Yaskawa DR2 User Manual

5 (1)
Yaskawa DR2 User Manual

YASKAWA

Series SGM/SGMP/DR2

USER'S MANUAL

AC Servomotors and Driver

SGM/SGMP Servomotors

DR2 Servopack

YASKAWA

MANUAL NO. TSE-S800-17D

PREFACE

The rapid progress being made in today’s automation and information technologies is resulting in a growing need for even more-advanced motion control for future high-tech equipment. The end result is a need for devices that can provide more-precise and quicker motion at higher speeds. Servo control technology makes this possible. Launched by Yaskawa in 1993, the Σ Series consists of innovative AC Servos that were developed using leading-edge servo control technology.

This manual covers all products information on the Σ Series SGMj/DR2, which feature superior functions and performance. This manual was designed to provide comprehensible information for users who are about to use a servo for the first time as well as for users who already have experience in using servos. This manual enables users to understand what Σ-Series AC Servos are all about and how to design, install, operate, and maintain a servo system. Keep this manual in a convenient location and refer to it whenever necessary in operating and maintaining the servo system.

YASKAWA ELECTRIC CORPORATION

General Precautions

SSome drawings in this manual are shown with the protective cover or shields removed, in order to describe the detail with more clarity. Make sure all covers and shields are replaced before operating this product.

SSome drawings in this manual are shown as typical example and may differ from the shipped product.

SThis manual may be modified when necessary because of improvement of the product, modification or changes in specifications.

Such modification is made as a revision by renewing the manual No.

STo order a copy of this manual, if your copy has been damaged or lost, contact your YASKAWA representative listed on the last page stating the manual No. on the front cover.

SYASKAWA is not responsible for accidents or damages due to any modification of the product made by the user since that will void our guarantee.

NOTES FOR SAFE OPERATION

Read this manual thoroughly before installation, operation, maintenance or inspection of the AC Servo Drives. In this manual, the NOTES FOR SAFE OPERATION are classified as “WARNING” or “CAUTION”.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious personal injury.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate personal injury and/or damage to the equipment.

In some instances, items described in . CAUTION may also result in a serious accident. In either case,

follow these important items.

iv

WARNING

(INSTALLATION)

SAfter voltage resistance test, wait at least five minutes before servicing the product.

Failure to observe this warning may result in electric shock.

(WIRING)

SGrounding must be in accordance with the national code and consistent with sound local practices.

Failure to observe this warning may lead to electric shock or fire.

(OPERATION)

SNever touch any rotating motor parts during operation.

Failure to observe this warning may result in personal injury.

(INSPECTION AND MAINTENANCE)

SBe sure to turn OFF power before inspection or maintenance.

Otherwise, electric shock may result.

SAfter turning OFF power, wait at least five minutes before servicing the product.

Otherwise, residual electric charges may result in electric shock.

CAUTION

(RECEIVING)

SUse the specified combination of SERVOMOTOR and SERVOPACK.

Failure to observe this caution may lead to fire or failure.

(INSTALLATION)

SNever use the equipment where it may be exposed to splashes of water, corrosive or flammable gases, or near flammable materials.

Failure to observe this caution may lead to electric shock or fire.

(WIRING)

SDo not connect three−phase power supply to output terminals U V and

W .

Failure to observe this caution may lead to personal injury or fire.

SSecurely tighten screws on the power supply and motor output terminals.

Failure to observe this caution can result in a fire.

v

CAUTION

(OPERATION)

STo avoid inadvertent accidents, run the SERVOMOTOR only in test run (without load).

Failure to observe this caution may result in personal injury.

SBefore starting operation with a load connected, set up user constants suitable for the machine.

Starting operation without setting up user constants may lead to overrun failure.

SBefore starting operation with a load connected, make sure emergencystop procedures are in place.

Failure to observe this caution may result in personal injury.

SDuring operation, do not touch the heat sink.

Failure to observe this caution may result in burns.

(INSPECTION AND MAINTENANCE)

SDo not disassemble the SERVOMOTOR.

Failure to observe this caution may result in electric shock or personal injury.

SNever change wiring while power is ON.

Failure to observe this caution may result in electric shock or personal injury.

vi

Manual Contents

This manual provides Σ-Series users with information on the following:

An overview of servo systems for first-time users.

Checking the product on delivery and basic applications of the servo.

Servo applications.

Selecting an appropriate servo for your needs and placing an order.

Inspection and maintenance.

Manual Structure

All chapters in this manual are classified into one or more of three areas according to their contents: A, B, and C. Refer to the applicable chapters for the information you require.

A:Chapters explaining how to select a servo: For users who wish to gain a basic understanding of Σ Series products or who need to select an appropriate servo.

B:Chapters explaining how to design a servo system: For users who are about to design, install, and operate a Σ-Series Servo Control System.

C:Chapters explaining maintenance: For users who are going to maintain and troubleshoot Σ-Series products.

Chapter

Title

Page

Area

CHAPTER 1 For First-time Users of AC Servos . . . . . . . . . . . . . . . . . . . . . .

