C-axis operation

Digital system

With the SIMODRIVE 611 digital system, the C-axis operation is implemented in direct communication with the SINUMERIK 810D powerline/840D powerline/840C. The standard high-resolution actual position acquisition provided by the drive control system allows the integrated motor measurement system to achieve a maximum resolution of 4,194,304 positioning increments per revolution (high-performance control). This produces, for example, a position resolution of approximately 1/10,000 degrees.

CNC link

Analog system

Control modules with tried and tested analog interface are available with the SIMODRIVE 611 universal HRS system to provide a link to the SINUMERIK 840C/802C base line or other controls.

Digital system

Control modules with digital drive bus interface are available with the SIMODRIVE 611 system to provide a digital link to the SINUMERIK 810D powerline/840D powerline/840C.

Closed-loop control of feed, digital

Closed-loop control in digital system

Closed-loop control of the digital feed modules is based on a powerful signal processor that performs the axis-specific current and speed control. Data communication with the position control of the SINUMERIK 810D powerline/840D powerline/840C is processed by a communications function block. The current and speed controls are based on a state controller that can be easily set. The closed-loop control system is optimally tuned to both the sinusoidal-current commutated 1FT6 and 1FK three-phase servomotors and the 1FN linear motors (with performance closed-loop control). In addition to the highly dynamic closed-loop control, the digital closed-loop control features easily parameterizable filters that can be used for damping mechanical resonance. In many cases, this damping will significantly increase the performance of the speed control loop and, where applicable, also of the position control loop (K_v).

SIMODRIVE 611 universal HRS closed-loop control

Closed-loop control of the feed motors is based on a powerful signal processor with current and speed control for axis-specific current and speed control. The closed-loop control system is optimally tuned to both the sinusoidal-current commutated 1FK and 1FT6 three-phase servomotors and the 1FN linear motors (with performance closed-loop control).

Closed-loop control of main spindle, digital

Feedrate or main spindle closed-loop control in digital system

Closed-loop control in digital system

The closed-loop control system for the digital main spindle modules is based on a powerful signal processor with closed-loop current and speed control of the 1PH main spindle motors with sine-cosine encoder. Via a communications block, data exchange with the SINUMERIK 810D powerline/ 840D powerline is controlled bidirectionally via the drive bus. The current and speed controls are based on a state controller that can be easily set. With the high control dynamics and parameterizable filters for damping mechanical resonances, excellent positioning and high C-axis quality are achieved.

SIMODRIVE 611 universal HRS closed-loop control

Closed-loop control of the main spindle motors is based on a powerful signal processor with current-speed controller for operating the 1PH main spindle motors with sine-cosine encoder.

Closed-loop control, induction motor

Closed-loop control, induction motor

Closed-loop control in digital system

Closed-loop induction motor control is an offshoot of the digital closed-loop control system for main spindle drives. The closed-loop control system for induction motors is based on a powerful signal processor with current and speed controllers for operating standard induction motors without encoder Excellent control quality is achieved through a field-oriented control algorithm, motor model-based controlled-system simulation, and extraction of actual values for the control loop. A speed/torque/frequency feedforward control has been integrated to improve the dynamic performance of the control. The bidirectional data exchange with the SINUMERIK 840D powerline via the drive bus is managed by a communication block.

The start-up tool automatically initializes optimum control settings. When the application requires positioning and high speed capabilities in one drive system, it is possible to operate 1PH motors in mixed main spindle/encoderless induction motor mode on one converter.

SIMODRIVE 611 universal HRS closed-loop control

The closed-loop control of the standardized induction motors is based on a powerful signal processor with current and speed controllers for operating encoderless standard induction motors. Excellent control quality is achieved through a field-oriented control algorithm, motor model-based controlled-system simulation, and extraction of actual values for the control loop. A speed/torque/frequency feedforward control has been integrated to improve the dynamic performance of the control.

