257. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents

C Definition of Terms C-259. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D References D-261. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D.1 Electrical applications D-261. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D.2 Hydraulic applications D-274. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E EC Declaration of Conformity E-275. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F Index Index-279. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.03

xiv

SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

General

1.1 Typical applications

Applications

Objective

Interfaces

The NCU 573.2 of the SINUMERIK 840D is capable of handling axis configurations of a maximum of 31 axes on up to 10 different channels. This functional sophistication makes the SINUMERIK 840D an increasingly popular system for the automation of rotary indexing machines. These machines are often highly compact in design and frequently equipped with hydraulic axes (cylinders and servo solenoid valves). The hydraulics (HLA) module provides a means of controlling hydraulic axes directly from the SINUMERIK 840D system via the digital drive bus.

The HLA module is a closed-loop control plug-in unit of the modular SIMODRIVE 611 converter system mounted in a 50 mm carrier module (universal empty housing).

The gating and closed-loop control electronics for operating controlled hydraulic drives are integrated on the HLA module.

From the point of view of the manufacturer of modern servo solenoid valves, an innovative step in the field of hydraulic drive systems has been taken by treating electric and hydraulic drives as equal partners and integrating them into a standard NC.

To place equal emphasis on the functional importance of both hydraulic and electric drives and make them available as a combined system within an interpolating axis grouping.

S Firmware

The communications interface is compatible with the SIMODRIVE 611D SRM(FDD)/ARM(MSD) for supported services. Code and data management is analogous to the SIMODRIVE 611D SRM(FDD)/ARM(MSD). The hydraulics software is stored as a separate program code in the control system.

S Hardware

The mode of integration into the SIMODRIVE 611 system is compatible with the SIMODRIVE 611 digital SRM(FDD)/ARM(MSD). This basically involves the following interfaces:

- Drive bus

- Device bus

- Power supply system

1-15

1.2 Comparison of electric and hydraulic drive systems

1 General

1.2 Comparison of electric and hydraulic drive systems

Table 1- 1 Comparison of electric and hydraulic drive systems

10.03

Criterion Electric direct drive Electric drive with

Power density / mounting space requirements

Mass inertia of moving parts

Operational reliability, service life

S Low weight and S reduced spatial re-

quirements of the electric part on the machine table.

Electric part on machine table has low mass.

Service life depends in principle only on linear guides.

S Servomotor and leads-

S Problematic with lim-

Servomotor and leadscrew have high mass moment of inertia.

S Shock-sensitive. S Service life limited by

leadscrew

crew large and heavy.

ited mounting space.

leadscrew.

S Sudden failure

possible.

Servicing Simple replacement Expensive replacement

and repair of leadscrew by specialists.

Energy storage Peak requirement must

be installed as no storage is possible.

Maximum forces

Load stiffness Very good;

maximum velocity

Maximum travel path

Collision protection

Peak thrust per unit area approx. 40 to 80 kN/m

Servo gain can be set to betw. 10-100 times higher than on the other two drives.

Up to 500 m/min v

Unlimited

Mechanically difficult Mechanically possible Mechanically possible

Peak requirement must be installed as no storage is possible.

Restriction with larger

forces.

S Elasticity under large

forces.

S Elasticity of leadscrew

is largely compensated as a control function.

@ ω

max=hs

=thread lead

=max. motor speed

max

v 6 m v 3 m

max

/2π

Hydraulic drive

S Cylinder and servo sole-

noid valve are light-weight and compact.

S Transfer of E motor to

hydraulic power unit.

Piston and piston rod have very low mass

S Protected against overload

by pressure limitation.

S Sturdy, insensitive to

shocks.

S Cylinder seals and valve

control edges have long service life.

S Warning of wear. S Simple error diagnosis

S Simple replacement and

repair of valves and cylinders.

S Compensation of energy

requirement peaks by hydraulic accumulator.

S Rapid traverse in differen-

tial circuit.

S Reduction of installed ca-

pacity.

Practically unlimited (cylinderφ, p

=700 bar)

max

S Oil compressibility is com-

pensated as a control function (I component).

S Good zero overlap quality

of valve ensures very high rigidity under load.

30...300 m/min (depending on which cylinder seal kit is used)

1-16

SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

1 General

02.99

10.03

1.2 Comparison of electric and hydraulic drive systems

Table 1-1 Comparison of electric and hydraulic drive systems

Criterion Hydraulic driveElectric drive with

Noise Noise produced by

Acceleration

Electric direct drive

leadscrew

Noise produced by servo-

linear guides

motor and leadscrew

max. 45 g max. 1 g max. 2 g

characteristics Drive cooling Absolutely essential Required only at high

speeds

Sensitivity to

High Low Low ferromagnetic swarf

Table 1-2 Analogy of characteristic data

Electric Hydraulic

Spindle speed Velocity Velocity Current flowrate DC link voltage System pressure Power Flow rate @ Valve pressure differential Transistor/power section Valve Motor Drive cylinder

S Flow through valve may

produce noise.

S Pump noise on

hydraulic power unit.

Required in some cases, in power unit only

1-17

1.3 Structure of an electro-hydraulically-controlled drive axis

1 General

1.3 Structure of an electro-hydraulically-controlled drive axis

SINUMERIK 840D, SIMODRIVE 611 digital with HLA module

Shutoff valve

Servo solenoid value with valve amplifier (OBE)

Machine guideway

02.99

10.03

Hydraulic power unit

Fig. 1-1 Construction of an electro-hydraulically controlled drive axis

1.3.1 Machine guideway

Guide mechanism

Friction

Hydrodynamic and hydrostatic slideways or roller slideways allow machine slides and tables to move in straight lines with minimum friction and maximum precision.

A degree of friction can be very useful for damping oscillations. However, excessive friction, especially pronounced transitions from static to

sliding friction, have a negative effect on the control result and impair the control loop stability.

Position measuring system

1-18

SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

1 General

02.99

10.03

1.3.2 Cylinder

1.3 Structure of an electro-hydraulically-controlled drive axis

Construction

Quality criteria

The cylinder represents the simplest form of linear motor and can be integrated easily into the machine guide. The cylinder normally has a piston rod at one end.

The following are critical quality criteria:

S The surface quality of barrel and piston rod and S The seals and guides (low-friction, servo quality...).

1.3.3 Servo solenoid valve

Task

Function

This is the final control element in the closed control loop and forms the electrohydraulic converter.

The valve steplessly converts electrical signals into a hydraulic flow. Its quality is defined by static and dynamic parameters, such as

S Zero overlap S Hysteresis S Limit frequency, etc.

1.3.4 Valve amplifier

This circuit contains the power electronics for the solenoid in the servo solenoid valve which adjusts the valve spool position.

The position controller in the valve amplifier (on-board electronics - OBE) controls the position of the valve spool proportionally to the output value (U=0..."10 V).

1.3.5 Shutoff valve

Shut-off valves are used to add safety functions to a valve control with servo solenoid valve. Shut-off valves can prevent uncontrolled motion of the cylinder.

1.3.6 Position measuring system

Task

The position measuring system supplies the actual value for the position of the moving machine element.

1-19

1.3 Structure of an electro-hydraulically-controlled drive axis

1 General

02.99

10.03

Function

The speed is acquired by continuous differentiation of the distance over time. Various systems are available depending on the level of accuracy required.

The highest accuracy requirements are fulfilled by digital systems (glass scale with photoelectric evaluation circuit) mounted directly on the machine.

The most widely used digital incremental systems require a reference point approach at the beginning of a machining operation.

1.3.7 SINUMERIK 840D/SIMODRIVE 611 digital

SINUMERIK controls and SIMODRIVE drive systems are specially designed for machine tools, manipulators and special-purpose machines.

The numerical control processes the machine program and converts it into control commands. It also monitors command execution continuously.

The control structures for the electrohydraulic control loop and the interfaces to

S the shutoff valve, S the servo solenoid valve, S the position measuring system and S the central arithmetic logic unit

are all provided by the HLA module. The HLA module is an integral component of the SINUMERIK 840D and

SIMODRIVE 611 digital systems. A range of different NCU modules with graded scope of functions is provided to

allow the SINUMERIK 840D system to be tailored to the varying functional requirements of machines. The control can therefore be optimally adapted to individual machines and machining applications and is suitable for equipping standardized machine series.

1.3.8 Hydraulic power unit

This unit supplies hydraulic energy. It is installed at a distance from the drive axis. Accumulators are employed to

compensate for strongly fluctuating hydraulic energy requirements and to minimize the installed power.

1-20

SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

Configuration

2.1 Configuring steps

2.1.1 Procedure for configuring electrical components

The procedure for configuring an HLA module is divided into steps in such a way that the user is guided through the full range of relevant settings, from the required force, to the hydraulics components, and finally the HLA and its encoder evaluation circuitry. This initial configuring phase may be followed by a second in some cases, in which the corresponding circuit recommendations and EMC measures are taken into account.

The functions of SIMODRIVE components are described with keywords in this Planning Guide. Limit values for functions may be specified in some cases. For further details (e.g. characteristics), please refer to the Installation and Start-Up Guides for SIMODRIVE 611 digital and SINUMERIK 840 digital.

Further configuring instructions and detailed ordering information can be found in Catalogs NC 60 and NC Z.

Phase 1

Selection of hydraulic components

Dimensioning of incoming mains supply

Dimensioning of power modules

Dimensioning of external power supply

Dimensioning of closedloop control components

and publication from Bosch Rexroth AG

and publication 6SN1197-0AA00

Section 2.3

Section 2.2

Section 2.4

Chapter 4

Dimensioning of position sensor (measuring system)

Fig. 2-1 Configuring steps in start-up sequence

Section 7.1

2-21

2.1 Configuring steps

2 Configuration

Phase 2

Recommended circuits EMC measures

10.03

Section 2.4

Block diagrams/ connection diagrams

Abbreviations, terms and index

Fig. 2-2 2. configuring phase

2.1.2 Procedure for configuring hydraulic components

Hydraulically controlled drives are normally configured by the technical sales and marketing personnel of the hydraulics supplier (e.g. Bosch Rexroth, see Chapter 8) in close co-operation with the machine manufacturer.

This configuring phase is divided into the following steps:

S Selection of the cylinder on the basis of forces and velocities required and

the cylinder mounting conditions in the machine (see Subsection 2.3.1).

Section 2.2

Appendix

S Selection of the servo solenoid valves on the basis of the cylinder data,

forces, velocities and dynamic requirements (see Subsection 2.3.2, 2.3.3).

S Selection of the position measuring system and optionally the pressure sen-

sors with regard to the measuring range, accuracy and linearity (see Section

7.1, 7.3).

S Dimensioning of the hydraulic power unit, taking all loads into account (see

Subsection 2.3.5).

S Calculation of the natural frequency of the drive for an initial assessment of

whether the expected control result can be achieved (see Subsection 2.3.4).

S In difficult cases, it may be worthwhile carrying out a dynamic simulation of

the drive as an aid to configuration. The basic data required to design a system are obtained from a question-

naire.

2-22

SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

2 Configuration

02.99

10.03

2.1 Configuring steps

Questionnaire

Company: Address:

Machine: Axis: Function/designation:

Straight-cut control: Continuous-path control:

Drive specification Cylinder dimensions [mm]

Piston diameter: 1st rod diameter: 2nd rod diameter: Stroke:

Cylinder mounting position: Velocity tolerance

051-001/

Design of hydraulic NC axes

Hydraulic NC axes

Dimensioning of systems with linear motions

Contact person:

Department: Phone:

Accuracy requirements Positioning precision [µm]

from rapid traverse: from feedrate: Path accuracy:

[mm/min]:

Connection: Position measuring Valve - cylinder

Pipe/hose length [mm]: Pipe/hose diameter [mm]: Moved mass [kg]: Machining forces [N] Piston advance: Piston retraction: Slide guide friction

µ:

FR [N]: Pump pressure [bar]: Velocities [m/min] Rapid traverse advance: Rapid traverse retract: Machining feed advance: Machining feed retract: Acceleration rates [m/s2] Max. acceleration: Max. delay:

system

Make: Type: Other: Resolution [µm]:

Numerical control Make: Type:

incremental,

output signal ...

SIEMENS 840D

Processed by: Dept.: No. of pages: Date:

2-23

2 Configuration

02.99

10.03

2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital

2.2.1 System overview

Components

A complete SINUMERIK 840 digital control system with HLA module consists of various individual components. These are listed below.

Table 2- 1 Components of SINUMERIK 840 digital control with HLA module (number,

No.in

Fig.

2-3

O NCU box B NC CPU

component, description)

Component Description

S Enclosure for NC CPU S Central processing unit of 840D

S Execution of NC program, S Contains modules with e.g. PLC, communications

functions

S NCU 573.2 includes a fan module

B1 Cable distributor

Operator panel

MMC module

S For insertion in NCU S Display, keyboard, power supply unit and

operator controls for NC

S Operator panel calculator (integrated in panel), S MMC 103 with hard disk

I Mains supply module

(MS)

Machine control panel

G11)ISA adapter

G21)Full CNC keyboard

References: /PJ1/ SIMODRIVE 611

S Machine operation S Allows AT modules to be used in conjunction with

the MMC module MMC103 (mounted in operator panel)

S Full keyboard for connection to MMC module

G3 Memory card (PCMCIA)

S Contains the system program, S can be slotted into the NCU 561.2, 571.2, 572.2,

573.2

G4 Diskette unit (accessory) H1 to

Cable References: /Z/, Catalog of Accessories NC Z

H 9 H10

Cable See Chapter 7, Peripherals/Accessories to H12

I SIMODRIVE hydraulics

module (HLA module)

50 mm carrier module

(universal empty housing) I1 Phoenix cable connection

S Built-in unit for connection to MMC module

S Closed-loop control of hydraulic drive S Actuation of servo solenoid valve

Holder for HLA closed-loop control plug-in module (see Fig. 2-6)

S Shutoff valve S External 24 V supply S BERO input S “Power enable”

J SIMATIC components References: /S7H/, Manual K Terminator Terminator for drive bus (inserted in last module in

drive grouping)

2-24

SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

10.03

2 Configuration

2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital

Table 2-1 Components of SINUMERIK 840 digital control with HLA module (number,

No.in

Fig.

