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In the following we show to you how to control the SMO function of ctrlX DRIVE via ctrlX SAFETY. Mind that you find a complete document with all details and as well a related Safe logic program file and drive parameter file as a start for commissioning for download at the end of the article. Prerequisites All the functions and screen shots are based on: ctrlX SAFETY Engineering version >= 1.7.1.8172 SAFEX Runtime / Firmwareversion >= 1.0.0.1 (C-sample) ctrlX DRIVE Engineering version 01V12 Runtime / Firmware version of drive AXS-V0304 or Runtime / Firmware version of drive AXS-V0210 A connection to the ctrlX SAFETY control and ctrlX DRIVE has been successfully established, the devices are correctly wired and 24 V are successfully put on. As well the engineering tools ctrlX SAFETY and ctrlX DRIVE Engineering have been started. 1. Function of the established SAFEX logic program The principle function of the SAFEX logic program is the following: EMERGENCY STOP (SMES) If the EMERGENCY STOP button at ctrlX SAFETY is pressed, the corresponding safety function at the drive, if an axis incorporating SMO function, is activated immediately, which leads to a deceleration of a still moving axis. After coming to standstill and acknowledging the EMERGENCY STOP function the drive is shut off and thus torque/force free. if an axis incorporating STO function, the non-safety related E-Stop function inside the drive is activated immediately, which leads to a deceleration of a still moving axis. After coming to standstill or exceeding a time delay of in here 0,5 s (in other applications this value may have to be adjusted) the Safe Torque Off (STO) function of the drive is acitvated and thus the axis is getting torque/force free. Note, that the “Drive Enable” signal from the control has to be removed before the time entered for the reaction time of the EMERGENCY STOP function or the time delay inside the Safe logic program for the STO function is exceeded, thus directly after the standstill is accomplished. Otherwise an error is shown. If the EMERGENCY STOP button is released again the Reset button needs to be shortly pressed in order that the EMERGENCY STOP or STO and thus the function is released again as well. Then the drive can be activated (drive enable be set) again. Mind that the EMERGENCY STOP is always prior to all other safety functions and, if activated, superseding the in before active safety function. Mode Select - Change to Safety Operation Mode (activating the safe operational stop (SMST2)) If “Mode Select” at ctrlX SAFETY is switched, if an axis incorporating SMO function, the corresponding safety function at the drive is activated immediately, which leads to a deceleration of a still moving axis. After getting to standstill the drive is in operational stop with torque/force on. if an axis incorporating STO function, the non-safety related E-Stop function inside the drive is activated immediately, which leads to a deceleration of a still moving axis. After coming to standstill or exceeding a time delay of in here 0,5 s (in other applications this value may have to be adjusted) the Safe Torque Off (STO) function of the drive is acitvated and thus the axis is getting torque/force free. If the “Mode Select” is switched back again all axes incorporating SMO function are ready for normal movement again. The axes incorporating the STO function need to be activated (the drive enable need to be set) again. Enabling Control (activating safe motion with limited speed) (SMM1) If the “Enabling Control” button at ctrlX SAFETY is pressed additionally to the “Change to Safety Operation Mode” button, the corresponding safety function at the drive incorporating the SMO function is activated immediately, which allows the control to set a command with reduced speed. If the “Enabling Control” button is released again, the safe operational stop (SMST2) is getting active again. SAFETY link The connection to the drives incorporating the SMO function is accomplished via the so-called SAFETY link connection, a ring connection from the ctrlX SAFETY control SAFEX to all ctrlX DRIVE and back. Fig. 1.: SAFETY link schematics 2. Wiring schematics The SAFEX control´s input devices are: 1 double channel EMERGENCY STOP button 1 single channel "Reset" button 1 double channel “Mode Select” switch 1 double channel “Enabling control” button 2 single channel inputs coming from the ctrlX DRIVE devices individually indicating that standstill is achieved All double channel buttons fed by pulsed 24V The output devices are: 1 