For incorrect parameterization (compare with r979 in the drive): Error 20005: Device type: 2, log.address: 1234 faulty. (Bit: 0, reason: 0x80h)
Encoder type:
• Absolute encoder
• Absolute encoder, cyclic absolute • Incremental encoder
Encoder type From V4.2 and higher, for SINAMICS drives it is possible to directly align the
encoder configuration dynamically with the encoder settings for SINAMICS during the runtime. This is not possible for "older" drive systems, for example
SIMODRIVE and MASTERDRIVES – or for third-party drives. In this case, the encoder must be manually configured.
The required encoder type must first be selected: • Absolute encoder
• Absolute encoder, cyclic absolute • Incremental encoder
Encoder mode The actual encoder type is set in the "Encoder mode" selection field. The following
settings are available for absolute encoders: • Endat encoder (encoder data interface) • SSI encoder (synchronous serial interface) The following incremental encoders are supported: • Sine/cosine encoder
• Square-wave TTL encoder • Resolvers
• Endat encoder
Alarm for incorrect If the encoder parameterization in SIMOTION and in the drive differ from one
parameterization another, the following technology alarm is triggered as soon as an online
connection is established between the control and drive/encoder and the TO is loaded to the control.
"Error 20005: Device type: 2, log.address: 1234 faulty. (Bit: 0, reason: 0x80h)" The comparison of the parameterization for drives is realized according to the PROFIdrive via a parameter: r979 (SensorFormat). For drives, which do not support parameter r979, the configuration without alarm is considered to be valid.
Date: 09.02.2012 File: MC-SMO-SYS_05.61 SIMOTION
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SITRAINTraining for Automation and Drive Technology
Mode of Operation of an Incremental, Optical Sin/Cos Encoder
Photo elements Indexing disk Scanning plate Capacitor Light source Reference
mark "Raw signal"
Type: ERN 1387 ERN 1381 C Spur D Spur
Additional inverted tracks A,B,R,C,D
E
R
N
1387
8 ramps per cycle
Each ramp is subdivided into 256 steps
Resolution with SINAMICS S120 : 2048 * 8 * 256 ≈ 4 million 2048 cycles A Spur B Spur Output signals: A Spur B Spur R Spur
2048 periods per revolution
E
R
N
1381
Principle The optical encoder is based on the following principle. Parallel light passes
through the lattice grid of a scanning plate opposite the light source onto the grid serving as the measuring standard. The lattice grid distribution on the scanning plate and on the indexing disk are identical
The lattice grid on the scanning plate is split up into 4 fields, which, regarding the grid distribution, have spatial offsets of 0º, 90º, 180º and 270º. For relative motion, a bright-dark modulation is created due to the alternating coverage. This modulation is evaluated using 4 photo elements (4 field scanning). These photo elements supply currents that are proportional to the illumination intensity. If the 0º and 180º, as well as the 90º and 270º signals are combined, then 2 sin or cos sequences are obtained.
Raw signals Encoder output signals, which supply a voltage that can be evaluated (raw
voltage signals) have 1 Vpp - raw current signals supply 11µApp.
Resolution Internally an additional resolution is realized through interpolation (2048 pulses
per period).
For interpolation with 2048 subdivisions, the resolution is again 11 bits, i.e. 22 bits, which means 222 = 4´194.304 signals per revolution.
Example: Ballscrew 10mm pitch, no gear,
2048 pulses per revolution x 2048 sinusoidal oscillation /10mm, i.e. 419 signals/µm or 0.0023 µm/pulse.
However, this resolution is only required when determining the actual speed for the closed-speed control inside the drive. In this case, even at low speeds (up to 1 revolution/minute) it must be possible to sensibly determine the actual speed. However, this high-resolution is transferred to SIMOTION (refer to the next page).
Date: 09.02.2012 File: MC-SMO-SYS_05.62 SIMOTION
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Settings for Incremental Encoders - "Cyclic Actual Value"
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
G1_XIST 1
Fine resolution: 2048 Encoder pulse number: 2048
Overflows: 0 - 1023
Number of pulses per revolution Fine resolution
Cyclic actual value The cyclic actual value in Gn_XIST_1 (n = 1 or 2, encoder number) is used by
incremental as well as absolute encoders to send the actual position value of the axis in cyclic operation to SIMOTION. SIMOTION cyclically calculates the actual position value of the axis from this value, the leadscrew pitch and the reference point value (with incremental encoders) or the absolute value, which is passed on by absolute encoders after activation.