2-3

component, description)

Handheld unit

DescriptionComponent

S Connect HHU to K bus via MPI S Handwheel, EMERGENCY STOP button, key-ac-

tuated switch, override, agreement buttons, dis-

Distribution box

play, unassigned keys

S For linking the hand-held unit to the MPI bus S Connection for EMERGENCY STOP circuit, en-

able keys, handwheel, 24 V DC

N Cable distributor O Hydraulic Drive References:

P External 24 V supply

1) A description of these components can be found in:

References: /BH/, Operator Components Manual

S 24V supply for connection to MPI connector

/BR1/, “Servo solenoid valves” catalog

/BR2/, “Sensors and electronics” catalog /BR3/, “Adapter plate valves” catalog

S SITOP stabilized power supply modules

References: SITOP catalog Order No. E860060-K2410-A101-A4

Note

An HLA module must never be operated directly on a SIMODRIVE monitoring module, i.e. it must always be connected via a mains infeed module.

For information about connecting further additional SIMODRIVE monitoring modules in configurations with several HLA modules, please refer to the Planning Guide for SIMODRIVE 611 Converters /PJU/.

In a multi-tier configuration, all the infeed supply units must be connected simultaneously.

2-25

2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital

2 Configuration

02.99

10.03

Floppy

MMC CPU

S7-300

MCP

(GND)

Device bus

H2 H3 H9

SITOP power (external PS)

module

HLA

NCU

Battery and plug-in fan unit

Digital I/O (high-speed NC I/O)

Measurement (2x)

Handwheel (2x) (1x of M)

External 26.5 V supply

H10

Position sensing

H11

H12

Pressure sensor A Pressure sensor B

Servo solenoid valve

BERO inputs

Enable

Shutoff valve

Note: Display of hydraulics for one axis

Fig. 2-3 System components

2-26

SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

2 Configuration

02.99

10.03

2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital

O B

Hydraulic drive, axis 1

Position measuring system

Pressure sensor

Servo solenoid valve

Pressure sensor A

Pressure sensor B Position sensing

Shutoff valve

Servo solenoid valve

Pressure sensor A Pressure sensor B Position sensing

Shutoff valve

O B

Hydraulic drive, axis 2

Axis 1

HLA

-X101

BOBB

-X102

Axis 2

Position measuring system

-X111

-X112

Pressure sensor

Servo solenoid

-X121

X431 X432

-X34

M PV1 MV1

C1 P24 M24 663

Functional ground

Shutoff valve, axis 1

Reserved, do not use!

External 26.5 V supply

Power enable at term. 663 Internal +24 V enabling voltage

X1141

Drive bus

Device bus interface (X151)

1) Only required if external 26.5 V is not electrically separated safely!

Fig. 2-4 Connection configuration for HLA module

-X35

-X122

X1341

Servo solenoid valvevalve

M PV2 MV2

C2 B1 19 B2

Functional ground

Shutoff valve, axis 2

Reserved, do not use! BERO input, axis 1 Internal 0 V enabling voltage BERO input, axis 2 Internal +24 V enabling voltage

Drive bus/drive bus terminator on last module

2-27

2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital

2 Configuration

02.99

10.03

Relay contact, Ready to operate message

Relay contact for group message

t and motor overtemperature

Reference potential for enable voltage

Enabling signal for internal line contactor

Signaling contact for starting lockout (NC contact)

DC link power supply for bridging line failures

Electronics power supply from external source

Power disable Enabling voltage Enabling voltage Drive enable

P24 P15

N15 N24 M M RESET (R+term.15)

Enabling voltage Setup mode

Contactor energization, start

Signaling contact, line contactor

NC contact

NO contact

73.1

73.2 72

5.3

5.2

5.1 63 9

64 19

7 45 44 10 15

15 R

9 112

48 111 213

113

NS1 NS2

AS1 AS2

M500 P500 2U1

1U1 2V1 1V1 2W1

1W1

X111

X121

X141

X161

X171

X172

LED displays

X181

X351

Device bus

LED displays

Electronics power supply faulty

Device is not ready, no enable signal (term. 63, 64 or 48)

Line fault

Red

Green

Red

Yellow

Red

5 V voltage level fault

Device ready (DC link precharged)

DC link overvoltage

1) Jumpers inserted in delivery state

Fig. 2-5 Interfaces on mains supply module (OI and I/RF module)

P600

DC link connection

M600

Power supply

U1 V1 W1 X131 PE

2-28

SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

10.03

2 Configuration

Mounting the HLA closed-loop control plug-in module

HLA closed-loop control plug-in module (6SN1115-0BA11-0AA1)

Slotted screw M3 / 0.8 Nm

2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital

Shield connection

50 mm carrier module (universal empty housing) (6SN1162-1AA00-0AA0)

P600

M600

Order No.

Slotted screw

M3 / 0.8 Nm

Fig. 2-6 Mounting the HLA closed-loop control plug-in module in 50 mm carrier module (universal empty housing)

M5 / 3.0 Nm

M4 / 1.8 Nm

Rating plate/Order No.

2.2.2 Required FW packages

S SINUMERIK 840D NCK SW w5.1

including SIMODRIVE 611 digital HLA module w1.0

S SINUMERIK 840D MMC SW u5.1

or SINUMERIK 840D HMI SW w6

2.2.3 Hardware requirements

S NCU 561.2, 571.2, 572.2, 573.2

2-29

2.3 Configuring the hydraulic drive

2 Configuration

2.3 Configuring the hydraulic drive

10.03

General

Hydraulic drives are generally configured by technical sales personnel from the hydraulics supplier, Rexroth.

The configuration is based on the data from the questionnaire in Subsection 2.1.2 .

Please refer to Appendix A for a description of hydraulic components. The hydraulic drive is configured in the sequence of steps described below.

2.3.1 Cylinder selection

Piston and rod diameter

The piston and rod diameters are calculated according to Pascal’s theorem on the basis of the necessary compressive and tensile forces F and a standard pressure value of P=40...100 bar for machine tools (a maximum pressure setting of 350 bar is permitted).

The force value calculation must include friction and acceleration forces as well as the actual feed force. Pistons and rods with the following standard diameter dimensions are available:

Table 2-2 Typical cylinder data

Description Diameter

Piston ∅ 25 32 40 50 63 80 100 125 Rod ∅ Standard 12 14 18 22 28 36 45 56 Rod ∅ Optional 18 22 28 36 45 56 70 90

p =

F O

Stroke length

2-30

The stroke is identical to the working stroke of the drive except that it includes a few additional safety reserves.

SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

10.03

2 Configuration

2.3 Configuring the hydraulic drive

Mounting

Mounting position

In order to ensure good control quality, backlash-free mountings, e.g. base or flange mountings, must be used.

Flange mounting

Flange at front Flange at rear

Base mounting

Fig. 2-7 Cylinder mounting methods

This is will depend on the machine’s situation and affects the choice of shutoff valves (see Subsection 2.3.3). Vertical loads must be protected via poppet valves. Forces due to weight must be taken into account in the final calculation of the operating pressure (MD 5151: CYLINDER_A_ORIENTATION).

See Fig. 4-17 in Section 4.9 for the possible cylinder mounting positions.

Seal, friction

Cylinder pipes

Position measuring system

Suitable seals must be used to minimize friction. Transitions from static to sliding friction have a particularly adverse affect on the control result.

The slide guide friction must be added to the cylinder friction. A friction compensation setting has been provided in the HLA module (MD 5460: FRICTION_COMP_GRADIENT) for the purpose of counteracting initial friction.

The distance between the cylinder and servo solenoid valve must be kept as short as possible for the sake of the drive’s natural frequency (compressibility of the oil volume). In ideal cases, the servo solenoid valve is flange-mounted directly on the cylinder.

The incremental and absolute position measuring systems supported by the HLA module are mounted on the machine slide. It is also possible to use position measuring systems (SSI encoders) integrated in the cylinder.

2-31

2.3 Configuring the hydraulic drive

2 Configuration

2.3.2 Selection of servo solenoid valves

References: /BR1/, “Servo solenoid valves” catalog

Valve types (overview)

Table 2-3 Overview of servo solenoid and HR servo solenoid valves from Bosch Rexroth AG

The HLA module supports servo solenoid valves with on-board electronics (OBE) supplied by Bosch Rexroth AG. The technical data for these valves and valves supplied by other manufacturers is stored in the HLA module software. The drive is parameterized automatically when the order number is entered. The following table lists the various types of servo solenoid valve and HR (= High Response) servo solenoid valves available from Bosch Rexroth AG.

For a complete list, please see Tables 2-4 to 2-10.

10.03

Title Nomi-

4WRPEH (directly-controlled servo solenoid valve)

4WRPE (pilot-controlled servo solenoid valve)

4WRPEH (directly-controlled HR servo solenoid valve)

nal

size

6 up to 40 / 35 bar linear and

10 up to 100 / 35 bar linear and

10 up to 70 / 5 bar with knee 40

16 up to 150 / 5 bar with knee 40

6 up to 40 / 35 bar linear and

Nominal flowrate (l/min)

for nominal pressure drop

per control edge (bar)

curve Limit fre-

110

with knee

210

with knee

quency

(Hz)

4WRVE (pilot-controlled HR servo solenoid valve)

1) The characteristic values specified for the valve limit frequencies relate to an amplitude of "5% and a phase offset in the Bode diagram of -90°, see also data in catalog supplied by Bosch Rexroth AG.

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SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

10 up to 70 / 35 bar with knee 80

16 up to 150 / 5 bar with knee 80

10.03

2 Configuration

2.3 Configuring the hydraulic drive

The choice of valve for a particular application is made with reference to the following criteria.

Servo solenoid or HR servo solenoid valves

Valve size

HR (High Response) valves are characterized by their improved dynamic quality, i.e. by a higher limit frequency compared to servo solenoid valves. They react with greater sensitivity to setpoint changes especially in the small-signal range. The use of HR servo solenoid valves is recommended in the following cases:

1. When extremely high contour precision is required in high-speed continuous-path control machining operations.

2. When very high response sensitivity is required to achieve the best possible positioning accuracy.

Note that HR servo solenoid valves do not generally have a fail-safe position. The connector is also 12-pin, rather than 7-pin as with servo solenoid valves.

The valve size is determined by the maximum flowrate Q

. This maximum flow-

rate is calculated according to the law of flow:

=v @ A

v: Maximum drive speed for extension and retraction A: associated cylinder surface area

The calculated maximum flow rate must not exceed the limit for use of the valve. This limit is generally specified in the catalog by the valve manufacturer (e.g. Rexroth: /BR1/, “Servo solenoid valves” catalog).

Within the limits for use, the flow rate that can be achieved with the valve is calculated by

Q=Q

nom

p

nom

Linear/knee-shape d flowrate characteristic

In practice, the cylinder speeds that can actually be achieved depend on the operating pressure, the load pressure and flow-specific characteristics of the drive. The dimensioning is left to the hydraulic configuration engineer, who has access to a number of design calculation and simulation programs.

V alues with either a linear or knee-shaped characteristic can be selected. The latter are suitable for obtaining a higher resolution in the low signal range (machining) and sufficient flow in the high signal range (rapid traverse).

The definition of the knee-point position as 40% or 60% means that only 10% of the nominal opening cross-section (nominal flowrate) is released at 40% or 60% of the nominal control signal (i.e. at U=4 V or 6 V).

The knee-shaped characteristic of the valve must be linearized in the HLA module to adapt it to the closed-loop control of the entire drive (cylinder).

2-33

2.3 Configuring the hydraulic drive

2 Configuration

10.03

Q/Q

nom

Rapid traverse

10%

40%

Fig. 2-8 Diagram of a knee-shaped servo solenoid valve characteristic and its correction in the HLA module

U/U

nom

Machining velocity

10%

Q/Q

nom

40%

Valve characteristic

Linearized characteristic

U/U

nom

compensation

Note

Recommended selection: Servo solenoid valves are generally recommended for applications where there

is a clear separation between machining operation and rapid traverse.

Asymmetrical flowrate characteristics

It is a good idea to use valves with asymmetrical restriction cross-sections for differential cylinders or for cylinders that are not arranged horizontally and move large loads. This improves the hydraulic clamping of the cylinder and adjusts the controlled system gain of the hydraulic servo-drive for both directions of travel.

Fig. 2-9 Asymmetrical characteristics

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SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

10.03

2 Configuration

2.3 Configuring the hydraulic drive

Fail-safe position

Pin assignments

Directly-controlled servo solenoid valves have a fail-safe position, i.e. the control spool moves to a safe position when the valve is disconnected from the power supply. The fail-safe position is either “closed” (A, B, P, T disabled) or “open” (A, B and T connected and P disabled). It should be noted that the “crossed” switching position is necessarily passed when the valve is switched on and off, and there can be temporary responses from the cylinder at these moments. Separate shut-off valves are therefore required in order to implement safety functions, such as a totally safe cylinder stop.

Pilot-controlled servo solenoid valves, pilot-controlled HR servo solenoid valves and directly-controlled HR servo solenoid valves do not have a fail-safe position and thus do not have a safe basic position when switched off. Any safety functions nmust therefore be implemented via separate shut-off valves.

Fail-safe closed Fail-safe open

Fig. 2-10 Fail-safe position in the valve graphical symbol

A distinction must be made between servo solenoid valves and HR servo solenoid valves.

S Servo solenoid valves (directly and pilot-actuated): 7-pin round connector

2.5 AF +24 V=O

B C

100k 100k

10k

Fig. 2-11 Connector pin assignment on servo solenoid valves

D I F

0 V 0 V

Sign.

