ADTECH Robotic Drive System ADT-RC400

Transcription

1 ADTECH Robotic Drive System ADT-RC400 User Manual (Servo Debugging for Pre-motion)

2 Information of manual Information of Manual This manual is edited By ADTECH (SHENZHEN) TECHNOLOGY CO., LTD. The editors of this manual: Jipeng Yang and Yan Chen. The version of this manual: V1.1.1 Copy Right All parts of this manual, property right owned by ADTECH (Shenzhen) Technology Co.,LTD (hereinafter referred to as) to all, without permission, no unit or individual is not any imitation, copying, copying or translation. Position this guide without warranty of any kind, expressed or implied. As mentioned by this manual or its product information, arising out of, directly or indirectly, information flow, loss of interest or career ending, and its employees will not take any responsibility. In addition, the products and information mentioned in this manual are for reference only, subject to updates without notice. All rights reserved, do not reproducing. ADTECH (SHENZHEN) TECHNOLOGY CO., LTD. I

3 Range of Manual This is the first manual of QC400 drive robotic control system concluding full description, drive control for the initial users, to help users select reasonable motor type; followed this specification for drive control electrical wiring between the machine and the robot in detail. II

4 Precautions Transport and storage Product package iteration of no more than six It is not available in the product box on the climb, stand or place heavy objects Cannot use drag the cables attached to the product or handling products No collision, scratching the Panel and display screen Product box should avoid wet, dry and the rain Opening inspection After opening the packaging please confirm whether you purchased the product Check whether the products in transit damage Control list identifies whether the part is complete, there is no damage Product model, lack accessory or transport damage, please contact with me Wiring To participate in connections and inspection personnel must have the appropriate skills for professionals Products must be reliable earthling, grounding resistance should be less than 4 ohms; you cannot use the neutral (zero line) instead of ground Wiring must be properly and firmly, so as not to lead to product failure or unexpected consequences And surge absorption diode must be connected in accordance with the regulations are connected with, otherwise you will damage Plug plugs or open the front of the chassis, you must cut off the power supply Maintenance Must cut off the power before repair or replacement of components Should check the fault when a short circuit or overload occurs, troubleshooting before they can restart Cannot pass off frequently, if required to re-apply after a power failure, separated by at least 1 minute Others Do not open the Cabinet without permission, Long when not in use, please cut off the power. To pay special attention not to let dust, iron powder into the controllers. Output relay if the use of solid state relays shall be freewheeling diode in parallel in the relay coil. Check if the power supply meets the requirements, put an end to the controller is burnt out. Life of the controller temperature has much to do with the environment, if the processing temperature is too high, please install the cooling fan. Controller working III

5 ambient temperature range between To avoid high temperatures, humidity, dust or corrosive gas environments. Shake strongly to add buffer rubber Rails. Maintenance Under normal conditions of use (environment conditions: average 30, load 80%, running 12 hours a day), please press the following items for routine checks and regular checks. Daily Check Period Check Daily 1 year Recognition of environmental temperature, humidity, dust and foreign bodies There are no abnormal vibrations, sound Substantial part is loose or not Terminal block damage Since the robot system is more complex, dangerous. The manual records and security-related precautions, please strictly observe transactions as recorded. Safety Precautions and mark Mark Danger note Mark meaning Use wrongly, it will lead to a dangerous situation, causing serious injury or death Use wrongly,it will lead to a dangerous situation that may cause personal injury or damage to equipment which caused material damage. Ban Absolutely unenforceable! Forcibly Must be implemented Danger Please do not use this system in the flammable and explosive environment. IV

6 Likely to cause injuries or fire. Please follow the instructions drawings or wiring. Prone to electrical shock and damage the motor. In an energized state, do not arbitrarily pull the plug, in the operating state; do not touch the robot operation site. Easy electric shock, causing personal injury. Energized state, not for wiring, maintenance and other operations, be sure to power at least 5 minutes before proceeding. Easy electric shock. Please be sure to take a reliable grounding between the drive and the robot body. When the fault occurs easily lead to electric shock, fire incident, easy to trigger errors. Non professional personnel, please do not open the drive and control one machine shell, please do not use hand to touch the drive and control of internal components Easy electric shock In the case of power, do not touch the power plug of the integrated machine. Easy electric shock. Please do not damage, the weight of cable or cable suspended load Easy electric shock V

7 The energized state, do not plug the drive terminal machine control on Easy electric shock and short circuit Running state, do not pull out the terminal on the one machine Easy electric shock and short circuit VI