Connection methods

A practical connection method increases electromagnetic compatibility and saves time on installation and wiring. To ensure that shielded cables are effectively contacted, pre-assembled shield contacting points are provided on the modules and/or in the system. Since signal and power leads should be routed separately when installing a control cabinet, the connection points on the SIMODRIVE 611 are located as follows:

• Power supply connectors or power terminals on the underside of the module, with line direction downwards
• DC link connection on the module front
• Unit bus and drive bus connections on the module front
• Measuring system connections and interface connections to machine control on the module front, with line direction upwards

The SIMODRIVE 611 has power supply connectors for connecting cables for lower power ratings, and power terminals for cables for higher ratings.

The interface connections in the form of clamp-type terminals can be optionally coded. Coded plug-in connections are provided on the front of the modules to allow additional external wiring of signal leads. The signal leads for the motor measuring system and the direct position measuring system are connected to the front of the module using subminiature D connectors.

A shielded drive bus cable provides the communication between the SINUMERIK 810D powerline/840D powerline/840C and the drive modules of the digital SIMODRIVE 611 system.

On the SIMODRIVE 611 universal HRS a communication link via PROFIBUS DP and the cyclic motion control system with PROFIBUS DP is possible. It is thus possible to use existing signal interfaces for solving drive tasks, i.e. positioning tasks, as well as applications involving cyclic interpolation.

This connection method, which is both captive and non-interchangeable, thus considerably simplifies installation, start-up and servicing.

Cooling

Depending on the application, module heat loss can be transferred to the environment using various cooling methods. Three different cooling methods are available for the modules. The modules differ primarily in the design of the module rear panel and the arrangement of the separate fan. The front panel with its connections and the module width remain unchanged.

Internal cooling

In this standard solution, the heat loss from the electronics and power sections of the converter components is removed by natural cooling or by a forced-ventilation system and routed to the interior of the control cabinet.

Hose cooling

The "hose cooling" option is directed at control cabinets with no separate ventilation channel for sizeable heat losses. Using flexible hoses, the dissipated heat from the specially prepared 300 mm (11.81 in.) modules is routed directly to the air surrounding the cabinet by a special fan unit.

In this drive combination, these modules are combined with smaller, internally cooled modules. IP54 protection can be attained at the "mechanical interface" to the outside air using hose-cooled systems.

External cooling

The modules' power section heat sinks pass through the mounting surface in the control cabinet and can thus release the heat losses of the power section to a separate external cooling circuit. The only heat dissipation that remains in the cabinet is emitted by the electronics. Degree of protection IP54 can be achieved at the "mechanical interface", the external heat sink.

The module-related heat sink cut-outs can be inserted directly in the mounting tier or rear panel of the control cabinet in accordance with the drawings shown in the planning instructions or, alternatively, they can be integrated in the control cabinet with the mounting frame specially designed for the modules and available as an accessory. In a large mounting plate cutout, the heat sink cutouts can be mounted modularly in a 50 mm (1.97 in) grid. For modules with a width ? 200 mm (7.87 in.), the separate fan and the air conduction panel are included with the module. For modules with a width of 300 mm (11.81 in.), the available fan boxes and external fans must be ordered separately.

Device bus

The device bus is a ribbon cable that leads via plug-in connectors from one module to the next. It carries the internal power from the central electronics power supply to the individual feed and main spindle modules and the special function modules. The main supply or monitoring modules also exchange fault and monitoring data with the other modules over the device bus.

Digital filter

Filter functions can be programmed in the torque setpoint channel of the drives. Filters with bandstop or low-pass characteristic offer settings for blocking frequency, transition frequency, and filter quality. These filters dampen oscillations produced in the control loop or by the transmission elements of the machine.

Direct power connection

With the use of high blocking-capability power transistors, the infeed/regenerative feedback module can be connected directly via a commutating reactor or a series connection of filter module and commutating reactor without the use of a transformer. The default setting is made using a simple coding switch and setting it to either direct regulated operation or regulated operation with regenerative feedback.

Electrical isolation

The drive group can be isolated from the supply by means of a mains contactor integrated in the infeed module. Potential energy can, however, remain stored for a short period of time in the DC link.

Electronics power supply

The electronic power supply to the closed-loop control modules is provided centrally for the drive group by the infeed modules, and is designed for the interconnection of several power modules. This means that a uniform concept can be devised, for example, to deal with power failures. An additional power supply in the form of a monitoring module can be used for larger drive configurations.