Supply Reference point for actual

valve spool value Setpoint 0..."10 V Actual value spool value

Protective conductor

Shield

2-35

2.3 Configuring the hydraulic drive

OB PT

PT PT

2 Configuration

S HR servo solenoid valves (directly and pilot-controlled); 12-pin round

connector

100k 100k

10k

10 11

10.03

2.5 AF +24 V=

0 V 1 2 3 4

5 6 7 8 9

24 V

Sign.

0 V

24 V

+24 V =/v0.5 A

0 V

24 V

Output stage supply

enabling of

Setpoint 0..."10 V

Actual value spool value

Enable acknowledgement

Electronics supply

Error message Protective

conductor Shield

Fig. 2-12 Connector assignment for HR servo solenoid valves

Preferred range of servo solenoid valves

Table 2-4 NG6 directly-controlled servo solenoid valves; model code 4WRPEH 6

HLA code

no.

10 0 811 404 601 12 Linear. 11 0 811 404 602 24 Linear. 12 0 811 404 603 40 Linear. 13 0 811 404 610 4 Linear. OB 14 0 811 404 611 12 Linear. 15 0 811 404 612 24 Linear. 16 0 811 404 613 40 Linear. 17 0 811 404 642 15 60

18 0 811 404 747 25 60 19 0 811 404 644 40 40 20 0 811 404 645 15 60 OB 21 0 811 404 646 25 60 22 0 811 404 647 40 40

Rexroth order number

9 0 811 404 600 4 Linear. 7-pin

The following tables list all the servo solenoid valves and HR servo solenoid valves supplied by Bosch Rexroth AG for which technical data is stored in the HLA module.

nom

(l/min) for

np / edge

= 35 bar

Character-

istic kneep-

oint (%)

No. of connector pins

Graphic symbol Rexroth

catalog

/BR1/

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SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

10.03

2 Configuration

2.3 Configuring the hydraulic drive

Table 2-4 NG6 directly-controlled servo solenoid valves; model code 4WRPEH 6

HLA code

no.

Rexroth order number

nom

(l/min) for

np / edge

Character-

istic kneep-

oint (%)

connector pins

Graphic symbolNo. of

= 35 bar

23 0 811 404 648 A:40; B:20

40 7-pin

24 0 811 404 649 A:40; B:20

40 OB

Table 2-5 NG10 directly-controlled servo solenoid valves; model code 4WRPEH 10

HLA code

no.

Rexroth order number

nom

(l/min) for

np / edge =

Character-

istic kneep-

oint (%)

No. of connector pins

Graphic symbol Rexroth

35 bar

41 0 811 404 800 50 Linear. 7-pin

42 0 811 404 801 100 Linear.

43 0 811 404 802 50 Linear. OB

Rexroth

catalog

/BR1/

catalog

/BR1/

44 0 811 404 803 100 Linear.

45 0 811 404 822 50 40

46 0 811 404 823 100 40

47 0 811 404 824 50 40 OB

48 0 811 404 825 100 40

B:50

40 OB 40

40 OB

49 0 811 404 826 A:50; B:25 50 0 811 404 827 A:100;

51 0 811 404 828 A:50; B:25

52 0 811 404 829 A:100;

1) Asymmetrical characteristic

2-37

2.3 Configuring the hydraulic drive

PTX Y

OB PT

OB PTX Y

PTX Y

2 Configuration

Table 2-6 NG10 pilot-controlled servo solenoid valves; model code 4WRLE 10

10.03

HLA code

no.

Rexroth order number

nom

(l/min) for

np / edge =

Character-

istic kneep-

oint (%)

No. of connector pins

Graphic symbol Rexroth

5 bar

25 0 811 404 686 40 40 7-pin

26 0 811 404 687 70 40 27 0 811 404 688 A:40; B:20 28 0 811 404 689 A:70; B:40

40 40

X Y

Table 2-7 NG16 pilot-controlled servo solenoid valves; model code 4WRLE 16

HLA code

no.

Rexroth order number

nom

(l/min) for

np / edge =

Character-

istic kneep-

oint (%)

No. of connector pins

Graphic symbol Rexroth

5 bar

1 0 811 404 263 90 40 7-pin

2 0 811 404 264 150 40

B:90

40 40

X Y

3 0 811 404 265 A:90; B:50 4 0 811 404 266 A:150;

Table 2-8 NG6 directly-controlled HR servo solenoid valves; model code 4WRREH 6

catalog

/BR1/

catalog

/BR1/

HLA code

no.

Rexroth order number

nom

(l/min) for

np / edge =

Character-

istic kneep-

oint (%)

No. of connector pins

Graphic symbol Rexroth

35 bar

33 0 811 404 720 40 Linear. 12-pin

34 0 811 404 721 24 Linear. 35 0 811 404 722 12 Linear. 36 0 811 404 723 8 Linear. 37 0 811 404 725 15 60 38 0 811 404 726 25 60 39 0 811 404 727 40 40 40 0 811 404 728 A:40; B:20

Table 2-9 NG10 pilot-controlled HR servo solenoid valves; model code 4WRVE 10

HLA

code

no.

Rexroth order number

nom

(l/min) for

np / edge =

Character-

istic kneep-

oint (%)

No. of connector pins

Graphic symbol Rexroth

5 bar

29 0 811 404 693 40 40 12-pin

30 0 811 404 694 70 40 31 0 811 404 695 A:40; B:20 32 0 811 404 696 A:70; B:40

40 40

catalog

/BR1/

HRV - Size 6

catalog

/BR1/

1) Asymmetrical characteristic

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SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

10.03

OB PTX Y

PTX Y

2 Configuration

2.3 Configuring the hydraulic drive

Table 2-10 NG16 pilot-controlled HR servo solenoid valves; model code 4WRVE 16

HLA

code

no.

1) Asymmetrical characteristic

Rexroth order number

5 0 811 404 296 90 40 12-pin 6 0 811 404 297 150 40

7 0 811 404 298 A:90; B:50 8 0 811 404 299 A:150;

nom

(l/min) for

np / edge =

5 bar

B:90

Character-

istic kneep-

oint (%)

40 40

2.3.3 Selection of shutoff valves

References:/BR3/, “Adapter plate valves” catalog

General

The shutoff valves are automatically enabled and disabled in the correct switching sequence by the HLA module.

Start condition: The hydraulic pressure must be available before

the system is switched on.

Warning

In the event of sudden failure (e.g. open circuit) of the external 24 V supply, an axial storage capacitor on the HLA module provides energy to supply the servo solenoid valve until such time as the pressure supply for a configured shutoff valve is disabled.

The machine manufacturer must verify the interaction between valves, making allowance for all tolerances in the controlled system. The energy content of the storage capacitors is dependent upon

No. of connector pins

Graphic symbol Rexroth

catalog

/BR1/

S the tolerances of the capacitors, S the voltage level of the external supply and S the charging time of the integrated capacitors (instant of voltage failure).

The available response time is mainly defined by

S the power required for the current machining step, S the response time of the shutoff valves and S the trip threshold of the servo solenoid valves.

2-39

2.3 Configuring the hydraulic drive

2 Configuration

10.03

Examples

Figure 2-13 shows an electrically-switched sandwich-type shut-off valve used to shut off the system pressure at the servo solenoid valve.

Interruption of the hydraulic power circuit upstream of the servo solenoid valve is sufficient to meet simple safety requirements. When a servo solenoid valve in the closed fail-safe position is switched off, then approximate shut-off of the consumer connections with respect to the cylinder is guaranteed.

There are some safety limitations, however, since the servo solenoid valve’s fail-safe position is not totally free of leakage oil, and thus does not work without some cylinder drift. In addition, when the servo solenoid valve is switched on and off, the “crossed” position is necessarily passed, which can result in cylinder movement.

T BOP

Servo solenoid valve

Shut-off valve (electrically switched)

Fig. 2-13 A typical example for an electrically-controlled shut-off valve

The circuit in Figure 2-14 achieves a high level of safety. In this case, an additional barrier block closes the consumer connections to the cylinder safely and with no leakage of oil. This means that even heavy loads on non-horizontal axis can be quickly stopped and held safely, regardless of the state of the servo solenoid valve. Totally safe scenarios for switching the drive on and off can thus be implemented.

T BOP

Servo solenoid valve

Shutoff valve (barrier block)

Shutoff valve (electrically

switched)

2-40

Fig. 2-14 Typical example for the combination of an electrically-switched shut-off valve

with an additional barrier block

SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

10.03

2 Configuration

2.3 Configuring the hydraulic drive

Preferred range of shut-off valves

Table 2-11 Shutoff valves

Rexroth order number

0 811 024 120 6

0 811 020 040 10

0 811 024 125 6

0 811 024 123 6

Nominal

size

Bosch Rexroth shut-off valves from the following table should ideally be used in conjunction with the HLA module. These are sandwich-plate valves in sizes 6 and 10. Additional shut-off valves are available upon request from Bosch Rexroth.

Graphic symbol Rexroth

P ’

P TOB

P ’

T’ A’ B’

TOB T’ A’ B’

catalog

/BR3/

0 811 004 102 6

0 811 004 103 6

0 811 004 104 6

0 811 024 122 6

0 811 024 121 6

A ’

O A

’

A ’

P ’

A ’

B ’

T ’

B ’

TOB

P’ T’

PT B’ P’

A’ P’

OPT T’ P’

TPB

B’ T’

BTO

2-41

2.3 Configuring the hydraulic drive

2 Configuration

2.3.4 Natural frequency of the hydraulic drive

10.03

Servo gain

Natural frequency

The possible servo gain is essentially determined by the natural frequency of the cylinder and its load ω

The cylinder and its load constitute a spring/mass attenuation system whose natural frequency is calculated using the following formula:

wo X

Where: E=modulus of elasticity (N/m2)

Oil volumes in the cylinder pipes must also be taken into account. The minimum natural frequency occurs only at a particular mid-position about

the middle and increases as the end positions are approached.

The natural frequency of the hydraulic drive is automatically calculated by the HLA module and applied in the controller once the corresponding data parameters have been set. See machine data, Sections 4.8 and 4.9:

and the limit frequency of the servo solenoid valve

4 @ E @ A m @ h

A=piston area (m AR=ring surface (m2) h=stroke (m) α=surface ratio AR/A m=mass (kg)

1 + α

( )

)

Possible dynamic response

S MD 5131: CYLINDER_PISTON_DIAMETER

... MD 5136: CYLINDER_DEAD_VOLUME_B

S MD 5140: VALVE_CYLINDER_CONNECTION

... MD 5143: PIPE_INNER_ DIAMETER_A_B

S MD 5150: DRIVE_MASS

... MD 5152: CYLINDER_FASTENING

S MD 5160: PISTON_POS_MIN_NAT_FREQ

... MD 5163: DRIVE_NATURAL_FREQUENCY

The dynamic response of the servo solenoid valves thus depends on the amplitude of the valve modulation. For valves that are used in controlled axes, the natural frequency is typically determined for a modulation amplitude of "10% and a phase offset of -180°. The relevant information is given in the valve manufacturer’s catalog, e.g. /BR1/.

For pilot-controlled servo solenoid valves, the dynamic response is determined by the pilot pressure p

The Rexroth catalog data relates to a pilot pressure of 100 bar. Servo valves can reach corner frequencies of up to 1000 Hz, but are very sensi-

tive to contamination.

, in addition to the valve type:

pilot

before0

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SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

10.03

2 Configuration

2.3.5 Hydraulic power unit

The hydraulic power is supplied by a hydraulic power unit installed separately or integrated in the machine. The power unit is configured individually to meet the requirements of all hydraulic loads. The following factors are of particular importance:

2.3 Configuring the hydraulic drive

Pressure p

Flow rate Q

Drive power P

Pump type

The pressure is determined from the cylinder geometry, hydraulic characteristics of the servo solenoid valve and other data such as load forces or flow resistance values in the hydraulic circuit due to the drive speeds and forces required. The standard value for the system pressure for machine tool feed drives is around 40... 100 bar.

The maximum flowrate is calculated from the rapid traverse velocity. If several cylinders are operating simultaneously, the sum of all loads must be

taken into account. Maximum flow is often reached for only brief periods and can be supplied by an

accumulator. The pump capacity is selected to satisfy the mean flow rate.

The power P output by the electric motor to the pump drive is calculated as the product of pressure p, flow rate Q and efficiency η.

P=p@Q@η

Variable displacement pumps with pressure regulators in combination with an accumulator are generally employed in order to prevent power losses and to match the energy supply to the fluctuating delivery requirement during the cycle.

Vane pumps have proven successful in the normal pressure range for these applications of 70 to 210 bar.

Axial piston pumps are commonly used for high-pressure applications up to 350 bar.

Filtration

Classic servo-valves with fluid converters as initial stages are extremely sensitive to contamination. However, even the control edges of modern servo solenoid valves require filtration.

To ensure general operational reliability, but more importantly, to protect the control edges against premature erosion and to maintain the quality of zero overlap, the oil contamination must be limited in compliance with Class 7...9 according to NAS 1638.

This is achieved by using class β in the pressure line directly upstream of the servo solenoid valve.

The most critical phase is start-up, since contamination which has “accumulated” prior to installation often causes failures. For this reason, it is advisable to purge the system before the servo solenoid valves are fitted.

=75 full flow filters, which must be positioned

2-43

2.3 Configuring the hydraulic drive

2 Configuration

10.03

Cooling

Since considerable power losses that cannot be compensated for solely through oil reservoir dissipation occur when the flow is throttled via the control edges on the valve, additional oil/air or oil/water heat exchangers must be provided in most cases.