8 Attention Please pay attention to the drive and control of the motor and the heat of the peripheral equipment. Easy to burn. When a fault occurs, the power supply is cut off, the cause is identified and removed, and the low speed running equipment should be removed. If there are adverse factors, easy to cause false action. When using the controller and the robot body, it cannot exceed the scope of its specification. Easily cause damage to the product. When the robot is moved, it needs to be fixed with the attached fixed tool. To prevent the lifting arm, due to accidents. The installation, operation, maintenance and inspection before, be sure to read the instructions carefully, according to the operating instructions in step. Easy electric shock, fire Power supply voltage, power capacity must be specified by the company's specifications. Improper use of equipment failure, easy to cause a fire. Please correct use of the correct control of each other to drive one machine and robot. Prone to failure VII

9 Should be regularly on the implementation of the robotics drive system maintenance and inspection operations. Neglect of maintenance and inspection is an important cause of equipment failure and accidents. Please do not put heavy objects on the product. Easily cause damage Please correct the wiring in the instruction manual. The wrong wiring way is easy to cause the robot or the drive control one machine damage or cause a fire. When an exception occurs, please stop. Easy electric shock, personal injury, fire Need to repair, please contact our company, please do not disassemble. Easy cause trouble. Do not impact Easy cause trouble VIII

10 Ban In the course of the robot's movement, no person is allowed to stand in the robot action area. There will be a major injury accident. Equipment to prevent the movement of the robot in the workplace. When the device is abnormal, it is easy to cause damage. The emergency stop switch on the handheld display device is prohibited. Robots in an accident or is not running properly, you need an emergency stop switch, stop operation of the equipment. There is no correct operation of the prohibition on the instruction manual. Incorrect operation will bring about the incorrect operation of the equipment. Other personnel outside the operating personnel to close to the equipment Touching the dangerous area can cause the injury or the major accident. When an accident, to cut off the power supply, clear reasons. When there are bad reasons, the robot may have a wrong action, causing adverse consequences. Users are prohibited to carry out parts of the exchange and transformation. Will reduce the system performance and may malfunction IX

11 Please do not remove the cleaning. Easy to cause fire, easy to get electric shock. Please don't make the product stored in the leaks, water, and other harmful gases in the environment. Prone to failure Forced! Please keep the sun out of the sun.! Easy cause trouble Please use the specified range.! Easily cause burn, failure Equipment protection cover must be shut off during operation.! Open the protective cover will have electric shock, the disabled. Operator to go through the full training.! Incorrect operation will cause the device to malfunction, resulting in disability or major disaster. If the robot is not in accordance with the specified direction of action, press the emergency stop, stop the equipment operation.! Accidents and failures. Power cord must be used with the specified wire.! Prone to fire and failure. X

12 Safety regulations Notification Before starting the run, we need to know all the tasks of robot in accordance with the program to be executed; Robots run in automatic mode, personnel are not allowed to enter any of its movement reach areas; When the need for programming, testing and maintenance work, the robot shall be placed under manual mode; When debugging personnel enter the robot work area, he shall carry a teach pendant, to prevent others from malfunction; When the robot does not work for a long time, the fixture should not place items; it shall be empty machine; After a power outage, the main power on the robot should shut down timely, and remove the clamp on the work piece. XI

13 Contents Contents INFORMATION OF MANUAL... I 1SOFTWARE INSTALLATION INSPECTION BEFORE DEBUGGING QUICK START INTRODUCTION OF THE PC SUITE COMMUNICATION CONNECTION PARAMETER MANAGEMENT UPLOAD PARAMETERS DOWNLOAD PARAMETERS CONFIGURATION OF BASIC PARAMETER CONFIGURATION OF MOTION MODE CONFIGURATION OF MOTOR S PARAMETERS CONFIGURATION OF PROTECTION PARAMETERS GAIN TUNING TEST OF ENCODER BEFORE TUNING COMMUTATION TUNING GAIN TUNING Tuning of Current Loop Tuning of Velocity Loop Tuning of Position Loop PRE-MOTION ERROR ALARM OF SERVO AND HANDLING XII

14 Debugging Process You must tune some servo parameters for pre-motion before using QC400 robotic drive system. If servo parameters have tuned before, you can download these parameters to drive system directly, and then have a pre-motion. If not, you have to tune servo parameters with following steps strictly. Without Servo Parameters Software Installation With Servo Parameters Software Installation Communication Communication Parameters Setting Downloading Parameters Commutation Run Curr\Vel\Pos Tuning Run Notice In the following figures, marks such as represent execution order. XIII

15 1.1 Inspection before Debugging 1.Software Installation For security and efficiency, some aspects should be checked before debugging. (1) State of servo motor Check fixed parts of motor to make sure that all the wires are connected well. Check the encoder wire and power wire of motor whether they are connected correctly. (2) State of robotic drive system Check the internal power of QC400 to make sure that it has the normal power supply. Make sure that the encoder and power wire are connected well with QC Quick Start This part is a quick tour of the PC suite to explain some of the basic concept and get used to navigating the software. This part can be done without a controller or a running system. Operating System Windows 7 32 位 Windows 7 64 位 ; Windows XP Screen Resolution The PC Suite requires display with a resolution of at least Even with resolution, you will need to Auto-hide the windows task bar to conveniently access the main menu. Resolutions of or higher are recommended. Installation The steps of Installation are shown in the following diagram. 1