After the converter has been switched on, Gn_XIST_1 = 0 is always output independent of the actual position of the axis. Each traversing movement of the axis is passed on via Gn_XIST_1.
SIMOTION interprets the bits in this Gn_XIST_1 in accordance with the settings in "encoder pulse number" and "fine resolution". This interpretation is correct only if the settings in SIMOTION correspond to the settings for Gn_XIST_1 in the converter and, of course, also correspond to the actual data of the encoder.
Fine resolution The converter does not only output the information on the pulse number to
Gn_XIST_1 but also increases the total resolution of the connected encoder by internally sampling the sin/cos signal with sin/cos encoders or resolvers. Resolution: Encoder pulses x 2n(n: fine resolution, no. of bits for internal multiplication
• The following applies for the No. of encoder marks:
Encoder marks = number of sine signal periods (sine/cos encoder with 1 Vpp) No. of encoder marks = 1024 x pole pair no. (resolver with 12 bit resolution) No. of encoder marks = 4096 x pole pair no. (resolver with 14 bit resolution) The pulse number and fine resolution are entered in parameters in the converter.
• The fine resolution for the cyclic actual value Gn_XIST_1 in the converter must be entered in SIMOTION as value = 2nin the input field.
An input value of 0 is interpreted as standard multiplication factor of 211= 2048. In this case 0 is equal to 2048.
Date: 09.02.2012 File: MC-SMO-SYS_05.63 SIMOTION
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SITRAINTraining for Automation and Drive Technology
Mode of Operation of an Absolute Encoder
Singleturn encoder Capacitor Light source Scanning plate Photo- couples
Indexing disk Hall-effect element
Gear box Coded disk
Type: EQN 1325
Incremental tracks mechanical revolutionBinary coding of a with 8192 positions Motor speed 16:1 16:1 16:1 Resolution: 16 revolutions Resolution: 256 revolutions Resolution: 4096 revolutions
Multiturn absolute encoder
Principle The optical design corresponds to a sin/cos encoder. In addition, the disks have
binary coded tracks, which can be interpreted as coded number of pulses in the incremental track.
For 2048 pulses, then at least 11 additional tracks are required, in order to code the position within one revolution (single turn encoder). The absolute traversing distance that can be measured is therefore too low for most applications (for example, 10 mm for a ballscrew with 10 mm pitch/revolution and directly mounted onto the motor).
This is the reason that the measuring range has been extended using a 3-stage gearbox. Every step down stage has a ratio of 16:1. As a consequence, the position information only repeats itself after 4096 revolutions or after a traversing distance of 40.96m. The position of the gear wheels in the gearbox are
evaluated using Hall elements.
EnDat interface In order that the traversing distance through the 4096 revolutions can be
uniquely represented, the following information must be known. Gearbox position: 3 x 4 bits (16 x 16 x 16 = 4096 revolutions) Pulse number: 11 binary tracks
When the control system is switched on, this 23-bit information is transferred from the encoder using the EnDat protocol (EncoderData Protocol).
The precise position information is retrieved using the interpolation technique described for sin/cos encoders.
Date: 09.02.2012 File: MC-SMO-SYS_05.64 SIMOTION
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SITRAINTraining for Automation and Drive Technology
Settings for Absolute Encoders - "Absolute Actual Value"
Gn_XIST 2
Fine resolution: 512 Encoder pulse
number: 512 Multiturn resolution: 4096
Number of data bits: 21 not
eval- uated
Number of pulses per revolution
Fine resolution for act. value in Gn_XIST_1 Fine resolution for act. value in Gn_XIST_2 Number of bits for multiturn resolution + no. of encoder pulses
Absolute When an absolute encoder is connected, SIMOTION retrieves the absolute
actual value position of the axis via Gn_XIST_2 (n = 1 or 2, encoder number) after the
control/converter has been switched on. From the transmitted value or the stored overflows of the multiturn information, SIMOTION calculates the actual position value of the axis.