(GND)



°C

 Variable displacement pump with pressure regulator  Pressure-relief valve (protection)  Accumulator with fail-safe circuit  Filters in pressure line  Filters in return line  Oil/water heat exchanger  Oil reservoir

Fig. 2-15 Overview of typical hydraulic power unit



2-44

SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

2 Configuration

04.00

10.03

2.4 Connection

2.4.1 Internal power supply

Comments

Note

The NC CPU is supplied by the SIMODRIVE power supply via the device bus. No provision has been made for any other type of voltage supply and failure to use the supply provided could damage the unit.

2.4 Connection

Connection and power loss calculation for the NCU

The HLA module is integrated as a single module into the network of SIMODRIVE modules (power supply or incoming supply module, possibly feed modules and/or main spindle modules) and 840D. The power supply is fed in via the device bus.

The total power requirement for the entire network must be calculated. This must not exceed the power supplied by the power supply module.

To make the calculation easier, each module has a weighting factor. This can be found in Chapter 9 of the following reference material: References: NC 60 catalog The sum of electronic and control points must not be larger than stated in the

data sheet of the power supply module.

2.4.2 External power supply

Requirements of external 26.5 V supply

The purpose of the external power supply is to switch and supply the hydraulic components

S closed-loop proportional valves S Shutoff valves S pressure sensors

via the closed-loop control. In principle, stabilized or unstabilized power supplies and switched-mode or

in-phase-controlled supplies can be used. The following points must, however, be noted:

S The required voltage tolerance can only be achieved in practice with stabi-

lization and preferably switched for the existing currents. The ripple associated with an unstabilized power supply may cause tripping at the lower monitoring threshold.

S The stabilization has 24000 µF input capacity per module, which can best

be charged up with a stabilized power supply (with current limitation).

2-45

2.4 Connection

2 Configuration

02.99

10.03

Warning

S The DC supply must be safely electrically isolated.

See also: References: /PHD/, Configuration NCU 561.2-573.2

S The DC supply must be connected to the functional ground of the control at

one point (e.g. X131 on I/RF module). As a rule, the connection is provided as standard in the S7-300 I/Os. See also:

References: /EMC/, SINUMERIK, SIROTEC, SIMODRIVE, EMC

Installation Guideline

S The input for the 26.5 V supply is protected against polarity reversal.

26.5 V "2% must be fed from the external 26.5 V supply to connector X431 to supply the hydraulics components (servo solenoid valves, shut-off valves, and pressure sensors). The power requirements is calculated from the power required by external components plus 0.1 A for the internal circuit.

The input voltage tolerance relates to the input terminals of the closed-loop control; the voltage drops on the supply leads are not negligible.

The external 26.5 V supply is monitored for violation of a lower limit in the control.

Caution

After the external 26.5 V supply has powered up, terminal X431 may no longer be inserted or switched since the high charging currents can irreparably damage the module or external switch.

S If the external 26.5 V supply has to be switched, then an external “precharg-

ing circuit” (e.g. relay with timer and resistor) must be used.

S The 26.5 V outputs are short-circuit-proof or protected by fuses.

The outputs for the shutoff valves are designed as electronic switches with integrated zener diodes for disconnecting inductive loads. The zener diodes are located between the 24 V input and the output, with a typical zener voltage of 58 V.

On supply disconnection, the energy produced by the coil inductance and the valve spool spring, plus the energy supplied from the 24 V source in the zener diode and ohmic resistance in the solenoid coil is converted to heat. This energy must not exceed 1.7 J during one power OFF process or else the zener diode will be destroyed; no electronic protection against this type of overload is available.

S Other requirements of the external 26.5 V supply:

- Voltage range (mean value) 25.97 V to 27.03 V DC

- Ripple 240 mVpp

- No voltage dips, otherwise disconnection

2-46

SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

10.03

(24...28.8 V) tol. "1%

tol. "1%

2 Configuration

2.4 Connection

Recommended power supply

The SITOP power product range supplied by SIEMENS is recommended for use as the external 26.5 V power supply.

References: SITOP catalog

Order no. E86060-K2410-A101-A4

S SITOP power for line supply connection

The SITOP power product types shown in the tables are recommended for the line supply connection:

Table 2-12 SITOP power for line supply connection

Input Output Order No.

Voltage range

[v]

2AC 85...132/176...550 24 V DC

3AC 320...550

Mains supply module

Voltage

X431

5 6

HLA module

P24EXTIN M24EXTIN

Current

a Nom

5 A 6EP1333-3BA00 10 A 6EP1334-3BA00 20 A 6EP1436-3BA00 40 A 6EP1437-3BA00

X131

SITOP

Line

Fig. 2-16 Connection of external 26.5 V SITOP power for line connection

L2 L3

AC/DC

M (GND)

L+ (26.5 V)

2-47

2.4 Connection

2 Configuration

2.4.3 Grounding concept/Electromagnetic compatibility (EMC)

The 840D system with HLA module consists of a number of individual components. The individual system components are:

S I/RF infeed/regenerative feedback module S NCU box S HLA module S Machine control panel MCP S Qwerty keyboard S Operator panel components (various monitors with different MMC CPUs) S Terminal block (NCU and L2 DP) S Distributor box and handheld unit

The individual modules are attached to a metal cabinet panel by means of screws. Make sure that near the screws a low-impedance contact of the NCU box with the cabinet wall can be made. Insulating varnishes must be avoided where possible.

The electronic grounding points of the modules are interconnected via the device and drive bus and at the same time conducted to the X131 terminal of the I/RF module.

The internal electronics ground of the HLA module is directly connected to the metal front (module) plate.

02.99

10.03

Operator panel

PA/SL

Grounding bar

Fig. 2-17 Grounding concept

MMC

- Ground (frame) -

S7-300 I/Os

Ground terminal

Machine control panel

PA/SL

Gating

NCU

PA/SL PA

MB: Shielded signal cable with reference ground PA: Equipotential bonding conductor SL: Protective conductor

electronics

Hydraulic drive

Machine bed

Line supply connection S

HLA module

Cross-sections (mm2)

10

S v 16 16 t S v 35 S u 35

Please note the following in relation to electromagnetic compatibility: References: /EMC/, EMC Installation Guidelines

Standards according to Declaration of Conformity (Appendix E)

Distribution box

PA/SL

Terminal block

PA/SL

PE minimum

S 16 S/2

2-48

SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

Installation and Start-Up

3.1 Overview of start-up process

Selection from

Selection list: valve data

Fig. 3-1 Overview of start-up process

Machine Configuration

a list

Data entry

Cylinder data Mechanical data

Specially designed start-up menu displays are provided by the SINUMERIK 840D control system.

Instructions for calling menu displays can be found in: References: /IAD/, Installation and Start-Up Guide

The hydraulic linear drive (HLA) is displayed as follows next to the electric drives (SRM, ARM and SLM) in the “Machine Configuration” screen (basic start-up display):

Calculate drive model data

Data input Data entry

Model data

Calculate controller data

Controller data

Fig. 3-2 Machine Configuration (basic start-up display)

3-49

3.1 Overview of start-up process

3 Startup

10.03

Machine Data

Start-up sequence

Hydraulic linear drives (HLA) are adapted to suit the machine using the machine data.

In addition to the following soft keys:

S General MD S Channel MD S Axis MD S Display MD

Softkey “Drive MD”.

The following list shows the general steps to be taken to start up an HLA module.

1. Select a valve ³ Select a valve from the list

2. Enter cylinder data

3. Mounting/supply data

4. Measuring system data

5. Calculate controller data, save boot file, NCK reset.

6. MD 5474: OUTPUT_VOLTAGE_POS_LIMIT and MD 5475: OUTPUT_VOLTAGE_NEG_LIMIT to low values to check the control direction.

7. Approach reference point and adjust position; Position adjustment if piston is in A position at end stop.

8. Adjust pressure sensors (MD 5550, MD 5551, MD 5552, MD 5553, MD 5704, MD 5705, MD 5708). Adjust “manually” using this machine data or automatically via MD 5650. Enter 1000 Hex in MD 5650. The data is reset to 0 after approximately 2 s and the sensors are then adjusted. The sensors must be unpressurized during adjustment.

9. Run offset compensation MD 5470. Automatic offset compensation can be run via MD 5650 if 2000 Hex is entered in MD 5650. Automatic offset compensation takes approximately 30 s and functions only if the P and I components of the velocity controller are active and all enabling signals are set (see Service Drive).

10.Reduce valve knee-point voltage in MD 5111 by 2...3% if necessary.

11.Area adaptation in MD 5462, set MD 5463 such that the control difference in the positive and negative traversing directions is almost identical.

12.Force limitation and friction torque compensation, see Section 4.4.

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10.03

3.2 Drive configuration

You must configure the drive bus before you can start up the drives. Do this by pressing softkey “Drive configuration”.

3.2 Drive configuration

Fig. 3-3 “Drive Configuration” menu display

The selected drive type (hydraulic linear drive in this example) is stored in NC machine data MD 13040: DRIVE_TYPE stored.

Table 3-1 Abbreviations of drive types

Drive Motors Contents of

SRM (FDD) Synchronous rotating motor (1FT6...) 1 ARM (MSD) Asynchronous rotating motor (1PH...) 2 SLM Synchronous linear motor (1FN...) 3 HLA Hydraulic linear drive 5 ANA Analog drive 4 PER I/Os 0

Once (at least) the following axis-specific machine data:

MD 13040 DRIVE_TYPE

S MD 30110: CTRLOUT_MODULE_NR S MD 30130: CTRLOUT_TYPE S MD 30220: ENC_MODULE_NR S MD 30240: ENC_TYPE

has been entered and an NCK power ON reset has been carried out (taking you to the “Drive Machine Data” menu display), the drive can be started up.

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3.3 Modify drive machine data

3 Startup

3.3 Modify drive machine data

You can use softkeys “Drive +” and “Drive -” to scroll through all digital (SRM, ARM, SLM and HLA) drives listed in the drive machine data.

02.99

10.03

Fig. 3-4 “Drive machine data” menu display

The softkey “Motor/Controller...” is renamed “Valve/Controller...” for the HLA. Softkey “Valve/Controller...” changes the keys of the vertical softkey menu for

the HLA as follows:

Drive +

Drive -

Direct selection...

Valve/ Controller...

Boot file/ NCK Res...

Search...

Continue search

Display options...

File functions

Drive +

Drive -

Direct selection

Valve selection...

Change valve data...

Calculate controller data...

Piston position...

File functions

(See Fig. 3-6)

(See Fig. 3-13)

(See Fig. 3-15)

(See Fig. 3-21)

3-52

Fig. 3-5 Rearrangement of vertical softkey menu for HLA

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3 Startup

3.4 Valve selection

General

“Valve selection...” soft key

You can select the servo solenoid valve from a list when you start up the SIMODRIVE 611 for the first time. Once you have made your selection, the valve machine data defaults are overwritten.

If the valve you want to use is not included in the list, you must enter the valve machine data manually.

This soft key starts the user-prompted start-up process for the HLA module. You can select a valve from a list stored in the module software, or a non-listed

valve, in the following menu display.

Fig. 3-6 “Valve selection for HLA” menu display

Enter “Unlisted valve” to call a new menu display (see Fig. 3-7) in which the corresponding machine data can be entered manually.

Choose softkeys “Search...” and “Continue search” to look for any character string within the list.

Select softkey “Back” to return to the previously displayed menu. This softkey is disabled in the menu display 3-6.

Note

When you select “Abort”, the program branches back to the drive machine data display (see Fig. 3-5), both in this screen and the following menu displays for user-prompted start-up. The “Abort” soft key also activates a prompt box in which you must confirm that you really want to abort start-up for this drive.

No data is ever changed when you select “Abort”. This also applies to the following menu displays.

From 10.03 onwards, the name of the company will be changed from Bosch to Rexroth in the menu displays. The order numbers will remain unchanged.

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3.4 Valve selection

3 Startup

10.03

If the “Unlisted valve” entry is selected, press the “Continue” soft key to go to the “Unlisted Valve Data for HLA” menu display (see Fig. 3-7). If you press softkey “Continue” otherwise, the machine data assigned to the entry are written to a buffer whose contents are transferred to the drive at the end of the start-up process. The “Cylinder data” menu display then appears (see Fig. 3-9).

Valve selection from a list

Loaded valve data

The following data appears in the MMC list display for a stored valve when you select one:

S Company e.g.: Rexroth S Order No. e.g.: 0811404829 S Type e.g.: 4WRPEH 10 S Nominal flow rate e.g: 100 l/min. S Knee-point voltage e.g.: Knee 40% S Nominal flow rate A:B e.g.: 2.0 S Code e.g.: 52

If you select a valve from the list, the following machine data is preset (i.e. the default value is overwritten):

S MD 5106: VALVE_CODE (valve code no.) S MD 5107: VALVE_NOMINAL_FLOW (nominal flow rate of valve) S MD 5108: VALVE_NOMINAL_PRESSURE (nominal pressure drop of valve) S MD 5109: VAL VE_NOMINAL_VOLTAGE (nominal valve voltage) S MD 5110: VALVE_DUAL_GAIN_FLOW (knee-point flow rate of valve) S MD 5111: VALVE_DUAL_GAIN_VOLTAGE (knee-point voltage of valve) S MD 5112: VALVE_FLOW_FACTOR_A_B

(ratio of flow rate at the A end to the B end of valve)

S MD 5113: VALVE_CONFIGURATION (valve configuration) S MD 5114: VALVE_NATURAL_FREQUENCY

(natural frequency of valve in small-signal range)

S MD 5115: VALVE_DAMPING (valve damping)

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3.4 Valve selection

Unlisted valve data

You must enter the valve machine data manually for an unlisted valve. You can also preset the machine data to the settings of a similar valve.

Fig. 3-7 “Unlisted valve data for HLA” menu display

Press the “Continue” softkey to call menu display “Cylinder data”. This data is not written to the drive until start-up has ended.

By pressing vertical softkey “Preset”, you can go to the corresponding menu display in which you can preset machine data by selecting “OK”. You then return to menu display “Unlisted valve data for HLA”.