1 . . . . . . . . .

A, B

 

Provides an overview of servos and the Σ Series

 

 

CHAPTER 2 Basic Uses of Σ-series Products . . . . . . . . . . . . . . . . . . . . . . . . .

15 . . . . . . . . .

B

 

Describes steps to take when product is received, plus basic

 

 

 

wiring and application methods.

 

 

CHAPTER 3 Applications of Σ-series Products . . . . . . . . . . . . . . . . . . . . . . .

49 . . . . . . . . .

B

 

Describes the effective usage of Σ-Series features according to

 

 

 

application.

 

 

CHAPTER 4 Using the Digital Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

169 . . . . . . . .

B

 

Describes operating procedures for Σ-Series servos, turning

 

 

 

features ON and OFF, setting control constants, etc.

 

 

CHAPTER 5 Servo Selection and Data Sheets . . . . . . . . . . . . . . . . . . . . . . . .

203 . . . . . . . .

A, B

 

Describes selection methods for Σ-Series servos and peripher-

 

 

 

als and provides servo specifications.

 

 

CHAPTER 6 Inspection, Maintenance, and Troubleshooting . . . . . . . . . . .

387 . . . . . . . .

C

 

Describes user maintenance and troubleshooting.

 

 

CHAPTER 7 Measures to Satisfy the Requirements of

415

 

 

EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B

Provides the measures to conform to the EMC Directive.

vii

APPENDIXES

 

 

 

A

Differences between DR2 and DR1, SGDA and SGD

 

 

 

Servopacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

423 . . . . . . . .

A, B. C

B

Servo Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

429 . . . . . . . .

B, C

C

List of I/O Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

445 . . . . . . . .

A, B, C

D

List of User Constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

465 . . . . . . . .

B, C

E

List of Alarm Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

477 . . . . . . . .

B, C

F

Relationship between Reference Forms and User Constants . . 481 . . . . . . . .

B, C

G

Reviewing the Full-closed Loop Specifications . . . . . . . . . . . . . . .

489 . . . . . . . .

B, C

INDEX . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

497 . . . . . . . .

A, B, C

viii

Basic Terms

Unless otherwise specified, the following definitions are used:

Servomotor:

Σ-Series SGM/SGMP Servomotor

Servopack:

An amplifier (Trademark of Yaskawa servo amplifier “DR2 Servopack”)

Servodrive:

A SGM/SGMP Servomotor and an amplifier (DR2 Servopack)

Servo system: A complete servo control system consisting of servodrive, host controller, and peripheral devices

Visual Aids

The following aids are used to indicate certain types of information for easier reference.

.

Indicates references for additional information.

 

 

Technical terms placed in bold in the text are briefly explained in a “TERMS” sec-

TERMS

 

 

tion at the bottom of the page. The following kinds of technical terms are explained:

 

 

Technical terms that need to be explained to users who are not very familiar with

 

 

servo systems or electronic devices and technical terms specific to Σ Series Ser-

 

 

vos that need to be explained in descriptions of functions.

Speed/Torque

Positions

JUSP-OP02A-1

The text indicated by this icon is applicable only to Servopack in speed/torque control mode.

The text indicated by this icon is applicable only to Servopack in position control mode.

The text indicated by this icon explains the operating procedure using hand-held type digital operator (Type: JUSP-OP02A-1).

NOTE A Σ-Series Servodrive alone cannot ensure the functionality and performance of the entire machine control system. It must be combined with an appropriate machine and host controller so that the entire control system works properly. Therefore, carefully read the instruction manuals for the machine to be used before attempting to operate the servodrive.

ix

Yaskawa, 1996

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission of Yaskawa. No patent liability is assumed with respect to the use of the information contained herein. Moreover, because Yaskawa is constantly striving to improve its high-quality products, the information contained in this manual is subject to change without notice. Every precaution has been taken in the preparation of this manual. Nevertheless, Yaskawa assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in this publication.

x

CONTENTS

CHAPTER 1 FOR FIRST-TIME USERS OF AC SERVOS . . . . . . . . . . . . . . .

1

1.1 Basic

Understanding of AC Servos. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

1.1.1

Servo

Mechanisms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

1.1.2

Servo

Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

1.1.3 Features of Σ-Series Servos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

CHAPTER 2

BASIC USES OF Σ-SERIES PRODUCTS . . . . . . . . . . . . . . . . .

15

 

2.1

Precautions . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

 

 

2.1.1

Notes on Use . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

 

2.2

Installation . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

 

 

2.2.1

Checking on Delivery . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

 

 

2.2.2

Installing the Servomotor . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

 

 

2.2.3

Installing the Servopack . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

 

2.3

Connection and Wiring . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

 

 

2.3.1

Connecting to Peripheral Devices . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

 

 

2.3.2

Main Circuit Wiring and Power ON Sequence. . . . . . . . . . . . . . . . . . . . . . . . . .

 

28

 

2.3.3

Examples

of Connecting I/O Signal

Terminals. . . . . . . . . . . . . . . . . . . . . . . . . .