Enables

Three enabling signals/terminals are provided for enabling the drives. Terminal 48 "Start" has the highest priority and also switches the line contactor integrated in the infeed module directly. The terminal is also instrumental in determining the ON/OFF sequence. Terminal 48 can also be used to apply the central pulse disabling and enabling signals.

Terminal 63 "Pulse enable" has the highest priority for disabling and enabling pulses. The enabling and disabling commands take immediate and simultaneous effect on the power modules of all axes. When the signal is removed, the drives coast to a standstill with no electrical braking effect. The same applies to the axis-specific pulse enabling terminal 663 on the analog and digital control modules.

With the "drive enable" terminal, the controllers of all modules in the drive group are enabled or disabled simultaneously, or for specific axes via the "controller enable" terminals, with the "drive enable" terminal. The enabling signals can also be used to brake the axes, since the speed setpoint can be set internally to zero when these terminals are opened.

Gantry operation

In "Gantry operation" mode, two coupled machine axes are traversed synchronously via mutually independent axis drives. Only one axis is programmed, but both gantry axes traverse as if they were one. Several gantry axis pairs can be generated.

Gear range

> Parameter block switchover

The control parameters can be adjusted in the main spindle axes by switching over between up to 8 gear stages, thus allowing speed value standardization, torque limitation, speed and torque monitoring, and controlled system parameters to be adapted to the properties of the relevant gear stage.

I/Os

Analog and/or digital inputs and outputs are integrated in the SIMODRIVE 611 universal HRS systems in order to make it possible to pick up and process signals from the process.

Increment multiplication

Multiplication factors are provided on the drive side to allow actual values supplied by the measuring systems to be processed with greater precision in the CNC. A multiplication factor of 128 is available for the High-Standard closed-loop control. The High-Performance closed-loop control and -universal HRS/-universal E HRS (with sin/cos encoders) have a factor of 2048. The resolution for 2048 motor encoder marks results in over 4,000,000 pulses per revolution.

Integrator disable

Shorter positioning times can be achieved by switching off or deleting the integral component when positioning from higher speeds.

Limit frequency

The limit frequency is the maximum frequency at which correct operation can be guaranteed.

Mains buffering

The potential and kinetic energy currently stored in the DC link or in the mechanics can be used to maintain the power supply to the electronics. The duration of any possible mains buffering depends on the amount of energy currently available. This can be increased by implementing capacitor modules.

Mechanical couplings

A power or torque increase in main spindle or feed drives can be achieved by a mechanical coupling of two or more drive motors operating in parallel. For the "Torque division" function, a rigid mechanical coupling of the drives is required. One of the drive modules can be initialized to be the master and the other the slave module. The master module supplies the torque setpoint to be used by the slave drive(s) via a terminal. The slave function can, if so configured, be made selectable via the terminals.

Messages and alarms

The current status of the starting lockout relay is provided via the positively driven signal outputs according to module for evaluation in the control interlocks of the machine.

Messages and alarms are output to the screen display of the SINUMERIK 810D powerline/840D powerline. Additional support is provided by drive-specific service graphics, in which all drive-related data can be visualized, e.g.:

• Enables
• Ramp-up phases
• Monitoring Functions
• Motor temperature and heat sink overtemperature
• Terminal status of the starting lockout

Every status message and diagnostic message from the drives can be post-processed by the PLC of the SINUMERIK 810D powerline/840D powerline. The PLC can use a comprehensive set of status messages in an axis-specific data block. The PLC can control the drive. External wiring is minimized thanks to the digital drive bus between the SIMODRIVE 611 and the SINUMERIK 840D powerline.

On SIMODRIVE 611 universal HRS, PROFIBUS can be used for diagnostics. Diagnostics are supported by the SimoCom U software tool.

Modular design

Drive configurations with almost any number of axes and main spindles are made possible by the modular design of the SIMODRIVE 611 converter system. The DC-link power and motor size required determine which central modules for the mains supply infeed are needed. The SINUMERIK 810D powerline/840D powerline modules have been designed so that they can be smoothly integrated into the existing module network.