Fig. 3-8 “Preset Unlisted Valve for HLA” menu display

When you press “OK”, the machine data in menu display “Preset unlisted valve for HLA” are preset. You then return to this menu display.

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3.5 Cylinder selection

3 Startup

3.5 Cylinder selection

The following cylinder data must be entered manually:

S MD 5131: CYLINDER_PIST ON_DIAMETER

S MD 5132: CYLINDER_ROD_A_DIAMETER

S MD 5133: CYLINDER_ROD_B_DIAMETER

S MD 5134: PISTON_STROKE

S MD 5135: CYLINDER_DEAD_VOLUME_A

S MD 5136: CYLINDER_DEAD_VOLUME_B

10.03

(piston diameter of cylinder)

(cylinder piston rod diameter at A end)

(cylinder piston rod diameter at B end)

(piston stroke)

(cylinder dead volume at A end)

(cylinder dead volume at B end)

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Fig. 3-9 “Cylinder data for HLA” menu display

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3.6 Mounting/supply data

Supply unit

Connection

Fig. 3-10 “Mounting/supply data for HLA” menu display

Select the “Back” softkey to return to the “Cylinder data for HLA” menu display. Then press “Continue” to go to the “Measuring system data for HLA” menu display.

The following mounting and supply data must be entered manually.

S MD 5100: FLUID_ELASTIC_MODULUS (modulus of elasticity of

hydraulic fluid)

S MD 5101: WORKING_PRESSURE (system pressure) S MD 5102: PILOT_OPERATION_PRESSURE (pilot pressure, for pilot-

actuated valves only)

S MD 5140: VALVE_CYLINDER_CONNECTION

(valve-cylinder connection configuration)

S MD 5141: PIPE_LENGTH_A (pipe length at A end) S MD 5142: PIPE_LENGTH_B (pipe length at B end) S MD 5143: PIPE_INNER_DIAMETER_A_B

(internal pipe diameter A-B (nominal diameter))

S MD 5530: CYLINDER_SAFETY_CONFIG (protection circuit)

Drive data

S MD 5150: DRIVE_MASS (moved mass of drive) S MD 5151: CYLINDER_A_ORIENTATION

(mounting position A end of cylinder)

S MD 5152: CYLINDER_FASTENING (cylinder mounting)

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3.7 Measuring system data

3 Startup

3.7 Measuring system data

Fig. 3-11 “Measuring System Data HLA, Incremental” menu display

10.03

Softkey “Ready”

To set the encoder parameters, select either the “Incremental” or the “Absolute (EnDat interface/SSI interface)” option.

The value of the associated machine data is displayed as the scale graduation. You can return to menu display “Mounting/supply data for HLA” by selecting softkey “Back”.

Select the “Ready” softkey to conclude the start-up for this drive. A dialog message then appears. This must be acknowledged with “Abort” or

“OK”.

Fig. 3-12 Dialog message “Start-up ready”

You can return to menu display “Measuring system data for HLA” by selecting softkey “Abort”.

Press “OK”, to write the machine data to the drive. The drive model and controller data are then calculated and the boot file saved. The program then jumps to the “Valve/Controller...” menu display (see Fig. 3-5), where data can be checked and/or modified using “Change valve data”.

The remaining drives can then be started up.

Activation of data

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The entered/calculated data can be activated by an NCK power On/Reset.

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3.8 Modifying data

Changing valve data

The following menu display appears when you press the “Change valve data...” softkey (see Fig. 3-5):

Fig. 3-13 Menu display “Change data for HLA”

If you press “Abort”, the old machine data settings are retained and you return to the initial menu display (see Fig. 3-5).

Softkeys “Valve data...”, “Cylinder data...” and “Mounting data...” each call a display that has the same format as the following screenshot except for display header and contents (e.g. valve data for HLA):

Fig. 3-14 Menu display “Valve data for HLA”

You can return to menu display “Change data for HLA” (see Fig. 3-13) by pressing “Abort” or “OK”.

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3.8 Modifying data

3 Startup

02.99

10.03

The valve and cylinder data and the mounting/supply data are used to preset the following data when you activate “Calculate drive model data”. These settings can be changed manually afterwards. It is advisable to confirm the calculated model data by carrying out tests on the drive and correct them in accordance with the test results.

S MD 5401: DRIVE_MAX_SPEED (maximum useful velocity) S MD 5440: POS_DRIVE_SPEED_LIMIT (positive velocity setpoint limit) S MD 5441: NEG_DRIVE_SPEED_LIMIT (neg. velocity setpoint limit) S MD 5160: PISTON_POS_MIN_NAT_FREQ (min. natural frequency,

piston position)

S MD 5161: DRIVE_DAMPING (drive damping) S MD 5162: DRIVE_NATURAL_FREQUENCY_A (natural freq. of drive A) S MD 5163: DRIVE_NATURAL_FREQUENCY (natural frequency of drive) S MD 5164: DRIVE_NATURAL_FREQUENCY_B (natural freq. of drive B) S MD 5231: FORCE_LIMIT_WEIGHT (weight force limitation) S MD5240: FORCECONTROLLED_SYSTEM_GAIN

(controlled system gain force controller)

S MD 5435: CONTROLLED_SYSTEM_GAIN (controlled system gain) S MD 5462: AREA_F ACTOR_POS_OUTPUT (fact. area adaptation pos.) S MD 5463: AREA_F ACTOR_NEG_OUTPUT (fact. area adaptation neg.)

The data entered for valve, cylinder, mounting/supply and drive model are used to preset the following data when you activate “Calculate drive model data”. These settings can be changed manually afterwards.

S MD 5242: FORCECTRL_GAIN (P-gain of force controller) S MD 5243: FORCECTRL_GAIN_RED (reduction of force controller P gain) S MD 5244: FORCECTRL_INTEGRATOR_TIME (force controller reset time) S MD 5245: FORCECTRL_PT1_TIME (smoothing time constant of

force contr.)

S MD 5246: FORCECTRL_DIFF_TIME (force controller D-action time) S MD 5476: OUTPUT_VOLTAGE_INVERSION (manip. variable inversion) S MD 5464: POS_DUAL_GAIN_COMP_FLOW

(knee compensation pos. flow rate)

S MD 5465: POS_DUAL_GAIN_COMP_VOLTAGE (knee comp. pos. voltage) S MD 5467: NEG_DUAL_GAIN_COMP_FLOW (knee comp. neg. flow rate) S MD 5468: NEG_DUAL_GAIN_COMP_VOLTAGE (knee comp. neg. voltage) S MD 5406: SPEEDCTRL_GAIN_A (P gain, P gain S MD 5407: SPEEDCTRL_GAIN (velocity controller P gain) S MD 5408: SPEEDCTRL_GAIN_B (P gain, P gain S MD 5409: SPEEDCTRL_INTEGRATOR_TIME[n] (vel. controller reset time) S MD 5413: SPEEDCTRL_ADAPT_ENABLE (selection of vel. c. adaptation) S MD 5414: SPEEDCTRL_REF_MODEL_FREQ[n] (natural freq. of ref.model) S MD 5415: SPEEDCTRL_REF_MODEL_DAMPING[n]

(damping of velocity controller reference model)

S MD 5430: SPEEDCTRL_PT1_TIME (smoothing time constant vel. lead time) S MD 5431: SPEEDCTRL_DIFF_TIME_A[n] (velocity controller A

derivative-action time)

S MD 5432: SPEEDCTRL_DIFF_TIME[n] (velocity controller lead time) S MD 5433: SPEEDCTRL_DIFF_TIME_B[n] (velocity controller B)

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3.8 Modifying data

Calculate controller data/drive model data

Press “OK” (in Fig. 3-13) to transfer the modified machine data is transferred to the drive and, depending on the option settings

S calculate drive model data and/or S Calculate controller data

the “Calculate controller/drive model data” dialog box appears with the corresponding text (see Fig. 3-15; in this case, for both options).

Fig. 3-15 Menu display “Dialog box for calculate controller/drive data”

Press “Abort” to return to the “Change Data for HLA” menu display (see Fig. 3-13).

Press “OK”, to recalculate the drive model data and/or controller data and then return to the initial menu display (see Fig. 3-5).

The filters, friction compensation and limitation parameters can then be set to suit the application.

Softkey “Help” displays a list of those machine data that are changed with softkey “OK”. In this case as well, the texts are dependent on the set options.

Fig. 3-16 Help screen for changing controller/drive model data

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3.9 Fine adjustment and optimization

3 Startup

3.9 Fine adjustment and optimization

On completion of start-up, the control loop settings must be checked.

3.9.1 Control direction, travel direction

10.03

General

Limitation of manipulated voltage

Determine control direction (step 1)

The control direction can be reversed by the following methods:

S Inversion of the manipulated voltage S Actual value inversion S Scale rotation S Pipes A ³ A to A ³ B (inversion)

Any adjustment in the hydraulic piping can be canceled by inversion of the manipulated voltage.

If the scale is rotated or attached at the wrong point (jacket or rod of cylinder), the control direction can be adjusted by means of actual value inversion.

The manipulated voltage must be limited before the system is first for a control direction check.

MD 5474: OUTPUT_VOLTAGE_POS_LIMIT [ 1 V MD 5475: OUTPUT_VOLTAGE_NEG_LIMIT [ 1 V

Note

It is not necessary to determine the control direction if the drive can already operate in JOG mode. In this case, the control direction is already set correctly (MD 32110). The control direction of the velocity controller still needs to be checked (MD 5011 bit 0). The control direction must be set identically: both “inverted” or both “not inverted”. Continue from step 2.

switched on

3-62

When the enabling signals are set, the axis may move in an uncontrolled manner.

Causes:

S Incorrect control direction of velocity controller

- Actual value encoder mounting

- Connections combining servo solenoid valve and cylinder

- Manipulated voltage polarity reversed

S Incorrect control direction of position controller

- Actual value encoder mounting

Fig. 3-17 shows the methods which can be used to adjust any uncontrolled traversing movements.

Note

If valve end A is connected to cylinder end B (MD 5140=1), inversion of the valve manipulated variable (MD 5476) is preset by “Calculate controller data”.

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3.9 Fine adjustment and optimization

Start

Definition of drive travel direction (step 2)

Do MD 5706 and MD 5707 (v have the same sign when the drive starts?

MD 32110: Modify ENC_FEEDBACK_POL (actual value sign) or MD 5476: Invert OUTPUT_VOLTAGE_INVERSION (manip. variable inversion) and MD 5011: invert ACTUAL_VALUE_CONFIG (actual value sensing)

Fig. 3-17 Start-up flow chart, determine control direction

, v

)

set

act

yes, but fails with error message

Step 2

MD 5476: Invert

OUTPUT_VOLTAGE_INVERSION (manip. variable inversion)

When the cylinder piston moves in the A ³ B direction (flow rate Q > 0) , the actual velocity value V

must be positive.

act

This definition MUST be made in the drive for the associated functionality of

S velocity controller adaptation and S force limitation

absolutely essential.

Step 2

Enter a small positive valve manipulated voltage (function generator)

traverse the drive in JOG mode to move the cylinder piston from the A to B end.

Is cylinder piston A ! B traversing and is MD 5707 positive?

Yes

Step 3

Fig. 3-18 Start-up flow chart, definition of drive travel direction

(adjust sign of actual velocity value)

MD 5476: OUTPUT_VOLTAGE_INVERSION Modify bit 0 (invert manipulated variable)

and MD 5011: ACTUAL_VALUE_CONFIG Modify bit 0 (invert actual value)

and

MD 32110: ENC_FEEDBACK_POL (actual value sign)

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3.9 Fine adjustment and optimization

3 Startup

10.03

Definition of travel direction in NC (Step 3)

The positive direction of travel of the machine is defined by the user. With adjustment of travel direction with setpoint MD 32100: AX_MOTION_DIR.

Step 3

Traverse with JOG key (override approx. 10%)

Does cylinder move in the set direction?

Yes

End

Fig. 3-19 Start-up flow chart, definition of travel direction in NC

(define travel direction of machine)

MD 32100: Change AX_MOTION_DIR (travel direction of machine)

Cancel manipulated voltage

The setpoint limitation must be set to 10 V in the following MDs: MD 5474: OUTPUT_VOLTAGE_POS_LIMIT

MD 5475: OUTPUT_VOLTAGE_NEG_LIMIT

limitation

3.9.2 Offset adjustment

Offset of pressure sensors

Note

Only in combination with pressure sensing function.

Condition: Sensors are pressure-free! Ideal: The pressure indicator should also display 0 bar at zero pressure. Adjustment:

S MD 5650: Set DIAGNOSIS_CONTROL_FLAGS bit 12 (canceled automati-

cally after 2 s).

S Pressure sensor A: MD 5551: PRESSURE_SENS_A_OFFS is automatically

adjusted.

S Pressure sensor B: MD 5553: PRESSURE_SENS_B_OFFS is automatically

adjusted.

For unpressurized pressure sensors, the display must read approximately 0.0 bar for both pressures (MD 5704, MD 5705).

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Reference value for pressure sensors

3.9 Fine adjustment and optimization

Note

Only in combination with pressure sensing function.

Pressure sensor characteristic data in

S MD 5550: PRESSURE_SENS_A_REF (ref. value for pressure sensor A) S MD 5552: PRESSURE_SENS_B_REF (ref. value for pressure sensor B)

according to data sheet.

Offset of valve manipulated voltage

Ideal: Adjustment of electro-hydraulic zero point The voltage is adjusted automatically by the following sequence of operations:

S Preset velocity controller with I component (e.g. V

Subsection 4.3.2).

S In position-controlled mode at zero speed with all enabling signals applied

(drive can be traversed with JOG keys).

S Set MD 5650 bit 13. (Bit 13 is automatically reset after about 30 s.) S MD 5470: OFFSET_COMPENSATION offset compensation is set automati-

cally.