 

30

2.4

Conducting a Test

Run. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

37

 

2.4.1

Test Run in Two Steps. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

37

 

2.4.2

Step 1: Conducting a Test Run for

Motor without. . . . . Load. . . . . . . . . . . . . .

 

39

 

2.4.3

Step 2: Conducting a Test Run with the Motor Connected to. .the. . .

Machine

43

 

2.4.4

Supplementary Information on Test . Run. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 

45

 

2.4.5

Minimum User Constants Requiredand Input Signals. . . . . . . . . . . . . . . . . . . .

 

47

CHAPTER 3

APPLICATIONS OF Σ-SERIES PRODUCTS . . . . . . . . . . . . . .

49

 

3.1 Setting User Constants According to Machine Characteristics . . . . . . . . . . . . . . . . . . . . .

52

 

 

3.1.1

Changing the Direction of Motor Rotation .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52

 

 

3.1.2

Setting the Overtravel Limit Function . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54

 

 

3.1.3

Restricting Torque . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57

 

3.2 Setting User Constants According to Host Controller

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

64

 

 

3.2.1

Inputting Speed Reference . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64

 

 

3.2.2

Inputting Position Reference . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69

 

 

3.2.3

Using Encoder Output . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76

 

 

3.2.4

Using Contact I/O Signals . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80

 

 

3.2.5

Using Electronic Gear . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82

 

 

3.2.6

Using Contact Input Speed Control . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86

 

 

3.2.7

Using Torque Control . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91

 

 

3.2.8

Using Torque Feed-forward Function . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97

 

 

3.2.9

Using Torque Restriction by Analog Voltage Reference . . . . . . . . . . . . . . . . . . .

98

 

 

3.2.10

Using the Reference Pulse Inhibit Function (INHIBIT) . . . . . . . . . . . . . . . . . . . .

100

 

 

3.2.11

Using the Reference Pulse Input Filter Selection Function . . . . . . . . . . . . . . . . .

101

 

 

3.2.12

Using the Analog Monitor . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102

 

3.3 Setting Up the Σ Servopack . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103

 

 

3.3.1

Setting User Constants . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103

 

 

3.3.2

Setting the Jog Speed . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104

 

 

3.3.3

Setting the Number of Encoder Pulses . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105

 

 

3.3.4

Setting the Motor Type . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

106

 

xi

 

 

CONTENTS

 

3.4

Setting Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107

 

3.4.1

Adjusting Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107

 

3.4.2

Using Dynamic Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

108

 

3.4.3

Using Zero-Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109

 

3.4.4

Using Holding Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110

3.5 Running the Motor Smoothly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114

 

3.5.1

Using the Soft Start Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114

 

3.5.2

Using the Smoothing Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115

 

3.5.3

Adjusting Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115

 

3.5.4

Adjusting Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

116

 

3.5.5

Setting the Torque Reference Filter Time Constant . . . . . . . . . . . . . . . . . . . . . . .

116

3.6

Minimizing Positioning Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

118

 

3.6.1

Using Autotuning Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

118

 

3.6.2

Setting Servo Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

118

 

3.6.3

Using Feed-forward Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120

 

3.6.4

Using Proportional Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120

 

3.6.5

Setting Speed Bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

121

 

3.6.6

Using Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

122

3.7 Forming a Protective Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

128

 

3.7.1

Using Servo Alarm Output and Alarm Code Output . . . . . . . . . . . . . . . . . . . . . .

128

 

3.7.2

Using Servo ON Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

132

 

3.7.3

Using Positioning Complete Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

133

 

3.7.4

Using Speed Coincidence Output Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134

 

3.7.5

Using Running Output Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

136

 

3.7.6

Using Servo Ready Output Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

138

3.8

Special Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

140

 

3.8.1

Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

140

 

3.8.2

Wiring for Noise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

142

 

3.8.3

Using More Than One Servo Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

147

 

3.8.4

Using Regenerative Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

148

 

3.8.5

Using an Absolute Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

151

 

3.8.6

Extending an Encoder Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

159

 

3.8.7

Using DR2 Servopack with High Voltage Line . . . . . . . . . . . . . . . . . . . . . . . . . .

161

 

3.8.8

Connector Terminal Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

163

CHAPTER 4

USING THE DIGITAL OPERATOR . . . . . . . . . . . . . . . . . . . . .

169

4.1

Basic Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

170

 

4.1.1

Connecting the Digital Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

170

 

4.1.2

Resetting Servo Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

171

 

4.1.3

Basic Functions and Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

172

 

4.1.4

Operation in Status Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173

 

4.1.5

Operation in User Constant Setting Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

176

 

4.1.6

Operation in Monitor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

179

xii

CONTENTS

4.2 Using the Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

183

4.2.1

Operation in Alarm Trace-back Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

183

4.2.2

Operation Using the Digital Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

186

4.2.3

Autotuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

188

4.2.4

Reference Offset Automatic Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

195

4.2.5

Speed Reference Offset Manual Adjustment Mode . . . . . . . . . . . . . . . . . . . . . . .

197

4.2.6

Clearing Alarm Trace-back Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200

4.2.7

Checking Motor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201

4.2.8

Checking Software Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201

CHAPTER 5 SERVO SELECTION AND DATA SHEETS . . . . . . . . . . . . . . .