SIMOTION interprets the bits in Gn_XIST_2 in accordance with the settings for "Data width of absolute value without fine resolution" and the "Fine resolution of absolute value in Gn_XIST2".
Number of data bits The "Data width absolute value without fine resolution" is obtained from the total
of the bits for multiturn resolution and encoder pulse number. The settings in SIMOTION must match the corresponding settings in the converter, otherwise the actual position will not be calculated and displayed correctly after switch on.
Fine resolution Just the same as for "cyclic actual value", the converter not only transmits
information about the number of encoder revolutions (for multiturn encoders) and the encoder pulse number to the higher-level control, but also performs fine resolution. This fine resolution is lower with the "absolute actual value" than with the "cyclic actual value" as the entire information must be stored in a 32-bit double word.
This means only 9 bits, i.e. a factor of 512, remain for the fine resolution for standard multiturn encoders with a multiturn resolution of 4096 (12 bits) and an encoder pulse number of 2048 (11 bits). This is the reason that for the "Fine resolution absolute value in Gn_XIST_2" an entered value of 0 is interpreted as a multiplication factor of 29= 512.
Note The encoder position word Gn_XIST_2 is used not only for transferring the absolute actual value after switch on but also for transferring the position in the functions: "Measuring input" and "Homing". In this case, however, the position value is coded in accordance with the format settings for the "cyclic actual value", i.e. in accordance with the multiplication factor for the cyclic actual value.
Date: 09.02.2012 File: MC-SMO-SYS_05.65 SIMOTION
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SITRAINTraining for Automation and Drive Technology
Settings for Absolute Encoders - Encoder Type
Fine resolution Encoder pulses
per revolution Multiturn resolution
Number of data bits: 23
Encoder information in Gn_XIST 2
. . . .
Overflows of multiturn information
Encoder type:
"Absolute encoder"
Overflows of the multiturn information are not saved in SIMOTION when it is switched off
"Absolute encoder, cyclic absolute":
Overflows of the multiturn information are saved in SIMOTION when it is switched off
Encoder mode The following two settings are available in the "Axis configuration - Encoder
assignment" dialog box in the "Encoder type" field: • Absolute encoder:
With this setting, the entire overflows of the absolute actual value, i.e. over- flows of the multiturn information are not saved when the SIMOTION is switched off.
The next time SIMOTION is switched on, the actual position value is
formed from the absolute actual value which is passed from the converter in Gn_XIST_2 to SIMOTION.
With a multiturn resolution of 4096 and a leadscrew pitch of 10mm/rev. The result is always a value between 0 m and approx. 40 m.
• Absolute encoder, cyclic absolute
With this setting, at switched off, the overflows of the multiturn information are stored in the retentive memory area of SIMOTION. The next time SIMOTION is switched on, this information is taken into account for calculating the actual position value.
This setting must be made if the absolute encoder with it's multiturn
resolution does not cover the complete traversing range of the axis or if, as a result of an unfavorable mounting of the absolute encoder, overflows of the multiturn information occur within the traversing range.
Note The overflows of the multiturn information and the value for the absolute encoder adjustment of an axis are deleted in the following situations: • OVERALL RESET of SIMOTION
Date: 09.02.2012 File: MC-SMO-SYS_05.66 SIMOTION
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SITRAINTraining for Automation and Drive Technology
Settings for Travel to Fixed Endstop
Maximum motor torque --> TypeOfAxis.SetPointDriverInfo.DriveData.maxTorque
Travel to As a result of the "travel to fix stop" command, the monitoring of "traversing
fixed endstop to fixed endstop" is activated in parallel to axis motion started using a motion
command. In addition, the maximum torque at the drive is restricted to the value specified in the command. Further, the active following error monitoring usual for traversing motion is deactivated.
The "Travel to fixed endstop" function assumes that the torque limiting at the drive is supported, i.e. this function can only be performed when using one of the message frames 103, 104, 105, or 106.
The command also ensures that a specific clamping torque is maintained after the fixed endstop has been reached. This command can also be used to switch over the clamping torque during active clamping.