3.9.3 Velocity adjustment

Target

Owing to the tolerances of the valves and drive units with

S real areas S real valve control edges

it is advisable to readjust the controlled system gain for the purpose of obtaining a symmetrical actual velocity.

The gain is adjusted via machine data

∆v

move out

= ∆v

move in

=-10%, TN=30 ms) (see

S MD 5435: CONTROLLED_SYSTEM_GAIN (stage 1)

and

S MD 5462: AREA_FACTOR_POS_OUTPUT/

MD 5463: AREA_FACTOR_NEG_OUTPUT (stage 2).

is substituted. Controller parameters

S P: P gain of velocity controller (MD 5406/MD 5407/MD 5408) S I: reset time of velocity controller (MD 5409) S D: D-action time of velocity controller (MD 5431/MD 5432/MD 5433)

must be set to 0.

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3.9 Fine adjustment and optimization

3 Startup

04.00

10.03

Adjustment of controlled system gain

Use function generator to enter a velocity setpoint of v

set

offset=0.

Output curve behavior ∆ Controller=0; D, I, P

0 ∆

∆

Cylinder travel-out

Cylinder travel-in

Adjustment stage 1: Identical setting for both velocity directions with

MD 5435; match v

∆

Cylinder travel-out

Cylinder travel-in

Aim of adjustment ∆v

set

act

∆

and v

set

act

∆

= 0

at one end.

act

∆v

out in

= 0

Adjustment stage 2: Direction-dependent adjustment with MD 5462 and/or

MD 5463.

Cylinder

∆

= 0

set

travel-out

act

∆

= 0

Cylinder

travel-in

3. Adjusted state

Fig. 3-20 Adjustment of controlled system gain

Note

S V

is not represented by the “servo trace” function if the setpoint is defined

set

by the function generator.

S The setting must be checked at different velocities.

- Generally speaking, the average value of the calculated controlled system gain must be set or

- the gain can be adjusted to match the relevant operating range.

S Both adjustment are equivalent, i.e. adjustment by the stage 2 method via

MD 5462 and (setting) of the controlled system gain (MD 5435) is applied.

MD 5463 produces equivalent results when the preset value

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3.9.4 Referencing data for HLA

3.9 Fine adjustment and optimization

Piston zeroing

The position of the cylinder piston is required for the “Force controller” and “Velocity controller adaptation” functions. For this purpose, the piston position must be adjusted once after referencing.

This is done by the following sequence of operations:

S Reference Point Approach S Press the “Piston position” soft key (see Fig. 3-5) S Move cylinder piston to limit stop at A end S Press softkey “Position adjust.” (see Fig. 3-21) to transfer the value set in

MD 5740: ACTUAL_POSITION to MD 5040: PISTON_ZERO.

S Saving the boot file

Fig. 3-21 Menu display “Referencing data for HLA”

Press the “OK” soft key to return to the initial menu display for HLA. The following machine data affects the position adjustment:

S MD 5040: PISTON_ZERO (piston zero in relation to machine zero)) S MD 5740: ACTUAL_POSITION (actual position in relation to machine zero) S MD 5741: ACTUAL_PISTON_POSITION (piston position in relation to piston

zero)

Note

The piston position adjustment must be repeated if the control direction, reference point offset or travel direction (MD 32110, MD 34090 or MD 32100) in the axis-specific machine data is changed.

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3.9 Fine adjustment and optimization

3 Startup

3.9.5 Controller optimization

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10.03

General

The most important travel motions are implemented via the feedforward control path.

The function of the controller parameters is to damp the oscillation characteristics of the valve/cylinder grouping.

In this respect, we distinguish between three different scenarios relating to the corner frequency (f):

1. f

valve

<< f

cylinder

(f)

The valve cannot actively influence any cylinder frequency that is higher than the valve corner frequency.

Disturbances with frequencies f

Amplitude log frequency curve

-1

-2

-3

-4

> f

cannot be damped.

valve

Valve: fv=100 Hz; Dv=0.8

Drive: fa=500 Hz; Da=0.1

-5

-90

-180

Phase angle log value

-270

Fig. 3-22 Frequency response of controlled system (f

Phase frequency curve

10 log f

valve

<< f

cylinder

)

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3.9 Fine adjustment and optimization

2. f

valve

-90

-1

-2

-3

-4

-5

[ f

(f)

cylinder

Amplitude log frequency curve

10 log f

Phase frequency curve

Valve: fv=100 Hz; Dv=0.8

Drive: fa=100 Hz; Da=0.1

-180

Phase angle log value

-270

log f

Fig. 3-23 Frequency response of controlled system (f

valve

[ f

cylinder

)

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3.9 Fine adjustment and optimization

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3. f

valve

>> f

cylinder

(f)

The valve can actively influence all natural frequencies of the drive.

-1

-2

-3

-4

-5

Amplitude log frequency curve

Phase frequency curve

10 log f

Valve: fv=100 Hz; Dv=0.8

Drive: fa=20 Hz; Da=0.1

-90

-180

Phase angle log value

-270

Fig. 3-24 Frequency response of controlled system (f

10 log f

valve

>> f

cylinder

)

The controller components are optimized in the following order:

1. P component (proportional component)

2. D component (derivative component)

3. I component (integral component) The preferred method of optimization uses unit step functions (step response)

with the function generator (FG) after entering a velocity setpoint v

set

The measuring function with noise signals (FFT, PBRS) may be difficult to interpret owing to non-linearities in the controlled system.

Differences in the characteristic data may be caused as follows:

S Theor. valve: Real valve S Pipes: Control pressure = f(Q) S Additional valves; shut-off valves; filters; throttles (pressure measuring

plates)

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3.9 Fine adjustment and optimization

Optimization of controller P component

Relevant machine data: MD 5406: SPEEDCTRL_GAIN_A (P gain of velocity controller A)

MD 5407: SPEEDCTRL_GAIN (P gain of velocity controller) MD 5408: SPEEDCTRL_GAIN_B (P gain of velocity controller B)

The theoretical characteristic data of the valve and cylinder are used to calculate a suggested P gain value. The positive feedback area (MD 5406...MD 5408 <0) is included in the calculation to damp the drive system.

The adjustment to real conditions on the machine (special damping requirements) should be made according to the following criteria:

1. P component must be as positive as possible. Optimization direction

MD 5406 MD 5407

0< 0 > 0

2. The acceptable overshoot behavior represents the upper limit for the setting.

Note

P<0 (positive feedback) may be necessary to achieve the required damping behavior. However, this setting will degrade the control quality. Friction in particular causes prolonged settling times.

MD 5408

Optimization of controller D component

Threshold values (typical):

S f



S f



S f



...f see section 3.9.5 point 1...3)



Note

The P gain is indicated as a % of MD 5435: CONTROLLED_SYSTEM_GAIN. P=-100% compensates the feedforward control.

Relevant machine data: MD 5431: SPEEDCTRL_DIFF_TIME_A (derivative-action time T

MD 5432: SPEEDCTRL_DIFF_TIME (derivative-action time TV of velocity MD 5433: SPEEDCTRL_DIFF_TIME_B (derivative-action time TV of velocity

MD 5430: SPEEDCTRL_PT1_TIME (velocity controller smoothing time

The positive phase displacement of the derivative term can be used to actively damp the controlled system for f

The derivative-action time constant/corner frequency parameters must be set to values higher than the minimum natural frequency of valve and drive.

P>0 P<0, or around zero P>0

type.



controller A) controller) controller B)

constant)

of velocity

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3.9 Fine adjustment and optimization

3 Startup

Test run:

S As long as the damping effect improves, the the D-action time value can be

raised further:

S Leave D-action time at its old value if the damping effect does not improve.

(see Fig. 3-22 - f) The smoothing time constant is set to values w 1 ms as a function of the con-

trolled system for “Calculate controller”. Owing to the fact that a derivative action amplifies the actual value noise, it is

necessary in this case to find a compromise between

S the derivative action (and thus vibration damping)

(MD 5430: SPEEDCTRL_PT1_TIME as low as possible, i.e. high corner frequency of D-action component or wide D-action frequency range)

and

S the noise of the manipulated variable.

Like the P component setting, the optimization criterion here is the maximum acceptable overshoot of the closed velocity control loop.

The main area of application is the valve/cylinder combination f with values TV>>0.

For applications f characteristics are only to be expected at specific points when T

cases TV=0 is the best choice.

(see Fig. 3-24)



+ f (see Figs. 3-22, 3-23) improvements of the damping



}0. In most

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Optimization of controller I component

Note

A second iteration loop (optimize P and D components) with further improvements can be connected in series downstream.

S Integrator/reset time (T

Objective: Elimination of errors in feedforward control channel. Implementation: TN>5 ms taking the overshoot

Note

The I component is deactivated if TN=0 (MD 5409) or if the P component is zero (MD 5406=0, MD 5407=0, MD 5408=0).

)

of the valve frequency response into account.

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3.9.6 Controller adaptation

3.9 Fine adjustment and optimization

General

Implementation

Since the natural frequency of the cylinder changes as a function of position, it may be useful to adapt the position of the velocity controller. The maximum values coincide with the limits, and the minimum approximately with the center (MD

5160), of the traversing range.

Requirement:

S NC end has been referenced. S Cylinder piston in neutral position has been adjusted as described in Section

3.9.4.

S Control parameters have been processed according to the relevant operat-

ing range.

Procedure:

S Optimize the velocity controller (P and D components) with the associated

machine data at the limits and at position set in MD 5160. Example: (see Fig. 4-11) operating range = total piston stroke Interpolation point 1 Optimization to A end of cylinder

³ MD 5406: SPEEDCTRL_GAIN_A (P gain) ³ MD 5431: SPEEDCTRL_DIFF_TIME_A (D gain)

Interpolation point 2 Optimization to piston position as set in

MD 5160: PISTON_POS_MIN_NAT_FREQ

³ MD 5407: SPEEDCTRL_GAIN (P gain) ³ MD 5432: SPEEDCTRL_DIFF_TIME (D gain)

Interpolation point 3 Optimization to B end of cylinder

³ MD 5408: SPEEDCTRL_GAIN_B (P gain) ³ MD 5433: SPEEDCTRL_DIFF_TIME_B (D gain)

Note

If one end of a cylinder cannot be approached, then the adaptation process can be limited to two interpolation points.

S Velocity controller adaptation active

MD 5413: SPEEDCTRL_ADAPT_ENABLE=1

Note

SPEEDCTRL_ADAPT_ENABLE=1 (MD 5413) is switched through only when the axis has been referenced and adjusted.

(see section 3.9.5), adaptation is deactivated in “Calculate controller

For f



data”.

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3.9 Fine adjustment and optimization

3 Startup

3.9.7 Hydraulic/electrical interpolation

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Target

Implementation

Contour accuracy between hydraulic and electric drives is achieved when the drive dynamic response is set identically on the axes involved.

In addition to identical servo gain settings, it must be ensured that the step response of the closed speed controller is “identical”.

A velocity setpoint filter of the faster axis (e.g. electric) must be set to the difference between the time constants of the closed velocity control loop (Tv, eqv).

filter, el

=Tv

eqv, hyd

0,5

- Tv

eqv, el

act, el

eqv, hyd

act, hyd

Fig. 3-25 Hydraulic/electrical interpolation

If dynamic stiffness control (DSC) is active, the DSC function must be activated on all interpolating axes.

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3.10 File functions

Save data

Load data

The drive type is recorded in the MD files when drive machine data is saved. Thus, the comment is inserted only if the entry “MdFileDriveType=TRUE” has been set in the [Compatibility] section of INI file “ib.ini”. This setting is the default.

Only MD files that are suitable for a particular drive type may be downloaded to that drive. If you attempt, for example, to load an MD file for SLM to an HLA module, the following message will be displayed:

Fig. 3-26 Menu display “Dialog box Load machine data”

Fig. 3-27 Menu display “File functions”

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3.11 Start-up functions

3 Startup

3.11 Start-up functions

The following start-up functions are implemented for axes with HLA:

S Measuring functions

- Measurement of valve control loop

- Measurement of velocity control loop

- Position control measurement

S Function generator S Circularity test S Servo trace S DAC configuration

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Disabled softkeys

Fig. 3-28 Menu display “Start-up functions”

The softkey “Self-opt.AM/MSD” in the “Start-up functions” menu is also disabled for axes with HLA since this is a special function for AM/MSD.

The “Aut. Controller setting” in the “Startup functions” menu is disabled for axes with HLA since the algorithms it uses are designed for automatic controller setting for electric digital drives.

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3.11.1 Measurement function

The measurement functions can be used to evaluate the most important speed and position control loop variables in the time and frequency range on screen without having to use external measuring devices.

An overview of the measurement functions provided for HLA is given below. Only the hydraulic-specific functionality for HLA is described in detail.

The following measurement functions can be performed in conjunction with the HLA:

S Valve control loop measurement

- Valve frequency response

S Velocity control loop measurement

- Reference frequency response

- Setpoint step change

- Interference frequency response

- Disturbance step change

- Velocity path

- Velocity path + controller

3.11 Start-up functions

Valve control loop measurement

S Position control loop measurement

- Reference frequency response

- Setpoint step change

- Setpoint ramp

Table 3- 2 Measurement types and measured variables for the valve control loop

Measurement Trigger Measured quantities

Valve frequency response

Table 3-3 Valve control loop measurement parameter settings

Amplitude Typ. 1 V V Bandwidth typ. 1000 Hz Hz Averaging operations typ. 10 Settling time typ. 100 ms Offset typ. 0 V

measurement

Valve spool setpoint in velocity controller cycle, valve control loop closed, velocity control loop open

Parameters Physical unit

Actual valve spool value/ valve spool setpoint

Note

It must be ensured that the drive is adequately lubricated before PBRS/FFT is applied (high-frequency movement at one position).

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3.11 Start-up functions

3 Startup

20.000

Ampl.