single channel output for control of so-called E-Stop function of drives (quick changeover to standstill) 2 OSSD fed outputs connected to double channel STO input of drives 1 single channel output SafeZoneError (SZE) to signal that an error is present in the SAFETY link connection or the drive safety functions 1 single channel output SafeZoneAcknowledge (SZA) to signal that the drive is in a safety state (EMERGENCY STOP (SMES), Safe Operational Stop (SMST2) or Safe Motion (in here SMM1) condition) Drives (in here 2 are used) controlled and connected over SAFETY link Fig. 2.: Wiring schematics 3. Settings inside SAFEX control The settings of the SAFEX control and the devices connected to the ctrlX SAFETY control should be according to the following. Fig. 3.: Settings of SAFEX control (number of slaves of SAFETY link participants could be set corresponding to the amount really present) Fig. 4.: Settings of “Emergency Stop” button connected to SAFEX control Fig. 5.: Settings of “Mode Select” switch connected to SAFEX control Fig. 6.: Settings of “Enabling Control” button connected to SAFEX control Fig. 7.: Settings of “Start/Reset” button connected to SAFEX control Fig. 8.: Settings of “Drive Standstill 1” signal connected to SAFEX control Fig. 9.: Settings of “Drive Standstill 2” signal connected to SAFEX control Fig. 10.: Settings of “SafeZoneError” output (SZE) of SAFEX control Fig. 11.: Settings of “E-Stop” output to drives of SAFEX control Mind that the E-Stop is not using an OSSD output. In order to achieve this, the property SIL Level of the SAFEY control needs to be set to SIL2 (see Fig. 4). Then the Output type may be selectable with Standard (see in here Fig. 12)”. If using OSSD outputs the overall SIL Level for those safety functions is SIL3, even if only SIL2 is been selected. Fig. 12.: Settings of “SafeZoneAcknowledge” output (SZA) of SAFEX control Fig. 13.: Settings of “Safe Torque Off” output channel 1 (STO_Ch1) of SAFEX control Fig. 14.: Settings of “Safe Torque Off” output channel 2 (STO_Ch2) of SAFEX control 4. Safe logic inside SAFEX control The safe logic inside the SAFEX control is created according to the following schematics. Fig. 15.: Safe logic inside SAFEX control (1) (inside Functional Scheme) Fig. 16.: Configuration of element “Restart 1” (inside Functional Scheme) Fig. 17.: Configuration of element “FastCh_1” (inside Functional Scheme) as “FastCh In 1” (inside FastChannel Scheme) Fig. 18.: Configuration of element “FastCh_2” (inside Functional Scheme) as “FastCh In 2” (inside FastChannel Scheme) Fig. 19.: Configuration of element “FastCh_3” (inside Functional Scheme) as “FastCh In 3” (inside FastChannel Scheme) Fig. 20.: Configuration of elements “And Block” (inside Functional Scheme) Fig. 21.: Configuration of elements “Not Block” (inside Functional Scheme) Fig. 22.: Configuration of element “Timer 0,5s” (inside Functional Scheme) Mind that for other applications this time might have to be set different! Fig. 23.: Configuration of element “Dummy” (inside Functional Scheme) Fig. 24.: Configuration of element “FastCh_In 1” (inside Functional Scheme) as “FastChOut 1” (inside FastChannel Scheme) Fig. 25.: Configuration of element “FastCh_In 2” (inside Functional Scheme) as “FastChOut 2” (inside FastChannel Scheme) Inside the FastChannel Scheme the input elements are connected to a SAFETY link block which communicates to the drives. Fig. 26.: Safe logic inside SAFEX control (inside FastChannel Scheme) Fig. 27.: Configuration of element “SAFETYlink” (inside FastChannel Scheme) 5. Settings of ctrlX DRIVE 5.1. Settings of ctrlX DRIVE with SMO The settings of ctrlX DRIVE are done according to the following: Fig. 28.: Settings of ctrlX DRIVE (1): Safety zone settings Fig. 29.: Settings of ctrlX DRIVE (2): I/O mapper input settings (1) Fig. 30.: Settings of ctrlX DRIVE (3): I/O mapper input settings (2) Fig. 31.: Settings of ctrlX DRIVE (4): I/O mapper input settings (3) Fig. 32.: Settings of ctrlX DRIVE (5): I/O mapper input settings (4) For further information to correct parameter settings of ctrlX DRIVE refer to: How-to-commission-SafeMotion-SMO-with-ctrlX-DRIVE 5.2. Wiring of ctrlX DRIVE with STO The wiring of ctrlX DRIVE with STO is done according to the following: Fig. 33.: Wiring of ctrlX DRIVE with STO 5.3. Settings of ctrlX DRIVE with STO The settings of ctrlX DRIVE are done according to the following: Fig. 34.: Settings of ctrlX DRIVE (1): I/O signal settings Fig. 35.: Settings of ctrlX DRIVE (2): Error reaction settings Fig. 36.: Settings of ctrlX DRIVE (3): E-Stop reaction settings     Record of revision: Version 03, 2021-10 Editorial Department: Drives Support [UwWe]     ... View more