16 Close the Antivirus Software of the Computer Unzip Debugging Package Install Microsoft.NET Framework4.0 Install Drive Program(Serial Drive USB Drive) Tes t whet her th e drive is installed s uc ce s sf u ll y b y Help *1 Double Click AgitoPCSuite.exe Help*1 Normally, we can test whether the drive is installed successfully by checking the existence of terminal. You need to re-install the serial and USB drives if the terminal can not be detected. The specific approaches of examining are listed based on your operating system: (1) Window XP system: Right click My Computer icon Left select Device Administration Left select Terminal (To check COM port); (2) Window 7 System: Right click Computer icon Left select Device Administration Left select Terminal (To check COM port). Depending on your PC s security settings, you may receive a request for permission (for first time execution of the installed software). Please allow PC Suite access to the requested resources. Two applications will open: QX Communicator 2

17 QX PC Suite Leave both of them open. The OX PC Suite firstly opens with a warning message. Please read it carefully and click OK. Notice The software interface may appear incomplete phenomenon if screen resolution is too low. Do not close the communication interface when using debugging software. 1.3 Introduction of the PC Suite The QX PC Suite window of QC400 Robotic Drive system as follows: 3

18 Current Tool Operating Button Language Favorite Tool Recent Tool Main Menu Information The window is made of a frame and the contents. The frame always has the same parts and the contents changes according to the tool selected by the user. Then several specific parts will be introduced. The operating button performs the following functions: Save all parameters to the controller Flash memory. Load all parameters from the controller Flash memory. Kill all the axes and servo off. Select axis drop down menu. Main menu In the main menu you can see all available tool sets, and each is represented by an icon at a given color. The tool sets are arranged from left to right by the most probable order which they should be used when setting up a new system. Clicking the below an icon of a tool set at the main menu, the sub-menu will display. The detail function of each tool will be introduced in the later chapter. 4

19 Left menu bar The left menu bar is used to personalize the display to the convenience of the user and to enable easy and fast access to frequency used tools. The lasted tools and favorite tools are displayed in the left menu bar. The latest tools are automatically displayed in the recent menu and the favorite tools are displayed by right clicking button on any tool to pin them. At the same time, the icon of current tool is also appeared on the upper left corner of the PC Suite frame. Right click on this icon to invoke a context sensitive menu, which includes Pin to Favorite, More Info, View: Terminal Only, View: Terminal with Status and View: Terminal with Statuses and Data Recording. Different views may be required depends on the user and the specific task. Current tool 5

20 Pin to Favorite: Set the current tools to the favorite ones. More Info: It contains more information; View: Terminal Only Only terminal is displayed; View: Terminal with Statuses Only statuses are displayed on the terminal; View: Terminal with Statuses and Data Recording Upper-left of the frame displays statuses, below-left displays terminal and right displays data recording. Favorite tools Right-click them, four operations can be performed as follows: Recent tools They have the similar operations as the favorite tools. Info You can click Info (at the button-right corner of the PC Suite frame) to receive information about QX PC Suit. The information of PC Suite, communication channel and connected controller will be displayed in this frame. 6

21 7 Servo Debugging for Pre-motion

22 2. Communication Connection Servo Debugging for Pre-motion You should connect the serial port with PC to realize the communication before debugging servo. The defined connections are listed in the upper-left of the frame and the QX PC Suite will detect the COM ports automatically. Then you can select a connection based on your specific task. Important Notice You should first connect the PC with QC400, then open the QX PC Suite software, if not, the QX PC Suite cannot detect the COM port. In this case, user should close the QX PC Suite software, and then open it again. In case of failure, you will receive a red message (in the following figure), please act according to the provided information and try to re-connect. Repeated failure means that you need to check your definitions, as well as your hardware and cables. Notice One DSP core board controls four motor in the robotic drive system. You should refer to Electrical wiring COM1 Port to complete wiring when 6-axis robotic drive system is debugged. The QX PC Suite can detect front four axis when 2#DSP_RX and 2#DSP_TX are connected, or it can detect the other two axis when 3#DSP_RX and 3#DSP_TX are connected. If the QX PC Suite cannot automatically detect the serial port, the user should configure the communication port manually according to the following order as the below figure 8

23 shows: 1 Defined by users 2 Consult PC/Device Administrator/C OM 3 Click this button 4 After test successfully, click Add button, then click Apply Changes to complete the configuration of communication. 9