[dB]

-60.000

1.000 1.000e+03log [Hz]

+180

Phase

[degrees]

-180

1.000 1.000e+03log [Hz[]

10.03

Measurement of velocity control loop

Fig. 3-29 Sample valve frequency response for type 4WRREH 6 HR servo solenoid

Table 3-4 Measurement types and measured variables for the velocity control loop

Measure-

Reference frequency response

Setpoint step change

valves from Bosch Rexroth AG Note: For setting the valve data, see Section 4.7.

measurement

Trigger Measured quantities

ment

Velocity setpoint in velocity controller cycle, valve control loop closed, velocity control loop closed

Actual velocity value/ velocity setpoint

Measured variable 1:

S Velocity setpoint S valve spool setpoint

Measured variable 2:

Actual velocity

Interference frequency response

Disturbance step change

Velocity controller path

Velocity controller path + controller

Valve spool setpoint in velocity controller cycle, valve control loop closed, velocity control loop closed

Velocity setpoint in velocity controller cycle, valve control loop closed, velocity control loop closed

Actual velocity value/ valve spool setpoint

Measured variable 1:

Valve spool setpoint

Measured variable 2:

Actual velocity Actual velocity value/

actual valve spool value

Actual velocity value/ control deviation

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3.11 Start-up functions

Table 3-5 Parameter settings for measurement of velocity control loop

Parameters Physical unit

Reference frequency response

Amplitude (linear axis) mm/min | inch/min Bandwidth Hz Averaging operations Settling time ms Offset (linear axis) mm/min | inch/min

Setpoint step change

Amplitude (linear axis) mm/min | inch/min Measurement time ms Settling time ms Offset (linear axis) mm/min | inch/min

Disturbance step change

Amplitude V Measurement time ms Settling time ms Offset (linear axis) mm/min | inch/min

Velocity controller path

Amplitude V Bandwidth Hz Averaging operations Settling time ms Offset (linear axis) mm/min | inch/min

Velocity controller path + controller

Amplitude (linear axis) mm/min | inch/min Bandwidth Hz Averaging operations Settling time ms Offset (linear axis) mm/min | inch/min

The following functional response in the diagrams were recorded with the equipment combination below:

Valve: Type 4WRREH 6 HR servo solenoid (15 l/min, knee 60 %)

from Bosch Rexroth AG

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3.11 Start-up functions

3 Startup

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20.000

Ampl. [dB]

-60.000

0.100 200.000log [Hz]

180.000

Phase [degrees]

-180.000

0.100 200.000log [Hz]

Fig. 3-30 Oscillogram showing reference frequency response of velocity control loop

Amplitude: 20 mm/min. Offset: 100 mm/min.

3-80

0.000 50.000

Fig. 3-31 Timing of setpoint step change in velocity control loop

t [ms]

Step change: 0 → 100 mm/min without closed-loop force control, real friction conditions

Trace 1: V elocity setpoint Trace 2: Actual velocity value

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3.11 Start-up functions

0.100 100.000t [ms]

Fig. 3-32 Timing of disturbance step change, integral branch of velocity controller

deactivated

Trace 1: valve spool setpoint Trace 2: Actual velocity value

90.000

Ampl. [dB]

10.000

1.000 1000.000log [Hz]

180.000

Phase

[degrees]

-180.000

1.000 1000.000log [Hz]

Fig. 3-33 Oscillogram showing velocity controlled system v

act/Qact

Note: Phase crossover -90 degrees essentially characterizes the

cylinder natural frequency

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20.000 0

Ampl. [dB]

-60.000

1.000 2000.000log [Hz]

180.000

Phase [degrees]

-180.000

1.000 2000.000log [Hz]

Fig. 3-34 Oscillogram for velocity controller path + controller

Phase margin at 0 dB

Amplitude margin at 180 degrees

Note: Measurement of open velocity controlled system,

indicative of the stability of the control loop. Target values for stability of control loop:

S At least 3 dB amplitude margin at 180 degrees S At least 60 degrees phase margin at 0 dB

Position control measurement

Table 3-6 Measurement types and measured variables for position feedback loop

Measurement Trigger Measured quantities

Reference frequency response

Setpoint step change

Setpoint ramp

measurement

Position setpoint in position controller cycle, position control loop closed, velocity control loop closed

Actual position/position setpoint

Measured variable 1:

Position setpoint

Measured variable 2:

S Actual position value S Control deviation S Following error S Actual velocity value

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3.11 Start-up functions

Table 3-7 Parameter settings for measurement of position control loop

Parameters Physical unit

Reference frequency response

Amplitude (linear axis) mm | inch Bandwidth Hz Averaging operations Settling time ms Offset (linear axis) mm/min | inch/min

Setpoint step change

Amplitude (linear axis) mm | inch Measurement time ms Settling time ms Offset (linear axis) mm/min | inch/min

Setpoint ramp

Amplitude (linear axis) mm | inch Measurement time ms Ramp time ms Settling time ms Offset (linear axis) mm/min | inch/min

20.000

Ampl. [dB]

-60.000

0.100 125.000log [Hz]

180.000

Phase [degrees]

-180.000

0.100 125.000log [Hz]

Fig. 3-35 Example of measurement of position control loop

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3.11 Start-up functions

3 Startup

3.11.2 Function generator

The function generator for HLA is based on the existing functionality provided for other drive types integrated to date. The funct. for HLA, which is not especially designed for hydraulic drives, is based on the SLM range of functions.

The function generator excites the drive with a periodic signal. The signal type is a modifiable parameter. External measuring instruments such as oscillographs can record the system responses via DAC output jacks.

The following signals (operating modes) and signal types are available on the HLA:

S Signals (operating modes)

- valve spool setpoint

- Velocity setpoint

- Position setpoint

S Signal type

- Square-wave

- Noise signal (only for signal output via DAC and external evaluation equipment for frequency response analyses)

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Fig. 3-36 Menu display “Function generator selection signal”

Fig. 3-37 Menu display “Function generator selection signal type”

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3 Startup

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Valve spool setpoint (manipulated voltage)

3.11 Start-up functions

For an explanation of how to use the function generator, please refer to References: /FBA/, DD2 “Speed control loop”

/SHM/, SIMODRIVE 611 “Manual for MCU 172A”

An overview of the function generator functions provided for HLA is given below, with only the purely hydraulic-specific functionality for HLA described in detail.

Table 3-8 Signal (operating mode) for valve spool setpoint

Trigger Signal type

Valve spool setpoint in velocity controller cycle, valve control loop closed, velocity control loop open

Table 3-9 Signal (operating mode) for valve spool setpoint parameter settings

Parameters Physical unit

Signal type: Square-wave

Amplitude V Period ms Pulse width ms Offset V limitation V

Square-wave

Tr. 1: Valve stroke setpoint

Tr. 2: Actual valve stroke

1.9890

2.0510

-2.0260

-2.0610

0.0000

Fig. 3-38 Servo trace of actual valve value with square-wave signal type to valve

setpoint

t [ms]

200.0000

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3.11 Start-up functions

3 Startup

Velocity setpoint

Table 3-10 Signal (operating mode) for velocity setpoint

Trigger Signal type

Velocity setpoint in velocity controller cycle, valve control loop closed, velocity control loop closed

Table 3-11 Signal (operating mode) for velocity setpoint parameter settings

Parameters Physical unit

Signal type: Square-wave

Amplitude (linear axis) mm/min | inch/min Period ms Pulse width ms Offset (linear axis) mm/min | inch/min Limitation (linear axis) mm/min | inch/min

Square-wave

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Note

The following diagram was created using a servo trace.

0.000 2.000e+03

Fig. 3-39 Servo trace of actual velocity with square-wave signal type to velocity setpoint

t [ms]

Amplitude: 100 mm/min.

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Position setpoint

3.11 Start-up functions

Table 3-12 Signal (operating mode) for position setpoint

Trigger Signal type

Position setpoint in position controller cycle, position control loop closed, velocity control loop closed

Table 3-13 Signal (operating mode) for position setpoint parameter settings

Parameters Physical unit

Signal type: Square-wave

Amplitude (linear axis) mm | inch Period ms Pulse width ms Offset (linear axis) mm/min | inch/min Limitation (linear axis) mm | inch

Square-wave

Note

The following diagram was created using a servo trace.

0.000 2.000e+03

Fig. 3-40 Servo trace of actual position with square-wave signal type to position setpoint

t [ms]

Amplitude: 100 mm

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3.11 Start-up functions

3 Startup

3.11.3 Circularity test

The circularity test is used among other things as a way of checking the resulting contour precision. It works by measuring the actual positions during a circular movement and displaying the deviations from the programmed radius as a diagram (especially at the quadrant transitions). For detailed information, see:

References: /FB/Part 2, K3, Sect. 2.7 “Circularity test” Example: The following example refers to a drive with an HRV.

Tr. 1: X1 axis: Circularity test (electric axis) Tr. 2: Y1 axis: Circularity test (hydraulic axis)

Scl/Div = 1.000e-03 Radius = 19.999

X1 axis: Horizontal movement by electric drive Y1 axis: Vertical movement by hydraulic drive

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Fig. 3-41 Example of circularity test on HRV size 06, 15 l/min, knee-point 60%; V=400 mm/min (traversing velocity)

3.11.4 Servo trace

The servo trace function is used for graphic representation of signals and operating conditions.

A hydraulic-specific signal list (servo and drive signals) is available as a support function for axes with HLA module.

The following hydraulic-specific drive signals are supported by the servo trace:

S Active power (with pressure sensing) S Actual force (with pressure sensing) S Actual velocity value S Valve stroke setpoint S Actual valve stroke S Actual pressure cylinder A end S Actual pressure cylinder B end

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3.11.5 DAC parameter settings

For DAC measuring sockets see subsection 5.1.5.

3.11 Start-up functions

DAC selection list

Fig. 3-42 Menu display “DAC parameter settings”

Table 3-14 DAC selection list

Description Unit

Pressure p(A) (with pressure sensing) bar Pressure p(B) (with pressure sensing) bar Actual value spool value V valve spool setpoint V Actual velocity value mm/min velocity Setpoint (upstream of filter) mm/min velocity Setpoint (limited at filter output) mm/min velocity Reference model setpoint mm/min Actual force (with pressure sensing) N Active power (with pressure sensing) kW Control deviation of velocity controller mm/min Velocity controller P component V Velocity controller I component V Velocity controller D component V Feedforward control component velocity controller V Friction feedforward control component velocity controller V Velocity controller output before filter V Velocity controller output after filter V Actual position value mm Force setpoint N Force controller control deviation N

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3.12 User views

3 Startup

Table 3-14 DAC selection list

P component of force controller V I component of force controller V D component of force controller V Feedforward control component force controller V Force controller output V Zero mark signal BERO signal Physical address (drive) -

3.12 User views

The horizontal softkey HLA is used under menu items “User Views/Edit View/Insert Date”.

Description Unit

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Fig. 3-43 Menu display “Edit view”

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3.13 Display options

The display options allow the user to selectively reduce the amount of machine data that is displayed.

3.13 Display options

Machine data groups

The machine data is grouped for display purposes is similarly to the machine data display for electric drives.

Fig. 3-44 Menu display “Display options”

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3.14 Configuring an OEM valve list

3 Startup

3.14 Configuring an OEM valve list

04.00

10.03

General

Structure

Example of an OEM valve list

[DATA]

;5106

1001=

1050=

1051= 1030=

OEM,

OEM, OEM,

01,

02,

03, 04,

ÁÁ

abc type,

xyz type,

ÁÁ

OEM users can add their own valves to the valve list by copying file ibhlvlvo.ini to the “\oem” directory. This list is added as a separate item under the heading “OEM valves” at the end of the system list (Siemens list).

The syntax of the valve list is identical to that of a Windows INI file. The list may be created under “Start-up”, “MMC” or “Editor”. Select C:\OEM, then “New”. Enter the filename ibhlvlvo.ini, followed by “OK”.

This file must have the following structure: [DATA]

Column1 = Column2, Column3, ... , Column15, . . .

def type,

gkl type,

5107,

100.1,

90.1,

40.2,

8.1,

510

35, 35,

510

5110,5111

10,

10, 10,

10,

10, 10,

511

39.8,1,

40.1 ,

10,

38.5,2,

5113,

0001B,

0000B, 0010B,

5114,511

35,

200,

70,

1.0,

0.8,

90,

40,

100,

ÁÁ

$T7ƕ40,

ÁÁ

$T8,

$T7ƕ40,

$L= “End of list” $L= “- - - - - - - - -”

Note

Columns 1 and 2 are separated by a “=” character. All other columns are separated by a comma. Column 15 ends with a comma.

An MMC Reset must be performed to make changes effective.

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in OEM

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3 Startup

Table 3-15 Meaning of individual columns

3.14Configuring an OEM valve list

Column

ÁÁ

in OEM

valve

list

Valve code number

Description

БББББББ

Column in

ÁÁÁ

MMC display

/ max. char-

acters

7 / 5

ББББББББББ

Reference to MD

Name No.

VALVE_CODE

5106 2 Manufacturer’s name 1 / 7 3

Order Number

Type

Nominal valve flow

Nominal pressure drop of valve

Nominal voltage of valve

Knee-point flow rate of valve

Knee-point voltage of valve

Nominal flow rate ratio between

2 / 13 3 / 11

6 / 10

VALVE_NOMINAL_FLOW VALVE_NOMINAL_PRESSURE VALVE_NOMINAL_VOLTAGE VALVE_DUAL_GAIN_FLOW VALVE_DUAL_GAIN_VOLTAGE VALVE_FLOW_FACTOR_A_B

5107

5108

5109

5110

5111

5112

A and B ends of valve

Valve configuration

Natural frequency of valve

Valve damping

VALVE_CONFIGURATION VALVE_NATURAL_FREQUENCY VALVE_DAMPING

5113

5114

5115

14 Nominal valve flow rate for display 4 / 9 [l/min] 15 Valve knee-point voltage for dis-

5 / 15 [%]

play

Unit

[l/min] [bar] [V] [%] [%]

[Hz]

The valve code is entered in the first column and must be a number. Numbers 1 to 1000 are reserved for Siemens. Individual values are separated by commas. Columns 1 and 2 are separated by an equals signal (=). Comments are preceded by a semicolon.