Prerequisites In the following we show to you how to control the STO function of ctrlX DRIVE via ctrlX SAFETY in using digital I/Os. All the functions and screen shots are based on: ctrlX SAFETY Engineering version >= 1.7.1.8172 SAFEX Runtime / Firmwareversion >= 1.0.0.1 (C-sample) ctrlX DRIVE Engineering version 01V12 Runtime / Firmware version of drive AXS-V0304 or Runtime / Firmware version of drive AXS-V0210 A connection to the ctrlX SAFETY control and ctrlX DRIVE has been successfully established, the devices are correctly wired and 24 V are successfully put on. As well the engineering tools ctrlX SAFETY and ctrlX DRIVE Engineering have been started.   Mind that attached to the article you find the ctrlX SAFETY program and ctrlX DRIVE parameter as sample. The word file of the article is as well attached for download for use without Internet connection.   1. Function of the established SAFEX logic program The principle function of the SAFEX logic program is the following:   If at the ctrlX SAFETY the EMERGENCY STOP button is pressed or the ModeSelector is switched, the non-safety-functional E-Stop function at the drive is activated immediately, which leads to a deceleration of a still moving axis. With a time delay of in here chosen 0,5 s, which is the time the axis needs to stop in worst case, the SAFEX control activates the safe STO function at the drive which prohibits a further movement. If the drive acknowledges the standstill (which is a non-safety-function only) already before the 0,5 s are exceeded, the safe STO function is directly activated after the drive acknowledges this standstill condition. If the EMERGENCY STOP button is released again, the Reset button needs to be shortly pressed that the EMERGENCY STOP and thus the STO function is released again as well. Then the drive can be activated again. If only the ModeSelector has been switched and is now switched back again, the STO function is directly released again. No Reset button needs to be pressed. Then the drive can be activated again. Timing diagrams The following timing diagram show the sequence for the functionality: Fig. 1.: Timing diagram with normal behavior at pressing EMERGENCY STOP button (axis is in movement but reaches standstill more quickly than time foreseen) Fig. 2.: Timing diagram with behavior at pressing EMERGENCY STOP button (axis is in movement but doesn´t reach standstill in the time foreseen) The timing diagram for switching the ModeSelect is exactly the same like for pressing the EMERGENCY STOP button.   Fig. 3.: Timing diagram after releasing EMERGENCY STOP button Fig. 4.: Timing diagram after switching ModeSelect back 2. Wiring schematics The SAFEX control´s input devices are: One double channel EMERGENCY STOP button fed by pulsed 24V One double channel Mode Select switch fed by pulsed 24V One single channel reset button fed by non-pulsed 24V Two single channel inputs coming from two ctrlX DRIVE indicating that standstill is achieved The output devices are: One single channel output for control of so-called E-Stop function of drives (quick changeover to standstill) Two OSSD fed outputs connected to double channel STO input of drives Fig. 5.: Wiring schematics 3. Settings inside SAFEX control The settings of the SAFEX control and the devices connected to the ctrlX SAFETY control should be according to the following. Fig. 6.: Settings of SAFEX control Fig. 7.: Settings of “Emergency Stop” button connected to SAFEX control Fig. 8.: Settings of “ModeSelect” switch connected to SAFEX control Fig. 9.: Settings of “Start/Reset” button connected to SAFEX control Fig. 10.: Settings of “Drive standstill” inputs connected to SAFEX control Fig. 11.: Settings of E-Stop output of SAFEX control Mind that the E-Stop is not using an OSSD output. In order to achieve this, the property SIL Level of the SAFEY control needs to be set to SIL2 (see Fig. 6). Then the Output type may be selected as Standard (see in here Fig. 11)”. If using OSSD output signals the overall SIL Level for those safety functions is SIL3, even if only SIL2 is been selected.             Fig. 12.: Settings of STO outputs of SAFEX control 4. Safe logic inside SAFEX control The safe logic inside the SAFEX control is created according to the following schematics. Fig. 13.: Safe logic inside SAFEX control Fig. 14.: Settings of Restart block Fig. 15.: Settings of Timer (in here as delay time 0,5 s is chosen, in your application this time may differ) 5. Wiring of ctrlX DRIVE The wiring of ctrlX DRIVE with STO is done according to the following: Fig. 16.: Wiring of ctrlX DRIVE with STO 6. Settings of ctrlX DRIVE The settings inside ctrlX DRIVE are done according to the following: Fig. 17.: Settings of ctrlX DRIVE (1): I/O signal settings Fig. 18.: Settings of ctrlX DRIVE (2): Error reaction settings Fig. 19.: Settings of ctrlX DRIVE (3): E-Stop reaction settings   Record of revision: Version 03, 2021-09 Editorial Department: Drives Support [UwWe]     ... View more