24 10 Servo Debugging for Pre-motion

25 3.1 Upload Parameters 3 Parameter Management Servo Debugging for Pre-motion In case of the data in the RAM and Flash overwritten, you can use the Management/Parameters tool to read all the current parameters and save them to a file on your PC. In this case, a single set of parameters can be used in multiple controllers for saving a lot of time. You can do as the following steps shows: Click, then Select Click Browse in Upload parameters window, then choose the save path of parameters Click Upload Parameters button After uploading completely, click OK 11

26 The specific approaches can be followed as the orders are listed in the below figure. Path and name of file are defined by users 1 Upload Progress Download Parameters The parameters of specific file are written to robotic drive system. The robotic drive system is required to be re-power after downloading parameters, then it can run directly without tuning servo parameters. 12

27 Click,select then enter the window of parameter management Click Confirm at right corner,then click OK after download completely Click Brown in Download parameters window, then select the file of download parameter Tick off Save to flash after download and Perform CalcFilter after download Click Download Parameters The following figure shows the specific steps: 13

28 Choose the path of file 1 Downloading Progress Notice Upload and download parameters only work in case of communication successfully. 14

29 Relevant explanations regarding to parameter files: Types of upload and download files are.par; Structure of file is made up of product type, upload data and version; You can change the file, or build your own files. 15

30 4. Configuration of Basic Parameter Servo Debugging for Pre-motion Basic parameter configuration mainly includes parameter configuration of motion mode, parameter configuration of motor and parameter configuration of motor s protection. Before setting these parameters, you need to choose axis one by one. 4.1 Configuration of Motion Mode Click, select enter window of motion mode configuration. Select control mode Other options are default values Click Apply Changes,then Save to Flash Select the control mode according to your own requirement. Generally, Position- Control mode is mainly applied. 16

31 4.2 Configuration of Motor s Parameters Parameter settings mainly include: motor type, number of pole pairs, encoder type, encoder resolution and other information. Click,Select enter the window of motor parameters Click Apply Changes,then Save To Flash Configuration of motor s parameters Specific configurations are as follows: Configuration of main encoder s paramters Other parameters are default values 17

32 1 The relationship between motor type and number of pole pairs refer to [Table 1] 2 Select the appropriate information of encoder based on use of the motor [Help *2] 3 4 table: Types of rotary motor corresponding to number of pole pairs are listed in the following Table 4-1 Common motor types and number of pole pairs Motor Type 17-bits Absolute encoder motor of Pole Pairs 5 Sanyo Panasonic Motor 4 Tamagawa Motor 4 Adtech Motor 4 Help*2 According to the information of the motor and encoder, select the type of main encoder. 18

33 5 17 bits absolute motor of Nikon(Sanyo); 6 20-bits incremental motor of Panasonic; 7 17-bits absolute motor of Panasonic; 10 Incremental and saving wire motor of Tamagawa; bits incremental motor of Tamagawa; bits absolute motor of Tamagawa; The relationship between resolution and encoder s bit is N 2,where N is the number of encoder s bit. Table 4-2 Encoder s bits and resolution of common motors Bits of Encoder Resolution 2500-wires bits bits

34 4.3 Configuration of Protection Parameters It will lose control of the motor by mistake during debugging. So we need to set the relevant conditions for protection to reduce the risk. Click enter,select window of protection parameters Maximal errors Set PWM limitations Motor stuck Current limitations and protections Other parameters Velocity/Acceleration are default values limitations Click Apply Motion limitations Changes,then S ave To Flash 20

35 The specific configurations are as follows: 1 Default 2 Rated Current on Motor Nameplate 3*Rated Current Default 4.2*Rated Current 4.2*Rated Current 3 Specific Conversion referred to Formula 1 Rated Speed 10*Rated Speed 4 Default Default

36 5 Help *3 Less than rated current 6 0.5*resolution Default Default 22

37 Formula 1 Unit is user-units/sec The conversion relationship is n(r/min)/60* 2 N where N is the number of encoder s bits For example, the maximal allowed velocity is 3000r/min and encoder s bits is 17, then the corresponding value of PC should be set as: n(r/min)/60* 2 N =(3000/60)* = user-units/sec Help*3 Maximal errors Maximal errors contain maximal allowed position errors and maximal allowed velocity errors. At the beginning of debugging, both of them should not be set too large in case of losing control. After completing debugging, they can be set 2~5 times of actual position errors and actual velocity errors respectively. The begin values are set as and the specific values can be updated according to the detected values. Motor stuck Minimal current to activate protection is set according to actual requirement, which is generally a litter less than rated current. Maximal velocity of define stuck is set based on actual requirement. Maximal time allowed in stuck is also set based on actual requirement. So system will create alarms when the velocity of motor is less than maximal velocity of define stuck, current is more than minimal current to activate protection and duration is bigger than Maximal time allowed. 23