203

5.1

Selecting a Σ-Series Servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

205

 

5.1.1

Selecting a Servomotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

205

 

5.1.2

Selecting a Servopack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212

 

5.1.3

Digital Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

216

5.2

SGM Servomotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

217

 

5.2.1

Ratings and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

217

 

5.2.2

Mechanical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

230

5.3

Servopack Ratings and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

233

 

5.3.1

Ratings and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

233

 

5.3.2

Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

238

 

5.3.3

Overload Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

239

 

5.3.4

Starting Time and Stopping Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

240

 

5.3.5

Load Inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

241

 

5.3.6

Overhanging Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

246

5.4

Σ-Series Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

247

 

5.4.1

Servomotor Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

247

5.4.2Servomotor Dimensional Drawings

 

(TÜV approved, conforming to the machine instructions) . . . . . . . . . . . . . . . . . .

289

5.4.3

Servopack Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

329

5.4.4

Digital Operator Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

334

5.5 Selecting Peripheral Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

335

5.5.1

Selecting Peripheral Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

335

5.5.2

Order List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

341

5.6 Specifications and Dimensional Drawings of Peripheral Devices . . . . . . . . . . . . . . . . . . .

349

5.6.1

Cable Specifications and Peripheral Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . .

349

5.6.2

Motor Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

355

5.6.3

Connector Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

358

5.6.4

Brake Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

363

5.6.5

Encoder Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

365

5.6.6

Battery for Absolute Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

371

5.6.7

1CN Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

371

5.6.8

Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

373

5.6.9

Noise Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

374

5.6.10

Magnetic Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

375

5.6.11

Surge Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

376

5.6.12

Regenerative Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

376

5.6.13 Variable Resistor for Speed Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

379

xiii

CONTENTS

 

5.6.14

Encoder Signal Converter Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

379

 

5.6.15

Cables for Connecting PC and Servopack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

381

 

5.6.16

4CN Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

385

CHAPTER 6 INSPECTION, MAINTENANCE, AND TROUBLESHOOTING . 387

6.1

Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

388

 

6.1.1

Servomotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

388

 

6.1.2

Servopack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

389

 

6.1.3

Replacing Battery for Absolute Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

390

6.2

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

391

 

6.2.1

Troubleshooting Problems with Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . .

391

 

6.2.2

Troubleshooting Problems with No Alarm Display . . . . . . . . . . . . . . . . . . . . . . .

409

 

6.2.3

Internal Connection Diagram and Instrument Connection Examples . . . . . . . . .

411

CHAPTER 7 MEASURES TO SATISFY THE REQUIREMENTS OF

 

 

 

EMC DIRECTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

415

7.1 What is European Safe Standard? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

416

 

7.1.1

What is EN Standard? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

416

 

7.1.2

What is CE Marking? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

416

 

7.1.3

EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

417

 

7.1.4

Certification Body TÜV Authorized by EU . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

417

7.2 Measures to Satisfy the Requirements of EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . .

418

 

7.2.1

Applicable Servomotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

418

 

7.2.2

Applicable Noise Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

418

 

7.2.3

Motor Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

419

 

7.2.4

Encoder Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

419

 

7.2.5

Control I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

420

 

7.2.6

Digital Operator and Monitoring by Personal Computer . . . . . . . . . . . . . . . . . . .

420

 

7.2.7

The Core on the Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

421

 

7.2.8

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

421

APPENDIXES

A

Differences Between DR2 and DR1, SGDA and SGD Servopacks . . . . . . . . . . . . . . . . . .

423

B

Servo Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

429

B.1

Σ-Series AC Servopack Gain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

430

 

B.1.1 Σ-Series AC Servopacks and Gain Adjustment Methods . . . . . . . . . . . . . . . . . . .

430

 

B.1.2 Basic Rules for Gain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

431

B.2

Adjusting a Servopack for Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

432

 

B.2.1

Adjusting Using Auto-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

432

 

B.2.2

Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

433

B.3

Adjusting a Servopack for Position Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

436

 

B.3.1

Adjusting Using Auto-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

436

 

B.3.2

Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

437

B.4

Gain Setting References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

441

 

B.4.1 Guidelines for Gain Settings According to Load Inertia Ratio . . . . . . . . . . . . . .

441

C

List of I/O Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

445

D

List of User Constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

465

xiv

 

CONTENTS

 

E

List of Alarm Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

477

F

Relationship between Reference Forms and User Constants . . . . . . . . . . . . . . . . . . . . . . .

481

G

Reviewing the Full-closed Loop Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

489

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

497

xv

FOR FIRST-TIME USERS OF AC

1

SERVOS

1

This chapter is intended for first-time users of AC servos. It describes the basic configuration of a servo mechanism and basic technical terms relating to servos.

Users who already have experience in using a servo should also take a look at this chapter to understand the features of Σ-Series AC Servos.