Introduction In the following we show to you how to commission 3 rd party motors with ctrlX DRIVE. The possible solutions are to control:  Asynchronous motors without encoder in open loop over U/f control for simple, non-demanding and non-dynamic applications Asynchronous motors without encoder in open loop over SVC control for medium demanding and medium dynamic applications Synchronous motors without encoder in open loop over SVC control for medium demanding and medium dynamic applications Asynchronous or synchronous motors with encoder in closed loop over FOC control for demanding and high dynamic applications   If the motors are linear or rotatory doesn´t matter. All the functions and screen shots are based on: ctrlX DRIVE Engineering version 01V10 Runtime / Firmware version of drive AXS-V0302  or Runtime / Firmware version of drive AXS-V0208 Prerequisites A connection to the ctrlX DRIVE has been successfully establi-shed, the device is correctly wired and 24 V are successfully put on. As well the engineering tool ctrlX DRIVE Engineering has been started. Mind that additional prerequisite like minimum inductance of motor in relation to chosen converter or inverter size depending on the later-on used PWM frequency has been checked. Similar, that the chosen encoder or linear scale, if using closed loop control, is been able to be evaluated with the used hardware and firmware (runtime) version. 1. Principle commissioning of 3 rd party motors 1.1. Prior settings Before starting the sequence for principle commissioning of 3 rd party motors the prior settings for Encoder Operation modes Drive Halt Limitations Drive control method should be adjusted according to the later operation or use. 1.1.1. Encoder settings Fig. 1.: Encoder settings 1.1.2. Operation modes settings The operation mode should be selected like the later use is planned. Mind, that, if operating a motor without encoder, operation modes requesting an encoder (like position control mode) are not possible. Fig. 2.: Selection of operation modes 1.1.3. Drive Halt settings Set the drive halt acceleration according to your application. Jerk is recommended to be set to “0”. Fig. 3.: Drive Halt settings 1.1.4. Torque/force limitation settings Check the limitation settings to protect the mechanics or the drive package. Fig. 4.: Limitation settings 1.1.5. Drive control method settings The drive control method should be set according to the later usage. Fig. 5.: Selection of “Control method” Fig. 6.: Selection of “Motor operation configuration” 1.2. Initial commissioning sequence of 3 rd party motors Underneath the node “Motor” and “Motor type” in the project tree a sequence for “Initial motor commissioning” can be started. Fig. 7.: Start “Initial motor commissioning” 1.2.1. Motor data In step 1 select the type of motor present and if encoder, temperature sensor or brake is present. Depending on this selection, the number of steps for commissioning is been adjusted. Fig. 8.: Step 1: Selection of motor type and encoder, temperature sensor or brake, if present In step 2 enter the data for the motor provided by the motor manufacturer. Fig. 9.: Step 2: Motor data input (1) Fig. 10.: Step 2: Motor data input (2) (advanced data) Then press the button “Calculate motor control parameters”! Fig. 11.: Step 2: “Calculate motor control parameter” (only possible in “OM”) 1.2.2. Encoder data (if present) Next step is to enter the motor encoder data. Fig. 12.: Step 3: Parameterization of motor encoder The mechanical attachment of the motor encoder to the motor has to be parameterized. Fig. 13.: Step 4: Mechanical attachment of motor encoder 1.2.3. Temperature monitoring / Temperature sensor The parameters for temperature monitoring of the motor have to be set. If no temperature sensor is used, at least the temperature model data have to be parameterized. The effective behavior can be checked in the motor temperature model. Fig. 14.: Setting motor temperature monitoring Fig. 15.: Step 5: Setting motor temperature model parameters Fig. 16.: Motor temperature model behavior 1.2.4. Brake (if present) If a brake is present enter the relevant data! Fig. 17.: Step 5: Brake settings 1.2.5. Validity check of motor parameters In the next step, the plausibility of the motor and encoder settings are checked. Press the button “Validity check of motor and encoder parameterization”! Fig. 18.: Step 6: Validity check of motor and encoder parameterization (1) If in operation mode “OM” and “Ab”, the drive is changing to “AF” and performing some movements. Fig. 19.: Step 6: Validity check of motor and encoder parameterization (2) If principle setting of motor data and encoder are correct, the command is executed successfully. If not, the original parameters have to be changed to correct values. 