38 5.1 Test of Encoder before Tuning 5 Gain Tuning After the basic parameters having been set, users have to use the QX PC Suite software to monitor the internal wiring of servo encoder to check whether it is correct. The specific test way can be followed as: Click,select The encoder wiring enter the window of PTP is correct if P1-P2 is not 0 Record current position P1 Move the corresponding manipulator by hand Then record the position P2 after moving (1) Select icon in the main menu of QX PC suite, then click mode. (2) Select the current axis needed to be detected, and record current position of this axis (Assume as P1). (3) Rotate robot s arm which corresponding to the selected axis with an angle, then record a new position (Assume as P2). (4) Determine whether P1 is equal to P2. If P1 is not equal to P2, you decide preliminary that there is no wrong with encoder, then execute next step by order. In turn, QX PC Suite cannot detect the signal of encoder, which shows that there is some wrong with encoder wiring or the selected type of encoder is incorrect. Then you need to check the encoder wires until that encoder s pulse has changed with different positions. After that, you can continue subsequent debug. The other three axis have same way as the first axis has done. 24

39 Important Notice The motor with brake cannot detect with this method. 5.2 Commutation Tuning QC400 robotic drive system supports several types of motor and encode. There are different commutation modes for different types of encoder. Table 5-1 Commutation mode and features Commutation mode Applied objects Execute features After setting parameters, click Perform 0-Jump To Zero Phase Commutation then Motor On. All the encoders After setting parameters, click Perform 1-Jog Mode 2-Absolute encoder with predefined offset 3-Incremental encoder(with Hall) Notice Absolute encoder Incremental encoder with Hall Commutation, then motor jog. Using 0-Jump to zero phase commutation mode to generates an updated value with 0 degrees, then click Refresh button and Apply Changes Generally, incremental encoder selects 1-Jog commutation mode and absolute encoder selects 2-Absolute encoder with predefined offset. The test way of motor s commutation is as follows: 25

40 Click icon, select Set commutation mode, then to enter the window of commutation click Apply Changes and Save To Flash Set main encoder resolution and Motor poles pairs Set commutation mode, time and gain Click Perform Commutation, and then click Refresh Assume that the encoder s type of motor is 17-bits absolute encoder, the commutation order of motor is listed as: Main encoder resolution(131072) Motor poles pairs(4) Commutation mode(0-jump To Zero Phase) Commutation time(1500ms) Motor enabled and run a certain angle, a few seconds after the display and motor shut down Completed Increment(4) Perform Commutation(Commutation status is Not Completed when start to perform commutation, then motor enabled and run a certain angle with a few seconds, at last the commutation state displays Completed and motor shut off) Refresh(a number between 0 and will display) commutation mode changes as 2-Absolute encoder with predefined offset Apply Changes Save To Flash. Specific steps of commutation are ordered in below figure as follows: 26

41 First Choose 0 Then choose 2 after refreshing Notice If motor do not move when find the commutation angle at first time, you should rotate motor manually to find the commutation angle again. Moreover, you should find 0 o position of motor several times for security in case of bringing bad influence. Test results of several commutation angles are as follows, which is based on types of motor s encoder supported QC400 robotic drive system. Table 5-2 Types of common motor and their commutation angles Motor Types 17-bits incremental and absolute Commutation Angle motor of Tamagawa 2500-wires motor of Panasonic bits incremental motor of Panasonic 17-bits absolute motor of Panasonic 17-bits incremental and absolute

42 motor of Gert 17-bits absolute motor of Sanyo Having known the commutation angle of motor, users can set this angle directly in tuning of commutation mode. Approaches of commutation tuning are set as: Click icon,select Select Commutation mode based on motor s to enter the window of commutation tuning type, then Apply Changes and Save To Flash. Set commutation mode as 0 Write the commutation angle at Absolute enc.reading at 0 item Click Apply Changes,then click Save To Flash 5.3 Gain Tuning After find the right 0 degree of the motor, you can adjust control parameters of robotic drive system. The robotic drive system includes three loops from inside to outside, which are current loop, velocity loop and position loop. In order to control the servo motor accurately, parameters of three loops are needed to be tuned one by one. 28

43 5.3.1 Tuning of Current Loop Click icon,select Choose one axis in Select axis list, then choose given current (CurrRef) and actual to enter window of current loop current. At last, click Apply Changes Click Current Command icon Click Trigger to set triggering conditions of the oscilloscope Click Current Tuning icon, then set Set the type, amplitude and frequency of current command Current PI, gain and Current PI, integral. At last, click Apply Changes and Apply Current Command Click Data Collection, then select General in window of Oscilloscope Click Start Recording and Show Graph to observe waveform of given and actual current. Then change PI to obtain the best effect. Set Recording period and Recording gap Click Disable Current Command to stop motor, then click Apply Changes and Save To Flash Click icon to enter debugging window of current loop as follows: 29