1.1 Basic Understanding of AC Servos . . . . . . . . . . .

2

1.1.1

Servo Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

1.1.2

Servo Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

1.1.3 Features of Σ-Series Servos . . . . . . . . . . . . . . . . . . . . . . . . . .

11

1

FOR FIRST-TIME USERS OF AC SERVOS

1.1.1Servo Mechanisms

1.1Basic Understanding of AC Servos

This section describes the basic configuration of a servo mechanism and technical terms relating to servos and also explains the features of Σ-Series AC Servos.

1

 

1.1.1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Servo Mechanisms

2

 

1.1.2

Servo Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

 

 

1.1.3 Features of Σ-Series Servos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

 

 

1.1.1

Servo Mechanisms

 

You may be familiar with the following terms:

• Servo

Servo mechanism

• Servo control system

In fact, these terms are synonymous. They have the following meaning:

A control mechanism that monitors physical quantities such as specified positions.

In short, a servo mechanism is like a servant who does tasks faithfully and quickly according to his master’s instructions. In fact, “servo” originally derives from the word “servant.”

 

Servo mechanism

TERMS

 

 

According to Japanese Industrial Standard (JIS) terminology, a “servo mechanism” is de-

 

fined as a mechanism that uses the position, direction, or orientation of an object as a pro-

 

cess variable to control a system to follow any changes in a target value (set point).

 

More simply, a servo mechanism is a control mechanism that monitors physical quantities

 

such as specified positions. Feedback control is normally performed by a servo mecha-

 

nism. (Source: JIS B0181)

2

1.1 Basic Understanding of AC Servos

Servo system could be defined in more detail as a mechanism that:

Moves at a specified speed and

Locates an object in a specified position

To develop such a servo system, an automatic control system involving feedback control

must be designed. This automatic control system can be illustrated in the following block dia-

gram:

Configuration of Servo System

 

 

1

 

 

 

 

 

 

 

 

 

 

Controlled

 

 

Specified position

Servo

Servo

Machine position

input

amplifier

motor

machine

 

 

(load)

output

 

 

 

Feedback part

Detector

This servo system is an automatic control system that detects the machine position (output data), feeds back the data to the input side, compares it with the specified position (input data), and moves the machine by the difference between the compared data.

In other words, the servo system is a system to control the output data to match the specified input data.

If, for example, the specified position changes, the servo system will reflect the changes.

In the above example, input data is defined as a position, but input data can be any physical quantities such as orientation (angle), water pressure, or voltage.

Position, speed, force (torque), electric current, and so on are typical controlled values for a servo system.

The main technical terms used in this manual are as follows:

1)Servo mechanism

2)Servo

Normally, servo is synonymous with servo mechanism. However, because “mechanism” is omitted, the meaning becomes somewhat ambiguous. Servo may refer to the entire servo mechanism but may also refer to an integral part of a servo mechanism such as a servomotor or a servo amplifier. This manual also follows this convention in the use of the term “servo”.

 

Feedback control

TERMS

 

 

A control that returns process variables to the input side and forms a closed loop. It is also

 

called closed-loop control.

3

FOR FIRST-TIME USERS OF AC SERVOS

1.1.1Servo Mechanisms cont.

3)Servo control system

Servo control system is almost synonymous with servo mechanism but places the focus on system control. In this manual, the term “servo system” is also used as a synonym of servo control system.

 

 

Related Terms

Meaning

1

 

Servomotor

General servomotors or Yaskawa SGM/SGMP

 

 

Servomotors. In some cases, a position detector (encoder)

 

 

is included in a servomotor.

 

 

 

 

 

 

Servopack

Trademark of Yaskawa servo amplifier “DR2 Servopack.”

 

 

 

 

 

 

 

 

Servo drive

A Servomotor and amplifier pair. Also called “servo.”

 

 

 

 

 

 

Servo system

A closed control system consisting of a host controller,

 

 

 

servo drive and controlled system to form a servo

 

 

 

mechanism.

 

 

 

 

 

 

 

 

Host controller

Reference

Amplifier

(Servopack) Servomotor

Controlled

Operate system

Servo drive

Servo system

4

1.1 Basic Understanding of AC Servos

1.1.2Servo Configuration

1)Configuration of Servo System

The following diagram illustrates a servo system in detail:

1

 

 

 

 

 

 

Host controller

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(5)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Position or

 

 

 

 

 

 

 

 

 

speed

 

 

 

 

 

 

 

 

 

 

 

 

reference

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Servo amplifier

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Comparator

Power

(4)

 

 

 

 

 

 

 

 

 

 

amplifier

 

 

 

 

(Output)

Position

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Motor

 

 

 

(Input)

 

 

drive

 

 

 

 

 

 

circuit

 

 

 

Speed

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Gear

(1)

 

Movable

 

 

 

 

 

 

 

 

 

 

table

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Position or

 

 

 

 

 

 

 

 

 

 

 

speed

 

 

 

 

 

 

 

 

 

 

 

 

feedback

 

 

(2)

 

 

 

 

 

Ball screw

 

 

 

 

(3)

 

 

Controlled

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

system

 

 

 

Detector Servomotor

Drive system

 

(1)

Controlled system:

Mechanical system for which the position or speed is to be con-

 

 

trolled.