Monitoring of critical parameters

During operation, parameters and states can be monitored on the drive modules for violations of limit values. Parameters and states are e.g.:

• Motor temperature
• Heat sink temperature
• Speed, torque and current limits
• Values defined by the user

Digital system

In the digital system, limit violations are reported directly to the SINUMERIK 810D powerline/840D powerline, and can be post-processed there, for instance in the PLC. The signals must be processed in the machine interface controller.

Motion Control with PROFIBUS DP

> SINUMERIK 802D/840Di/SIMODRIVE 611 universal HRS/-E HRS/-POSMO SI/CD/CA

PROFIBUS DP

> SIMODRIVE 611 universal HRS

Parameter set changeover

> Gear stages

Various setting values of the control with up to 8 parameter sets are available for SIMODRIVE 611 main spindle controls, asynchronous motor modules, and for digital feed controls, such as:

• Speed controller parameters
• Filter settings
• Messages and monitoring functions
• Current and power limit

In the case of the main spindle controls of the analog system, the parameter sets can be selected externally via assignable-function terminals. In the digital drive system, the parameter sets can be switched via the SINUMERIK 810D powerline/840D powerline/840C. This makes it easy to adapt the control to changing conditions during machining, e.g.:

• Workpieces with different dimensions
• Changing a spindle head
• Switching between different monitoring limits dependent on machining

Parking axis/spindle

The "parking axis/spindle" function allows an axis or spindle to be immobilized so that a motor or encoder can be replaced without disconnecting the power.

Position detection, direct

Suitable measuring systems:

• Rotary encoders with sine/cosine-shaped voltage signals
• Linear scales with sine/cosine-shaped voltage signals
• Distance-coded measuring systems (SIMODRIVE 611 digital with CNC only)
• Measuring systems with sine/cosine-shaped voltage signals and EnDat interface (linear scales, single-turn and multi-turn encoders)
• Measuring systems with SSI (SIMODRIVE 611 digital with CNC only)

A direct measuring system is needed, for example, when a high degree of accuracy has to be achieved on the workpiece with a linear scale or exact positioning is required with a multi-stage gear.

SIMODRIVE 611 digital/universal HRS

The optional measuring system for position detection is suitable for the evaluation of incremental encoders with sine/cosine-shaped voltage signals. It is possible to connect linear scales and rotary encoders with sinusoidal voltage signals and distance-coded measuring systems to drive controls for operating 1FT6 and 1FK feed motors. The measuring signals supplied by the encoder system are evaluated with high resolution.

Position detection, indirect

SIMODRIVE 611 digital/universal HRS

When the SINUMERIK 810D powerline/840D powerline/840C and SIMODRIVE 611 are digitally linked, the measuring systems are connected to the digital control modules. The modules are equipped with the connection for the measuring system integrated in the feed and main spindle modules as standard. Together with the high-resolution position detection of the digital control modules, the integrated motor measuring system achieves a resolution of 4,000,000 increments per revolution (performance control). This makes an additional C-axis encoder unnecessary, even on the main spindle. The high-resolution actual position value can also be transferred to the CNC position control loops via the drive bus so that, given the right mechanical conditions, a direct table-top measuring system is no longer required. The same supplementary conditions apply to SIMODRIVE 611 universal HRS. The one difference is the drive link, which is established via PROFIBUS.

Positioning functionality

On the SIMODRIVE 611 universal HRS it is possible to store and execute traversing blocks automatically with the aid of the integrated positioning functionality. As many as 64 traversing blocks can be programmed for each axis.

Positioning to external zero mark

In spindle positioning mode, an external zero mark can be evaluated instead of the zero mark of the encoder.

Applications:

• One or several gear stages between the motor and the spindle
• No high precision requirements (e.g. M19 with mechanical indexing). In this case, it is possible to do without a spindle measuring system.

Ramp-function generator, programmable

The ramp-up and ramp-down time ramps can be set independently of one another. The ramp-function generator can also be bypassed by means of an assignable-function terminal (ramp-up time = zero). Separate ramp function generators can be set for each motor data block.

SIMODRIVE 611 universal HRS closed-loop control for synchronous motors with resolver

Feedrate controller with 1FK motors with resolver

This solution is intended for applications in which positioning accuracy is not a primary concern. The resolver encoder system integrated in the motor supplies the signals required by the control system, such as motor rotor position and actual speed, as well as an incremental shaft-angle encoder interface with TTL signals for external processing.