44 State Window of Motor Running Window of Oscilloscope Tuning Window of Current Loop The debugging window of current loop are made up of three parts, which are state window of motor running (display the states of motor running), tuning window of current loop (set current command, current gain and PI) and window of oscilloscope (observe the situation of actual current following given current). Based on the process of current loop, the configuration of specific parameters of current loop and steps of debugging are shown below. (1) Current Command Click Current Command icon to set corresponding parameters as follows: Square Wave 20%-30% of Rated Current Frequency 50~80Hz After setting completely, click Apply Changes, then Save to Flash. 30

45 (2) Setting of Oscilloscope window Waveforms of CurrRef and MotorCurr are observed when executing the tuning of current loop. Set Recording period as and Recording gap as Owing to QC400 robotic drive system with four axis, you should tune each axis by order (A\B\C\D). Specific approaches are: click Data Collection General Recording period (0.448s) Recording gap (0.122) select axis from Selected axis item select Current in Select message category Add select MotorCurr in Select message: Add Apply Changes. Specific orders are listed in the following figure: 2 3 Default Default Select CurrRef and MotorCurr Select Current

46 Notice Number of sampling points of QC400 is less than 8000 an, the oscilloscope window can record up to four variables. (3) Setting of trigger condition Click Trigger icon to set corresponding parameters of trigger, and configuration of interface is as follows: 2 3 Default Default Select CurrRef and MotorCurr Select Current 7 1 (4) Tuning of current loop Once complete the configuration of oscilloscope s parameters, click Current Tuning icon to set values of Current PI, gain and Current PI, integral which should be set from small to large. 32

47 2 3 Default Default Select CurrRef and MotorCurr Select Current 7 1 When P = 100 and I = 50, waveforms of current loop are plotted as: 33

48 Current Loop: P=100,I=50 Given Signal: Ref Feedback Signal As shown above, red line represents CurrRef and green line represents MotorCurr. From the above figure, it shows that feedback signal is far less than the given signal, P and I of current loop should be increased to obtain better performance. Analysis: It is needed to increase P to obtain higher current response Analysis: The oscillation is greater, which means that it is needed to increase I appropriately Current Loop: P=900,I=550 34

49 Current Loop: P=1100,I=580 The wave has already met the requirement on account of load. At this moment, you had to analyze the performance of current loop to avoid affecting the tuning of velocity and position loop. 35

50 Put the thin gray line at the stable place Place the thick gray line where it coincides with red line Two gray lines will be in the picture if you choose this item. Right-click the waveform, you can select corresponding operations according requirements. Commonly: Zoom X zoom the graphics in X axis; Zoom Y zoom the graphics in Y axis; Show vertical markers two vertical rulers appear, Show horizontal markers two horizontal rulers appear ; Reset Graph recovery acquired waveforms. And then properly use this analysis tool: 36

51 Finally, after clicking Analysis button, the following analysis result will be displayed, showing the calculated bandwidth, damping and other information. Notice The tuned parameters should be saved to flash after finishing current loop debugging. 37

52 5.3.2 Tuning of Velocity Loop Click icon, select to enter interface of velocity loop. Choose one axis in Select axis list, then choose given current (CurrVel) and actual position. At last, click Apply Changes Click Vel.Command icon Click Trigger to set Set type, amplitude and frequency of velocity command triggering conditions of the oscilloscope Click Vel.Tuning icon, then set Click Filters icon, then tick off LPF1 to set frequency and damp Velocity PI, gain and Velocity PI, integral. At last, click Apply Changes and Apply Velocity Command Click Data Collection icon, then select General Click Start Recording and Show Graph to observe waveform of given and actual velocity. Then change PI to obtain the best effect. Setting Recording period and Recording gap Click Disable Velocity Command to stop motor, then click Apply Changes and Save To Flash Click icon to enter the interface of velocity loop. Parameters configuration of velocity loop and approaches of debugging can be followed with following steps: (1) Setting of Velocity Command 38

53 follows: Click icon, then select Vel.Command icon. Some parameters are set as 2 3 Default Default Select CurrRef and MotorCurr Select Current 7 1 After finishing configuration, click Apply Changes, then Save to Flash. (2) Setting of Oscilloscope Window Waveforms of VelRef and Vel are observed in oscilloscope window when tuning of velocity loop is executing. Set Recording period as 1 and Recording gap as 1. Owing to QC400 robotic drive system with four axis, you should tune each axis by order (A\B\C\D) with A first. Specific approaches are: click Data Collection General Recording 39

54 period (1) Recording gap (1) select A axis from Selected axis item select VelRef in Select message category Add select Vel in Select message: Add Apply Changes. Specific orders are listed in the following figure: 2 3 Default Default Select CurrRef and MotorCurr Select Current 7 1 After finishing above configuration, click Apply Changes, then Save to Flash. (3) Setting of Trigger Condition Click Trigger icon to define variables and set their values which are used in trigger. Trigger condition is defined according to actual requirement. Interface of configuration is as follows: 40