 

 

This includes a drive system that transmits torque from a servo-

 

 

motor.

(2)

Servomotor:

A main actuator that moves a controlled system. Two types are

 

 

available: AC servomotor and DC servomotor.

(3)

Detector:

A position or speed detector. Normally, an encoder mounted on

 

 

a motor is used as a position detector.

(4)

Servo amplifier:

An amplifier that processes an error signal to correct the differ-

 

 

ence between a reference and feedback data and operates the

 

 

servomotor accordingly. A servo amplifier consists of a

 

 

comparator, which processes error signals, and a power ampli-

 

 

fier, which operates the servomotor.

(5)

Host controller:

A device that controls a servo amplifier by specifying a position

 

 

or speed as a set point.

5

FOR FIRST-TIME USERS OF AC SERVOS

1.1.2 Servo Configuration cont.

Servo components (1) to (5) are outlined below:

(1)Controlled system

In the previous figure, the controlled system is a movable table for which the position or speed is controlled. The movable table is driven by a ball screw and is connected to the servomotor via gears.

So, the drive system consists of:

1

Gears + Ball Screw

 

 

This drive system is most commonly used because the power transmission ratio

 

 

(gear ratio) can be freely set to ensure high positioning accuracy. However, play in the

 

gears must be minimized.

 

The following drive system is also possible when the controlled system is a movable

 

table:

 

Coupling + Ball Screw

When the power transmission ratio is 1 :

Rolling-contact

 

1, a coupling is useful because it has no

guide

 

play.

Coupling

Rolling-contact

 

Ball screw

This drive system is widely used for ma-

 

bearing

 

 

chining tools.

 

 

 

Housing

 

Timing Belt + Trapezoidal Screw Thread

 

 

A timing belt is a coupling device that allows the power transmission ratio to be set freely and that has no play.

A trapezoidal screw thread does not provide excellent positioning accuracy, so can be treated as a minor coupling device.

Trapezoidal screw thread

Servomotor

Timing belt

 

To develop an excellent servo system, it is important to select a rigid drive system that has no play.

Configure the controlled system by using an appropriate drive system for the control purpose.

 

Drive system

TERMS

 

 

Also called a drive mechanism.

 

A drive system connects an actuator (such as a servomotor) to a controlled system and

 

serves as a mechanical control component that transmits torque to the controlled system,

 

orientates the controlled system, and converts motion from rotation to linear motion and

 

vice versa.

6

1.1 Basic Understanding of AC Servos

(2)Servomotor

(a)DC Servomotor and AC Servomotor

Servomotors are divided into two types: DC servomotors and AC servomotors.

DC servomotors are driven by direct current (DC). They have a long history. Up until the 1980s, the term “servomotor” used to imply a DC servomotor.

From 1984, AC servomotors were emerging as a result of rapid progress in micro-

1

processor technology. Driven by alternating current (AC), AC servomotors are

 

 

now widely used because of the following advantages:

 

• Easy maintenance:

No brush

 

• High speed:

No limitation in rectification rate

 

Note however that servomotors and Servopacks use some parts that are subject to mechanical wear or aging. For preventive maintenance, inspect and replace parts at regular intervals.

For details, refer to Chapter 6 Inspection, Maintenance, and Troubleshooting.

(b)AC Servomotor

AC servomotors are divided into two types: synchronous type and induction type. The synchronous type is more commonly used.

For a synchronous type servomotor, motor speed is controlled by changing the frequency of alternating current.

A synchronous type servomotor provides strong holding torque when stopped, so this type is ideal when precise positioning is required. Use this type for a servo mechanism for position control.

The following figure illustrates the structure of a synchronous type servomotor:

Rotary disc

Light-receiving

 

 

element

Armature Housing

Front cap

Light-emitting

 

wire

Stator core

 

 

element

 

 

 

Ball bearing

 

 

 

 

Shaft

Rotor core

Position detector

Magnet

(encoder)

Lead wire

Yaskawa SGM and SGMP Servomotors are of the synchronous type.

7

FOR FIRST-TIME USERS OF AC SERVOS

1.1.2 Servo Configuration cont.

(c)Performance of Servomotor

A servomotor must have “instantaneous power” so that it can start as soon as a start reference is received.

The term “power rating (kW/s)” is used to represent instantaneous power. It refers to the electric power (kW) that a servomotor generates per second. The greater the power rating, the more powerful the servomotor.

1

(3) Detector

 

 

A servo system requires a position or speed detector. It uses an encoder mounted on

 

 

a servomotor. Optical and magnetic detection methods are both available.

 

Encoders are divided into the following two types:

 

(a) Incremental Encoder

 

An incremental encoder is a pulse generator, which generates a certain number

 

of pulses per revolution (e.g., 2,000 pulses per revolution). If this encoder is con-

 

nected to the mechanical system and one pulse is defined as a certain length

 

(e.g., 0.001 mm), it can be used as a position detector.

 

However, this encoder does not detect an absolute position and merely outputs a

 

pulse train. Hence zero return operation must be performed before positioning.