Setpoint smoothing filter

The current and speed setpoint filters (low-pass or bandstop) can be used to dampen drive resonance. The controller parameters can therefore be optimally adjusted to the mechanical characteristics of the machine, allowing the maximum dynamic capability of the control/drive system to be utilized.

Spindle positioning

SIMODRIVE universal HRS

In this drive system, the "Spindle positioning" function is integrated in the software and can be triggered via terminals.

Digital system

In the digital drive system, the spindle positioning function can only be triggered by the SINUMERIK 810D powerline/840D powerline.

Spindle power display

In digital systems, the spindle power is displayed directly on the monitor of the SINUMERIK 810D powerline/840D powerline/840C control in the form of a bar chart.

Start-up support

Digital system

To assure fast and easy start-up of the digital SIMODRIVE 611 drives and optimization of the control loops, a start-up software package is available on the PCU 50. The start-up software permits drive configurations to be initialized quickly and reliably on the basis of order numbers. Standard data blocks that are specially adjusted to the drives are loaded depending on the selected configuration. The set drive and control parameters are stored as data blocks in the SINUMERIK and are automatically available on every system restart. The data blocks can be duplicated via the PC/PG for identical machines.

Additional tools are available for optimization and diagnostics:

• Parameterizable function generator for traversing drives without CNC part program

User-parameterizable DACs (digital/analog converters) on the digital control modules for the output of any selected display and diagnostic values:

• Time-range measuring functions for optimizing current, speed and position controllers
• Frequency-range measuring functions for optimizing the entire controlled system and analyzing mechanical properties (resonance).

SimoCom U

The SimoCom U software provides a fast and easy start-up of the SIMODRIVE 611 universal HRS, as well as for optimizing the drive parameters for the relevant application. This software makes the generation, initialization and optimization of drive configurations easy and reliable.

Starting lockout

A starting lockout is integrated in every drive module to prevent accidental restart after the drives have stopped. The starting lockout blocks the power transistors with a circuit authorized by the German Employers' Liability Insurance Association. The circuit interrupts the energy supply to the motor (in accordance with IEC 60204). The starting lockout, in combination with a suitable external locking circuit, can be used to implement a machine control that complies with EN 954, Category 1 or 3, or subject to certain conditions even Category 4. The starting lockout can be used to provide the "Safe stop" safety function.

Storage of customer-specific setting data

Digital system

The closed-loop control software and the customer-specific data are stored centrally in the SINUMERIK 810D powerline/840D powerline/840C and loaded to the drive module designed for feed and main spindle applications during system power-up. This enables centralized data and software management, ensuring shared data administration and easy software updating.

SIMODRIVE 611 universal HRS closed-loop control

The closed-loop control software and the customer-specific setting parameters are stored locally on a memory card in each control. When servicing is required, devices can simply be replaced, all setting data remain on the memory card, and the drive is immediately ready for operation.

Synchronous spindle

The "synchronous spindle" function allows a workpiece to be transferred on the fly from the workspindle to the speed-synchronized and/or position-synchronized spindle. Workpieces can thus be machined without interruption.

Torque feedforward control

The torque feedforward control function can be applied to reduce contour deviations resulting from following errors. The feedforward control can be selected and deselected in the part program.

Travel to fixed stop

The drive can approach a mechanical stop on the machine with a defined motor torque in speed-controlled mode.

A contact force for the fixed stop selected specially for the machining process concerned can be input as an infinitely variable quantity via a limiting input for the torque or current setpoint. The controller monitor is deactivated when this function is selected.

V/F operation

Encoderless induction motors can be operated on the digital SIMODRIVE 611 universal HRS in the V/Hz mode. V/Hz mode is primarily intended for simple applications, i.e. with minimum start-up requirements and parallel connection of several induction motors on one power module, as well as for diagnostic purposes.

Weight counterbalance, electronic

The electronic weight counterbalance function makes it possible to fix a vertical axis without a mechanical compensating weight. An additional torque setpoint is injected to start the compensatory control immediately after the axis is enabled and ensuring that it is held in its position.