1.2.6. Determining motor data The motor data are identified via the drive. Select the method and press button “Automatic identification of the motor data”! Fig. 20.: Step 7: “Automatic identification of the motor data” (1) If in operation mode “OM” and “Ab”, the drive is changing to “AF” and performing some movements. Fig. 21.: Step 7: “Automatic identification of the motor data” (2) Motor resistance and inductance parameters are changed to the measured values in the background. 1.2.7. Commutation setting (if synchronous motor is operated with encoder) Synchronous motors, if operated with encoders or linear scales, need to determine their commutation (alignment of electric field to magnetic field). For most synchronous motor, except on ironless linear motors, the suitable method is to do this commutation routine using the so-called “Saturation method”. For ironless linear motors the “Sine-wave” method is to be chosen. Select the proper method! Fig. 22.: Step 8: Commutation method setting With the start value "0" for "Amplitude", the motor-specific values for "Amplitude" and "Frequency" are automatically determined. If in operation mode (OM) and “Ab”, check the “Initial commissioning mode” and then press button “Determine commutation offset”! Fig. 23.: Step 9: Commutation settings (1) Some current is applied and the commutation offset determined. If routine was successful, uncheck the “Initial commissioning mode” again! Fig. 24.: Commutation settings (2) 1.2.8. Limitation settings Next step is to check and eventually correct the limitation figures both for speed and torque/force. Fig. 25.: Step 10: Limitation settings 1.2.9. Homing (set absolute reference of encoder 1)(if needed) Then the axis should be homed using the drive-controlled homing procedure or the absolute reference should be set.   Fig. 26.: Step 11: Homing or Set absolute position 1.2.10. First movements Finally the motor should be moved using the “Easy Startup” mode. Fig. 27.: Step 12: Start “Easy startup” mode Fig. 28.: Step 12: Enable the motor Enter a proper speed for jogging! Then start jogging in the desired direction! Fig. 29.: Step 12: Input proper speed Fig. 30.: Step 12: Jog in desired direction If everything is fine, finish the commissioning sequence of 3 rd party motors. Fig. 31.: Step 12: Finish commissioning sequence for 3 rd party motors 1.3. Check of regulation loops and their behavior Now follow the routine for first setup to set the limitations and directions correctly, autotune and check the regulation loops. The positioning behavior should be checked as well. See:   1st setup and execute initial movements       -  video 1       -  video 2       -  blog entry              Autotuning        -  video        -  blog entry   Check positioning movements        -  video        -  blog entry 1.3.1. Check of current loop (not possible in open loop control) Check and adjust the settings, if needed, by obtaining frequency response diagram. The bandwidth at -3 dB should be higher than 1000 Hz in dynamic servo axis, in more simple applications like handling 500 Hz may be sufficient. 1.3.2. Check of velocity loop Check and adjust the settings, if needed, by obtaining frequency response diagram. Especially the filters may be set to suppress resonances in the mechanics. Mind that this filter settings is not possible in U/f control. The usual stability limits for regulation loops should be adjusted: In closed loop frequency diagram (blue line diagram): Bandwidth is measured at amplitude – 3dB in Amplitude shouldn´t exceed + 5dB line At higher frequencies than bandwidth amplitude shouldn´t get positive again à indication for resonance causing vibration Recommendation for phase margin measured at 0 dB of open loop frequency diagram (purple line diagram, cursor 1) 40° to 70° for good command response behavior 20° to 50° for good load response behavior 40° to 60° for well balanced Recommendation for amplitude margin measured at 