 

The following figure illustrates the operation principle of a pulse generator (Opti-

 

cal method):

 

 

Phase A pulse train

 

Phase A

 

 

Phase B pulse train

 

Phase B

 

 

 

 

Phase Z

 

 

 

Slit

Center of

Fixed slit

revolution

 

 

 

Light-emitting

 

Rotary

element

 

Light-receiving

 

disc

element

 

 

Rotary slit

(b)Absolute Encoder

An absolute encoder is designed to detect an absolute angle of rotation as well as to perform the general functions of an incremental encoder. With an absolute encoder, therefore, it is possible to create a system that does not require zero return operation at the beginning of each operation.

Difference between an absolute and incremental encoder:

An absolute encoder will keep track of the motor shaft position even if system power is lost and some motion occurs during that period of time. The incremental encoder is incapable of the above.

8

1.1 Basic Understanding of AC Servos

(4)Servo amplifier

A servo amplifier is required to operate an AC servomotor.

The following figure illustrates the configuration of a servo amplifier:

Servo amplifier

Power

Motor driving AC power

1

 

 

 

Comparator amplifier

 

 

Reference input

Feedback

Servomotor

Commercial AC power

A servo amplifier consists of the following two sections:

(a)Comparator

A comparator consists of a comparison function and a control function. The comparison function compares reference input (position or speed) with a feedback signal and generates a differential signal.

The control function amplifies and transforms the differential signal. In other words, it performs proportional (P) control or proportional/integral (PI) control. (It is not important if you do not understand these control terms completely at this point.)

(b)Power Amplifier

A power amplifier runs the servomotor at a speed or torque proportional to the output of the comparator. In other words, from the commercial power supply of 50/60 Hz, it generates alternating current with a frequency proportional to the reference speed and runs the servomotor with this current.

 

Proportional/integral (PI) control

TERMS

 

 

PI control provides more accurate position or speed control than proportional control, which

 

is more commonly used.

9

FOR FIRST-TIME USERS OF AC SERVOS

1.1.2 Servo Configuration cont.

(5)Host Controller

A host controller controls a servo amplifier by specifying a position or speed as a set point.

For speed reference, a position control loop may be formed in the host controller when a position feedback signal is received. Yaskawa PROGIC-8 is a typical host controller.

1

TERMS PROGIC-8

A programmable machine controller. If combined with a servo amplifier for speed control (maximum eight axis control), the PROGIC-8 can provide position control.

The PROGIC-8 also provides programmable controller functions.

10

1.1 Basic Understanding of AC Servos

1.1.3Features of Σ-Series Servos

1)Σ-Series SGM/SGMP Servomotors are synchronous type servomotors and have the following features:

Size and weight reduced to one-third those of our conventional models.

Compact Servomotor for saving installation

 

1

space.

 

Servo performance (power rating) enhanced to three times that of our conventional models.

Enhanced power rating (kW/s) to satisfy every

SGM type

need.

 

A wide product range covering rated output of 30 W to 750 W.

Supply Voltage

Rated Output

SGMP type

100 VAC:

30 W, 50 W, 100 W, 200 W, 300 W

 

(0.04 HP, 0.07 HP, 0.13 HP, 0.27 HP, 0.40 HP)

 

200 VAC:

30 W, 50 W, 100 W, 200 W, 400 W, 750 W

 

 

(0.04 HP, 0.07 HP, 0.13 HP, 0.27 HP, 0.53 HP, 1.01 HP)

2) DR2 Servopacks can perform speed/torque or

 

position control. Select the control mode by set-

 

ting of the user constant Cn-02 (memory switch).

 

• Speed/Torque

Control Mode: User constant

 

Cn-02 (memory switch) Bit B = 0

 

This mode uses speed or torque reference in-

 

put. Reference input is by analog voltage.

 

• Position Control Mode: User constant Cn-02

DR2 Servopack

(memory switch) Bit B = 1

This mode uses position reference input. Reference

 

input is by pulse train.

 

 

Power rating (kW/s)

TERMS

 

 

A constant that represents response performance of a servomotor. It can be determined by

 

dividing squared rated torque by motor inertia. Power rating is the electric power (kW) that a

 

servomotor can generate per second.

 

The greater the power rating, the more powerful the servomotor.

11

FOR FIRST-TIME USERS OF AC SERVOS

1.1.3 Features of Σ -Series Servos cont.

3)The most common usage of a speed/torque control Servopack is shown below:

• Using Servopack in Speed/Torque Control Mode (Speed Control)

 

 

 

 

 

 

 

 

 

Host controller

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Position reference +

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

Position control loop

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Position

 

 

 

 

 

 

 

Servopack

 

 

Speed

 

feedback

 

 

 

 

 

(speed/torque control)

 

 

reference

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Power

 

 

 

 

 

 

 

 

 

 

 

amplifier

 

 

 

 

 

 

 

 

 

 

 

 

Servomotor

 

 

 

 

(Analog

 

 

 

 

Torque

 

 

 

 

voltage)

 

 

 

 

 

 

 

 

 

 

 

 

(current)

 

 

 

 

 

Position

 

 

Speed

Convert

feedback

 

 

 

 

 

 

Pulse train

 

 

 

 

 

 

Position feedback

Encoder

 

 

 

 

As shown in the figure above, a position control loop is formed in the host controller. The host controller compares a position reference with a position feedback signal and sends processing results to the Servopack as a speed reference.