Different numeric formats may be used.

S The following applies to the display (selection list) on the MMC:

The character strings used are identical to those stored in the INI file.

S The following applies to writing machine data:

- Unless otherwise specified, the decimal format is always used. If the number is followed by a capital B, it is interpreted as a binary number. If a capital H is inserted after the number, it is interpreted as a hexadecimal value.

- Floating-point numbers must be specified in US format (decimal point=“.”) and without the separator symbol for 1000s (“,”).

- The individual fields in this section can be left empty, i.e. they contain 2 commas one after the other or two blanks between the 2 commas. Empty fields are not written to the drive, i.e. the default setting of the machine data is transferred unchanged. The number of blanks is optional. The maximum permitted number of characters is shown in Table 3-15.

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3.15 System variables

3 Startup

Languagedependent texts

10.03

Any language-dependent texts can be inserted in the OEM valve list. These all start with $T.

Syntax: $T<X> (no semicolon)

<X> refers to a text in the language-dependent text files (see also language-dependent OEM texts)

Subheadings can also be inserted in the OEM valve list by adding the instruction “$L=<any text>;” at the beginning of a line. $T<X> can be used to insert other language-dependent texts within this optional text instruction.

Languagedependent system texts

Languagedependent OEM texts

The following language-dependent texts are predefined by the system and can be used in OEM valve lists.

$T1=Order No.; $T2=Type; $T3=Nominal flow rate; $T4=Knee-point voltage; $T5=Nominal flow rate A:B; $T6=Code; $T7=“ Knee”; $T8=“ Linear”; $T9=Company; $T10=Unlisted valve; $T11=l/min;

Language-dependent OEM display texts are stored in the \oem\language directory in \ibdrv_<SPRACHE>.ini files

<LANGUAGE> stands for the appropriate language code. This file would be called ibdrv_gr.ini for German. The codes for all languages installed in a sys- tem are listed in the \mmc2\mmc.ini file, [LANGUAGE] section, LanguageList entry. Language-dependent OEM text files must be formatted as follows:

[TEXT] $T<X>=<any text>;

:<X> is any number w1000 and v32767, which must only occur once.

The number range from 1 to 999 is reserved for the system.

3.15 System variables

The NC control can use system variables to read in the measuring signals applied to connectors X121/X122 or X111/X112.

Table 3-16 Assignment of system variables

Name Male connector Pin

$VA_VALVELIFT[X] X121/X122 14 and 15 $VA_PRESSURE_A[X] X111/X112 11 and 12 $VA_PRESSURE_B[X] X111/X112 14 and 15

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Firmware Drive Functions

4.1 Block diagram of closed-loop control

Integration in overall system

Control Drive

Velocity feedforward control v’

Position setpoint x

forw

Position controller

set

Actual position x

Velocity setpoint v

act

The following diagram shows how the HLA module is embedded between the control system and the hydraulic drive. The control functions of the module are shown in greatly simplified form. They are shown in more detail in the diagram on the following page.

HLA module

Cylinder

Flow feedforward control

set

Velocity controller

Actual velocity v

act

Characteristics compensation

Valve setpoint voltage U

set

Actual position value

Servo solenoid valve

Pressure supply

Valve amplifier

Fig. 4-1 General block diagram of NC - HLA module - drive system

Possible dynamic response

The dynamic response is dependent on:

S Natural frequency of the servo solenoid valve (see Subsection 2.3.2) S Natural frequency of the drive (see Subsection 2.3.4)

The greater the natural frequency, the better the achievable dynamic response. For the purpose of oscillation damping, the natural frequency of the servo sole-

noid valve must be greater than that of the drive.

4-95

4.1 Block diagram of closed-loop control

4 Firmware Drive Functions

10.03

Block diagram of control functions

Manipulated voltage

Control output filter

MD 5280/5281

MD 5284/5285

MD 5288-MD 5290

Area adapt-

Fig.4-2 shows the functionality for velocity and closed-loop force control plus characteristics implemented in the HLA module.

MD 5474

limitation

MD 5475

Knee-point

compensation

MD 5464-MD 5468

MD 5480-MD 5488

Selection

logic

MD 5241

MD 5462

ation

MD 5463

DAC

Offset

MD 5470

Friction injection

MD 5460/MD 5461

Flowrate feedforward control

Control output filter

MD 5200-MD 5205/

Velocity controller

P component

MD 5435

Setpoint

limitation

MD 5440/

MD 5210-MD 5215

Adaptation

I component

MD 5406-MD 5408

Reference

model

MD 5415

MD 5414/

MD 5441

set

MD 5409

Limitation

control

Adaptation

D component

MD 5430-MD 5433

act

Actual velocity v

act

Feedforward control filter

MD 5260/5261

MD 5264/5265/MD 5268-MD 5270

Actual position x

Area adapt-

ation

MD 5247

factor

Feedforward control

Force controller

MD 5230-MD 5235

MD 5241 (configuration)

Adaptation

Attenuation

(valve dynamic response)

P component

MD 5243

Adaptation

MD 5242

set

I component

MD 5244

only if pressure sensor system is connected

Adaptation

D component

MD 5245/MD 5246

(see Section 4.4, Fig. 4-11)

act

Fig. 4-2 Controller and characteristic functions of the HLA module

4-96

Velocity

Setpoint filter

MD 5500-MD 5502/

MD 5506/MD 5507/

MD 5514-MD 5516/

MD 5520/MD 5004

setpoint v

Velocity

SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

10.03

4 Firmware Drive Functions

4.2 Functions

4.2.1 Overview of functions

The document has been organized under the following main topics with reference to Fig. 4-2:

S Velocity feedforward control (Subsection 4.3.1)

- Servo gain

- Velocity setpoint filter

- Setpoint limitations

S Velocity controller (Subsection 4.3.2)

- P/D/I components

- Deactivate adaptation

- Integrator feedback

- Reference model

- Control output filter in velocity controller

4.2 Functions

S Force control (Section 4.4)

- P/D/I components

- Force limitations

- Servo gain

S Manipulated voltage output (Section 4.5)

- Characteristic compensation

- Control output filter

- Manipulated voltage limitations

4-97

4.2 Functions

4 Firmware Drive Functions

4.2.2 Parameter set changeover

It is possible to switch between 8 different parameter sets. Data which are assigned to specific parameter sets are identified by an [n] in the string code [0-7].

The request is made from the PLC by means of IS “Select drive parameter set” DB 31-61 DBB 21 bits 0-2. They are predominantly controller and filter data that can be switched over as a function of parameter set.

The status is interrogated by means of IS “Active drive parameter set” DB 31-61 DBB 93 bits 0-2.

Section 4.15 contains a complete parameter list with the attributes for each parameter.

Servo solenoid valve

HLA module

10.03

PLC

Controlled system 1 Controlled system 0

Fig. 4-3 Example of a parameter set changeover

Changeover block

e.g. parameter set 0e.g. parameter set 1

Press

Hydraulic cylinder

4-98

SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

4 Firmware Drive Functions

08.99

10.03

4.3 Closed-loop velocity control

4.3.1 Velocity adaptation/feedforward control

4.3 Closed-loop velocity control

Velocity setpoint

The NC ³ drive transfer interface is normalized to the maximum velocity set in data MD 5401: DRIVE_MAX_SPEED.

5401 DRIVE_MAX_SPEED Cross reference: -

Unit:

mm/min

Maximum useful velocity

Default:

0.0

Minimum:

0.0

Maximum:

120 000.0

Related to:

HLA

Data type:

FLOAT

Protection level:

3/3

Active:

Power On

The velocity limit is defined by the settings in MD 5440: POS_DRIVE_SPEED_LIMIT and MD 5441: NEG_DRIVE_SPEED_LIMIT, but not with MD 5401: DRIVE_MAX_SPEED.

Velocity setpoint interpolation

5004 CTRL_CONFIG Cross reference: -

Unit:

HEX

Configuration structure

Default:

1000

Velocity setpoints are preset in the position controller cycle. In order to prevent rigorous drive positioning motions at the beginning of each position controller cycle, the current and previous velocity setpoint are interpolated linearly in the drive.

Bit 12=0: no interpolation, velocity setpoint only changes in the Bit 12=1: linear interpolation of the velocity setpoint over one

Related to:

HLA

Minimum:

Maximum:

1000

Data type:

UNS.WORD

position controller cycle. position controller cycle. The default setting is active.

Protection level:

3/3

Active:

Power On

Velocity setpoint

Fig. 4-4 Velocity setpoint interpolation

Velocity setpoint interpolation deactivated

Velocity setpoint interpolation activated

Velocity setpoint from the NC

Velocity setpoint active in drive

Dwell

Position control cycle

Dwell

Position control cycle

4-99

4.3 Closed-loop velocity control

4 Firmware Drive Functions

10.03

Velocity setpoint filter

The complexity of applying velocity setpoint filters means that it is not possible to provide generally-applicable, definitive guidelines for their use. However, criteria for selecting filters and their parameters are defined below.

The velocity setpoint filters are used to adapt the velocity-controlled drive grouping to the higher-level position control loop. You can choose between bandstop filters and low passes (PT2/PT1).

The task of a filter is to

S smooth the control response characteristic, S damp mechanical resonance and S symmetrize axes with different dynamic responses, especially the response

of interpolating axes.

Note

Low-pass filters can be employed on interpolating axis groupings to compensate for differences in dynamic response in velocity control loops.

The total equivalent time constant (equivalent time constant of velocity control loop + equivalent time constant of velocity setpoint filter) must be set to an identical value for all mutually interpolating axes.

Entering damping values close to the minimum input limits results in overshoots up to a factor of 2 in the time range.

5500 NUM_SPEED_FILTERS [n] 0...7 index of the parameter set Cross reference: -

Unit:

5501

5502

No. of velocity filters 0: No velocity filters active 1: Velocity filter activated

Default:

SPEED_FILTER_TYPE [n] 0...7 index of the parameter set

Type of velocity filter Bit 0= 0: Low-pass (see MD 5502, MD 5506, MD 5507)

1: Bandstop (see MD 5514 - MD 5516, MD 5520)

Bit 8= 0: PT2 low-pass (see MD 5506, MD 5507)

1: PT1 low-pass (see MD 5502)

Default:

SPEED_FILTER_1_TIME [n] 0...7 index of the parameter set

PT1 time constant for velocity filter 1

Default:

0.0

Minimum:

0.0

Maximum:

257

Maximum:

500.0

Related to:

HLA

Data type:

UNS.WORD

Related to:

HLA

Data type:

UNS.WORD

Related to:

HLA

Data type:

FLOAT

Protection level:

3/3

Active:

Immediately

Cross reference: -

Protection level:

3/3

Active:

Immediately

Cross reference: -

Protection level:

3/3

Active:

Immediately

The filter is activated via MD 5500 (1) and deactivated via (0). The default setting is deactivated. The type of velocity filter can be defined by setting MD 5501 to PT1 or PT2 low-pass or to band-stop filter. The key data for the filter is defined in MD 5502 to MD 5520.

The filter is deactivated if machine data MD 5502 is set to 0.

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SINUMERIK 840D/SIMODRIVE 611 digital, HLA Module (FBHLA) - 10.03 Edition

Siemens Sinumerik 840D Series, Simodrive 611 digital, SINUMERIK 840DiE, SINUMERIK 840D, SINUMERIK 840DE Function Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

HLA module

Preface

Notes for the Reader

Danger and warning notices

Table of Contents

General

1.1 Typical applications

1.2 Comparison of electric and hydraulic drive systems

1.3 Structure of an electro-hydraulically-controlled drive axis

1.3.1 Machine guideway

1.3.2 Cylinder

1.3.4 Valve amplifier

1.3.5 Shutoff valve

1.3.6 Position measuring system

1.3.7 SINUMERIK 840D/SIMODRIVE 611 digital

1.3.8 Hydraulic power unit

Configuration

2.1 Configuring steps

2.1.1 Procedure for configuring electrical components

2.1.2 Procedure for configuring hydraulic components

2.2 Integration in SINUMERIK 840D/SIMODRIVE 611 digital

2.2.1 System overview

2.2.2 Required FW packages

2.2.3 Hardware requirements

2.3 Configuring the hydraulic drive

2.3.1 Cylinder selection

2.3.2 Selection of servo solenoid valves

2.3.3 Selection of shutoff valves

2.3.4 Natural frequency of the hydraulic drive

2.3.5 Hydraulic power unit

2.4.1 Internal power supply

2.4 Connection

2.4.2 External power supply

2.4.3 Grounding concept/Electromagnetic compatibility (EMC)

Installation and Start-Up

3.1 Overview of start-up process

3.2 Drive configuration

3.3 Modify drive machine data

3.4 Valve selection

3.5 Cylinder selection

3.6 Mounting/supply data

3.7 Measuring system data

3.8 Modifying data

3.9 Fine adjustment and optimization

3.9.1 Control direction, travel direction

3.9.2 Offset adjustment

3.9.3 Velocity adjustment

3.9.4 Referencing data for HLA

3.9.5 Controller optimization

3.9.6 Controller adaptation

3.9.7 Hydraulic/electrical interpolation

3.10 File functions

3.11 Start-up functions

3.11.1 Measurement function

3.11.2 Function generator

3.11.3 Circularity test

3.11.4 Servo trace

3.11.5 DAC parameter settings

3.12 User views

3.13 Display options

3.14 Configuring an OEM valve list

3.15 System variables

Firmware Drive Functions

4.1 Block diagram of closed-loop control

4.2.1 Overview of functions

4.2 Functions

4.2.2 Parameter set changeover

4.3.1 Velocity adaptation/feedforward control

4.3 Closed-loop velocity control