0 dB of open loop frequency diagram (purple line diagram, cursor 2) Minimum + 5dB Usually at least + 10dB for well balanced loop settings Fig. 37.: Frequency response of velocity loop (not possible to obtain with axes operated in open loop (without encoders)) The usual behavior for step responses should be adjusted Overshoot not exceeding 1,4 times the command value No vibration visible at coming to commanded speed Fig. 38.: Step response 1.3.3. Check of position loop (not possible in open loop control) Fig. 39.: Position loop settings Fig. 40.: Frequency response of position loop If running a typical cycle the maximum model deviation is shown. With some safety margin (factor 1,5 to 2,0) the monitoring window should be keyed in! The velocity loop monitoring should always be active. Fig. 41.: Loop monitoring 1.4. Further settings 1.4.1. Error reaction settings The error reaction settings should be set according to the application! Fig. 42.: Error reaction settings 1.4.2. Status message settings The status message settings should be set according to the application! Fig. 43.: Status message settings   2. Specialties for control of 3 rd party motors in open loop 2.1. Asynchronous motors using U/f control For simple, non-demanding and non-dynamic open loop applications (no encoder required) asynchronous motors maybe controlled over U/f control. As a prerequisite the encoder settings should be set to "No encoder". All operation modes should be set to “Velocity control”. The control method has to be set to “Open-loop drive control”! Fig. 44.: Drive control overview Eventually the maximum stator frequency slope should be limited. Fig. 45.: Settings in “Motor operation configuration” Then the “Initial motor commissioning” should be started. Choose “Asynchronous motor” and follow the steps! Set “search mode” only, if needed, e.g. if motor could still be running if applying the drive enable signal. 2.2. Asynchronous motors using SVC control For medium demanding and medium dynamic open loop applications (no encoder required) asynchronous motors maybe controlled over SVC control. As a prerequisite the encoder settings should be set to "No encoder". All operation modes should be set to “Velocity control”. The control method has to be set to “Closed-loop drive control”! Fig. 46.: Drive control overview The Motor mode – motor control should automatically be set to “sensorless” (SVC: sensorless vector control). Fig. 47.: Settings in “Motor operation configuration” Then the “Initial motor commissioning” should be started. Choose “Asynchronous motor” and follow the steps! 2.3. Synchronous motors using SVC control For all open loop applications (no encoder required) synchronous motors have to be controlled over SVC control. This is suitable for medium demanding and medium dynamic applications. As a prerequisite the encoder settings should be set to "No encoder". All operation modes should be set to “Velocity control”. The control method has to be set to “Closed-loop drive control”! and the "Motor mode – motor control" should automatically be set to “sensorless” (SVC: sensorless vector control). Then the “Initial motor commissioning” should be started! As motor category the “Standard synchronous motor” has to be selected! As Flux-generating current, limit value, 2- to 3-times the motor current at standstill is recommended to enter. The nominal and maximum figures should be known from the motor manufacturer.   3. Specialties for control of 3 rd party motors in closed loop (FOC control) 3.1. Asynchronous motors As a prerequisite the encoder settings should be selected according to the application. Fig. 48.: Parameter settings of encoder for synchronous motor in FOC control The operation modes should be set according to later use! The control method has to be set to “Closed-loop drive control”! Fig. 49.: Drive control overview The Motor mode – motor control should be set to “with encoder” (FOC: field oriented control). Fig. 50.: Settings in “Motor operation configuration” Then the “Initial motor commissioning” should be started! As motor category the “Asynchronous motor” has to be selected! 3.2. Synchronous motors As a prerequisite the encoder settings should be selected according to the application. The operation modes should be set according to later use! The control method has to be set to “Closed-loop drive control”! The Motor mode – motor control should be set to “with encoder” (FOC: field oriented control). Then the “Initial motor commissioning” should be started! As motor category the “Standard synchronous motor” has to be selected! ... View more