In this way, the host controller can freely perform the control required for the servo mechanism.

The Servopack undertakes the speed control loop and subsequent control processing.

Yaskawa programmable machine controller PROGIC-8 is available as a typical host controller.

12

1.1 Basic Understanding of AC Servos

4)Speed/torque control Servopack can also provide torque control as shown below.

• Using Servopack in Speed/Torque Control Mode (Torque Control)

1

Position information

Set the user constants for Servopack to switch between the following torque control modes:

(1) Controlling servomotor torque by torque reference

(Torque control I)

(2)Operating servomotor by switching between torque reference and speed reference

(Torque control II)

The host controller outputs a torque reference or speed reference to control the Servopack.

It also receives a pulse train (position information) from the Servopack and uses it to monitor the position.

13

FOR FIRST-TIME USERS OF AC SERVOS

1.1.3 Features of Σ -Series Servos cont.

5)Position control Servopack can be used as below.

• Using Servopack in Position Control Mode

Host controller

1

Position reference

 

 

 

 

 

Position

 

 

 

 

information

 

 

 

 

 

 

Power

 

 

 

 

amplifier

Servomotor

 

 

 

 

 

Pulse

 

 

train

 

 

 

Speed/current loop

 

 

 

Pulse train

 

 

 

Position feedback

Encoder

 

 

 

 

The host controller can send a position reference (pulse train) to the Servopack to perform positioning or interpolation.

This type of Servopack contains a position control loop.

User constants can be used to select either of the following pulse trains:

(1)Code and pulse train

(2)Two-phase pulse train with 90° phase difference

(3)Forward and reverse pulse trains

The host controller receives a pulse train (position information) from the Servopack and uses it to monitor the position.

6)A Digital Operator can be used to set user constants for a Servopack as follows:

(1)Setting user constants to enable or disable each function

(2)Setting user constants required for functions to be used

Set user constants according to the servo system to be set up.

14

BASIC USES OF Σ-SERIES

2

PRODUCTS

This chapter describes the first things to do when Σ-Series products are deliv-

ered. It also explains the most fundamental ways of connecting and operating 2 Σ-Series products. Both first-time and experienced servo users must read

this chapter.

2.1

Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

 

2.1.1

Notes on Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

2.2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

 

2.2.1

Checking on Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

 

2.2.2

Installing the Servomotor . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

 

2.2.3

Installing the Servopack . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

2.3 Connection and Wiring . . . . . . . . . . . . . . . . . . . . . 25

2.3.1

Connecting

to

Peripheral

Devices. . . . . . . . . . . . . . . . . . . . .

25

2.3.2 Main Circuit Wiring and Power ON Sequence. . . . . . . . . . . .

28

2.3.3

Examples

of

Connecting

I/O Signal Terminals. . . . . . . . . . .

30

2.4

Conducting

a

Test

Run. . . . . . . . . . . . . . . . . . . . .

37

 

2.4.1

Test Run in Two Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37

 

2.4.2

Step 1:

Conducting

a Test Run for Motor without. . . . Load

39

 

2.4.3 Step 2: Conducting a Test Run with the Motor Connected

 

 

 

to the Machine. .

. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 3

 

2.4.4

Supplementary Information on Test .Run. . . . . . . . . . . . . . .

45

 

2.4.5

Minimum

User

Constants Required and Input . Signals. . . . .

47

15

BASIC USES OF Σ-SERIES PRODUCTS

2.1.1Notes on Use

2.1Precautions

This section provides notes on using Σ-Series products.

 

2.1.1 Notes on Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

2.1.1 Notes on Use

NOTE Always note the following to ensure safe use.

2

Two types of supply voltage are available, 100 V and 200 V.

Both Σ-Series Servomotor and Servopack have 100 V and 200 V types. Be sure to use the correct type.

Type NP

Voltage label

Always use the SGM/SGMP Servomotor and DR2 Servopack in pairs.

The SGM/SGMP Servomotor cannot run without the DR2 Servopack.

Do not plug the SGM Servomotor directly into the commercial power supply. (Direct connection to the commercial power supply will damage the Servomotor.)

Do not change wiring when power is ON.

Always turn the power OFF before connecting or disconnecting a connector.

(Except for Digital Operator (Type: JUSP- OP02A-1))

Direct connection

200 V or

100 V power supply

Damage will result!

CHARGE Lamp

Extinguished

Always turn the power OFF before connecting or disconnecting a connector.

Note that residual voltage still remains in the Servopack even after the power is turned OFF.

Even after the power is turned OFF, residual voltage still remains in the capacitor inside the Servopack. Before inspection is to be performed, make sure if CHARGE lamp is extinguished.

CHARGE

Lamp

16

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