55 2 3 Default Default Select CurrRef and MotorCurr Select Current 7 1 (4) Setting of Filter Click Filters icon in the Velocity Control to enter tuning interface of velocity loop. Specific configuration and steps are shown in below figure: 41

56 2 3 Default Default Select CurrRef and MotorCurr Select Current 7 1 Filtering velocity signals of encoder s feedback and given. Cut-off frequency is adjusted appropriately according to the waveforms of feedback and given observed in oscilloscope. (5) Velocity Tuning After settings of filter, click Vel.Tuning icon to enter the velocity loop interface. Then set gain and integral of the velocity loop, which should be set from small to large. Approaches of velocity tuning is similar with current tuning s. 42

57 2 3 Default Default Select CurrRef and MotorCurr Select Current 7 1 The waveforms of velocity loop without filters are shown below. It can be seen that the waveform of actual velocity has significant interferences. 43

58 Considering the bad performance shown in above figure, a better waveform is obtained after adding filters: At this moment, the velocity tuning has basically completed. The gain of velocity loop should be increased appropriately when the system has a load. Obtained good parameters of velocity loop are advised to be saved to flash. 44

59 5.3.3 Tuning of Position Loop Click icon, select Choose one axis in Select axis list, then choose given current (CurrVel) and actual to enter interface of position loop position. At last, click Apply Changes Click Trigger to set triggering Click Pos.Command conditions of the oscilloscope Click Pos.Tuning icon, then set Set the type, amplitude and frequency Position PI, gain and Position PI, integral. At last, click Apply Changes and Apply Position Command Click Data Collection icon, then select General Click Start Recording and Show Graph to observe waveforms of given and actual velocity. Then change P to obtain a better effect. Setting Recording period and Recording gap Click Disable Position Command to stop motor, then click Apply Changes and Save To Flash Click icon to enter the interface of position loop. Parameters configuration of position loop and approaches of debugging can be followed with following steps: (1) Setting of Position Command Click Position Command icon in Position Control interface to set corresponding parameters in following interface: 45

60 Select Square wave About Hz After finishing configuration, click Apply Changes, then Save to Flash. (2) Setting of Oscilloscope Window Waveforms of PosRef and Pos are observed in oscilloscope window when tuning of velocity loop is executing. Set Recording period as 1 and Recording gap as 1. Owing to QC400 robotic drive system with four axis, you should tune each axis by order (A\B\C\D) with A first. Specific approaches are: click Data Collection General Recording period (1) Recording gap (1) select A axis from Selected axis item select PosRef in Select message category Add select Pos in Select message: Add Apply Changes. Specific orders are listed in the following figure: 46

61 2 3 Default Default 4 Select Pos and PosRef 6 5 Select Position 7 1 After finishing above configuration, click Apply Changes, then Save to Flash. (3) Setting of Trigger Condition Click Trigger icon to define variables and set their values which are used in trigger. Trigger condition is defined according to actual requirement. Interface of configuration is as follows: 47

62 2 3 Default Default Select CurrRef and MotorCurr Select Current 7 1 (4) Tuning of Position Loop Only gain (P) is applied in position loop. Try to increase the P value to increase the responsiveness of the system without overshoot. However, the actual gain should be set according to requirements. 48

63 1 3 2 For example, debugging effect of position loop is shown below: For practical applications, gain of position loop should not be set too high, particularly in the industrial robotic occasions, because the high gain of position loop may cause arm jitter. 49

64 6 Pre-motion The motor need to have a pre-motion once the configuration of basic parameters and debugging are completed. Since each arm of industrial robot has the limitation stroke range, the point to point movement could be used to test the effect of debugging. Click icon,select Click Go 1 Rep or Go 2 Rep, to enter the window of Point to Point motor will move from the current position to the target reciprocally Click Point to Point icon, then set relevant parameters Further optimize parameters of current loop according to the states of point to pint monitored in the oscilloscope window. Click Go 1, then motor can arrive the goal 1 from the current position. Further optimize parameters of velocity and position loop as well as Click Go 2, then motor can arrive the goal 2 from the current position. Debug completely, then click Apply Changes and Save To Flash Click set parameters in the following figure: icon to enter the debugging window, then select Point to Point icon to 50

65 Select Square wave About Hz Acceleration: unit is user-units/sec^2,which is usually set 5~10 times of speed. Deceleration: unit is user-units/sec^2,which is also usually set 5~10 times of speed. Speed: unit is user-units/sec Assume that speed= user-units/sec and bits of encoder is 17 then convert to common unit of motor with a equation: /131072*60=460r/min Repetitive wait: the waiting time is from one cycle to next cycle. Target1 : unit is user-units Target2: unit is user-units Both speed and acceleration are should be set a litter smaller during preoperation. After completing configuration, click Go 1 or Go 2 to run the motor. If no alarms appear during pre-motion process, the values of speed and acceleration can be set larger, or exclude alarms to continue debugging. Notice Set reasonable values of goal 1 or goal 2 according to motion range of each axis in case of collision. Further optimize the parameters of current loop according to the state of actual current following given current which is monitored by oscilloscope. Below figures show the comparison between before optimizing and after. 51