Fixed endstop In the dialog "Limits", "Fixed endstop" tab, in the "Fixed endstop detection" field,
detection it can be selected as to how it can be detected when the fixed endstop is
reached:
• when the following error is exceeded. In this case, in the entry field
"Following error to the fixed endstop detection", the required value should be entered, which results in the status "Fixed endstop reached".
• when the torque is exceeded: In this case, when reaching the torque programmed at the command for the status "Fixed endstop reached". If the criterion "Fixed endstop reached" is reached, then the interpolator is stopped; however the position control remains active. The axis is now clamped with the torque programmed at the command. The usual traversing commands in the same direction are rejected by the TO, only traversing commands in the opposite direction are permitted.
In the system variables moveToEndStopCommand. ClampingState the state "Fixed endstop reached" is displayed. The state "Fixed endstop reached" is canceled if the actual axis position deviates by more than the value specified in the "Position tolerance after fixed endstop detection" (e.g. because the clamping force is overcome, traversing command in the direction opposite to the clamping direction).
Date: 09.02.2012 File: MC-SMO-SYS_05.67 SIMOTION
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SITRAINTraining for Automation and Drive Technology
Travel to Fixed Endstop - "Determining the Reference Torque"
Max. drive torque--> TypeOfAxis.SetPointDriverInfo.DriveData.maxTorque
Determining the For SINAMICS from V2.6.2 and higher, the reference torque of the motor
reference torque is automatically adapted by SIMOTION and entered into the corresponding
configuration data.
<Axis>.TypeOfAxis.SetPointDriverInfo.driveData.maxTorque
All of the reference variables of an axis are listed in the screen form: Configuration -> Reference variables.
Resolution For the resolution of the torque reduction, from V4.0 two options are available.
The setting in SIMOTION is made in the configuration data
SetPointDriverInfo.driveData.torqueReductionGranularity (standard motor) or in
SetPointDriverInfo.linearMotorDriveData.forceReductionGranularity (linear motor).
1. Setting: "STANDARD" (default setting) - resolution 0.006 %
The value of 4000H or 16384 (dec.) in the message frame corresponds to a torque reduction of 100%.
In SINAMICS, P1544 must be set to 100 (default setting). 2. Setting: "BASIC" - resolution 1 %
The value of 64H or 100 (dec.) in the message frame corresponds to a torque reduction of 100%.
Date: 09.02.2012 File: MC-SMO-SYS_05.68 SIMOTION
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Travel to Fixed Endstop - "Settings in the Command"
For linear axes:
F = Torquemotorx 2 x π x (ηspindle/ S) x (motor revolution / load revolution)
F : Force in N
Torquemotor: Motor torque in Nm
ηspindle: Efficiency of the spindle (no dimensions)
S: Spindle pitch in m
Clamping value The clamping value is entered in the force unit for the particular axis type,
(without unit) i.e. in N, kN, ... (Newton) for linear axes or in Nm, kNm for rotary axes.
If a linear axis is implemented using a standard motor and a ballscrew, then the motor reference torque must be converted to the "reference force" of the linear axis. The following relationship is used for the conversion:
F = torquemotorx 2 x π x (ηspindle/ S) x (motor revolution/load revolution) F = force
M = torque
S = spindle pitch (leadscrew.pitchVal) η = spindle efficiency (leadScrew.efficiency) Motor revolution (Gear.numFactor)
Load revolution (Gear.denFactor)
Example In the following example, the reference torque 3.68 Nm of a motor is converted
into a reference torque. In this example, the conversion is made without any additional load gearbox, the spindle pitch is assumed to be 10 mm/revolution F = 3.68 Nm x 6.28 / 0.01 m = 2312, 21 N
When 231.22 is entered as clamping value in the command, this corresponds to a torque reduction of 90% in the message frame. As a consequence, the drive generates a maximum torque of 0.368 Nm at the motor.
Clamping value When selecting the clamping value as a %, the required max. torque at the
(as a percentage %) drive can be directly entered in units of 0.01. The required maximum torque at
the drive of 0.37 Nm then corresponds to an input of 37.
When implementing a linear axes via a ballscrew at the motor, then a value of 628.0 must be entered into the system variable