66 52 Servo Debugging for Pre-motion

67 7 Error Alarm of Servo and Handling QC400 robotic drive system has set a serial of protections regarding to driver and motor. There are inevitably some alarms during debugging. User must to exclude alarm once they have appeared in order to fulfill the following debug. Alarm contents of current axis can be observed directly from status of QX PC suite software. tables. Common alarms of servo and corresponding processing ways are listed in the below 1) Position error is over limitation Cause of the alarm Maximal allowed position error is set too small. Gain of position loop is incorrect. Processing way Increase the maximal allowed position error appropriately. Adjust the gain of position loop. high. Acceleration or deceleration is too Decrease values of deceleration. acceleration or QC400 is wrong connected to UVW phase of the motor. Abnormality of internal circuit in Check the connection state of UVW between motor and QC400. Change internal circuit of QC400. QC

68 2) Velocity error is over limitation Cause of the alarm Maximal allowed velocity error is set too low. Gain of velocity loop is set incorrect. QC400 is wrong connected to UVW phase of the motor. Encoder s wires of QC400 are Processing way Increase the maximal allowed velocity error. Adjust parameters of velocity loop (mainly modify gain) Check whether the connection of power cable is wrong or loose. Change internal circuit of QC400. damaged. Shield wire of 72-pins overload connector is not connected. wires. Check the connection state of shield 3) Temperature of motor current is too high Cause of the alarm Maximal allowed motor current is set too small. The electrical angle of motor is found incorrectly. QC400 is wrong connected to UVW phase of the motor. Acceleration or deceleration is too high. Load is too heavy and power is too low Processing way Increase the maximal allowed motor current appropriately. Re-execute commutation to find the correct electrical angle. Check whether the connection of power cable is wrong or loose. Decrease values of acceleration or deceleration. Change a motor with higher power (Considering maximal power of QC400). 54

69 4) Main encoder is not connected Cause of the alarm Connection of motor encoder s wires is wrong. The type of selected encoder is incorrect. Processing way Check the connection between motor s encoder and QC400 s. Modify the type of encoder in the window of motor parameter. 5) Alarm of IPM module Cause of the alarm Encoder s wires of QC400 are Processing way Change the wires of internal encoder. damaged. The temperature of QC400 s drive Cut off power supply to drop temperature. module is too high. Abnormality of QC400 s internal Check the module of drive board. drive board. Configuration of servo parameters is Check the values of servo parameters. set incorrect. 6) Motor stuck Cause of the alarm The stuck does not open when the Open this stuck. Processing way motor has this stuck. The value of motor stuck is wrong set. Modify the value of motor stuck in the window of protection parameters. Load is too heavy and power is too Change a motor with higher power low. (Considering maximal power of QC400). 55

70 7) Female voltage is too low or too high Cause of the alarm Abnormality of power connection or Processing way Check internal wires. internal power supply of QC400. Abnormality of QC400 s internal drive Check the module of drive board. board. 8) Failure of commutation Cause of the alarm The commutation mode is set wrong. The selected encoder is not match with the actual encoder. The set motor poles pairs are not match Processing way Select correct commutation mode. Change the type of encoder in the window of motor parameter. Change the motor poles pairs. with the actual. Commutation time is incorrect. Change commutation time. 9) Alarm of communication connection error under the motor enabled incorrect. Cause of the alarm Configuration of commutation tuning is Processing way Select the correct commutation mode according to the encoder type (incremental encoder Option 1 jog mode; absolute encoder Option 2 - Absolute Encoder preset angle) during the commutation tuning. 10) Alarm of battery s low voltage Cause of the alarm The voltage of battery inside the Processing way Change a new battery. encoder is too low. 56

71 11) Failure of calculate filter Cause of the alarm Not perform calculations or unsuccessful filter after modifying filter. Processing way Close motor enabled and re-execute the calculation filters. 12) Temperature alarm Cause of the alarm Protection temperature of the robotic drive system is wrong. The temperature inside the robotic drive system is too high. Processing way Change the value of maximal allowed power unit temperature. Cut off power supply to drop temperature. 13) Overload alarm Cause of the alarm Processing way The continuous limitation of the Set the continuous limitation of current current which is in protection parameters is as the rated current of this axis. wrong set. Load is too heavy and the power of motor is too low. Change a motor with higher power (Considering maximal power of QC400). 14) Phase current is too high Cause of the alarm Protection parameters are set Processing way Modify the maximal phase current. incorrectly. QC400 is wrong connected to UVW phase of the motor. Check whether the connection of power cable is wrong or loose Notice If you cannot solve the alarm problems, please contact our company immediately. 57