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Evaluation of CNC Controllers in MillingMachines-Relationship Between Dynamic
Capability, Productivity and Cost-Edición Única
Title Evaluation of CNC Controllers in Milling Machines-RelationshipBetween Dynamic Capability, Productivity and Cost-Edición Única
Issue Date 2005-12-01
Publisher Instituto Tecnológico y de Estudios Superiores de Monterrey
Item Type Tesis de maestría
Downloaded 25/05/2018 11:33:37
Link to Item http://hdl.handle.net/11285/567191
INSTITUTO TECNOLÓGICO Y DE ESTUDIOSSUPERIORES DE MONTERREY
CAMPUS MONTERREY
DIVISIÓN DE INGENIERÍA Y ARQUITECTURAPROGRAMA DE GRADUADOS EN INGENIERÍA
ff TECNOLÓGICO
DE MONTERREY
EVALUATION OF CNC CONTROLLERS IN MILLINGMACHINES - RELATIONSHIP BETWEEN DYNAMIC
CAPABILITY, PRODUCTIVITY AND COST
TESIS
PRESENTADA COMO REQUISITO PARCIALPARA OBTENER EL GRADO ACADÉMICO DE:
MAESTRO EN CIENCIASCON ESPECIALIDAD EN SISTEMAS DE MANUFACTURA
POR:FERNANDO DAVID REYES LUNA
MONTERREY, N.L. JUNIO DE 2005
INSTITUTO TECNOLÓGICO Y DE ESTUDIOSSUPERIORES DE MONTERREY
CAMPUS MONTERREY
DIVISIÓN DE INGENIERÍA Y ARQUITECTURAPROGRAMA DE GRADUADOS EN INGENIERÍA
Los miembros del Comité de tesis recomendamos que la presente Tesis del Ing.
Fernando David Reyes Luna sea aceptada como requisito parcial para obtener el grado
académico de Maestro en Ciencias con especialidad en:
SISTEMAS DE MANUFACTURA
COMITÉ DE TESIS
Dr. Ciro A. Rodríguez GonzálezASESOR
Dr. Horacio Ahuett Garza Dr. Nicolás Hendrichs TroeglenSINODAL SINODAL
APROBADO
Dr. Federico Viramontes BrownDirector del Programa de Graduados en Ingeniería
Junio de 2005
DEDICATORIA
A mis padres Claudio y Aracely,
por su apoyo incondicional, confianza y cariño
pero sobre todo por ser el ejemplo de mi vida.
A mis hermanas Claudia y Pochi,
a mi familia y amigos
por siempre creer en mi.
ni
AGRADECIMIENTOS
A mi asesor, el Dr. Ciro A. Rodríguez González, por su guía, buenos consejos y
sobre todo paciencia durante la realización de esta tesis.
A mis sinodales, el Dr. Horacio Ahuett Garza y el Dr. Nicoás Hendrichs Troeglen
por su participación en el comité de tesis y por sus atinados comentarios y sugerencias.
Al Ing. Miguel de Jesús Ramírez por su apoyo, motivación y confianza, pero
sobre todo su amistad.
Al Departamento de Ingeniería Mecánica del ITESM, por el apoyo de beca
brindado para la realización de mi maestría.
A la Cátedra de Investigación en Mecatrónica del ITESM, por financiar parte de
mi colegiatura.
A mis compañeros de estudio y trabajo: Eva Delgadillo, Victor Flores, Alejandro
Martínez, Francisco Jasso, Esteban Suárez, y Gabriel Soto, por su amistad y apoyo.
IV
LIST OF FIGURES
Figure 1. Example of machine tools with different price ranges and their cost drivers 1
Figure 2. Machine tool cost tends for productivity and capability [Adapted form Amone; 1998]. 2
Figure 3. Controller architectures for different markets 6
Figure 4. Three level classification scheme for controllers, actuators and mechanism 7
Figure 5. Block processing times and prices of different controllers 8
Figure 6. Different motor types with their corresponding drives 9
Figure 7. Balls Screws accuracy performance for three levéis 10
Figure 8. Different bearing systems with their corresponding friction valúes 11
Figure 9. Taxonomy of VKM3 and VM16 machines 11
Figure 10. Application requirement comparison between VKM3 and VM 16 12
Figure 11. Method summary ,evaluation procedures for different performance indexes 14
Figure 12. Method Summary, relative valué evaluation 15
Figure 13. Controller productivity and quality based on certain application requirement 16
Figure 14. General evaluation procedures for productivity and capability quantification 17
Figure 15. Ishikawa diagrams for productivity and dynamic capability 17
Figure 16. Block definition 18
Figure 17. Block processing time capability experiment of three different total length lines 19
Figure 18. Heidenhain KGM-181 grid encoder Set Up 21
Figure 19. Contour error graph of Milltronics VKM3 at 4000mm/min 22
Figure 20. Velocity profile at4000mm/min of Milltronics VM16 machine 23
Figure 21. Acceleration profile at 4000mm/min of Milltronics VM16 machine 23
Figure 22. Percentage representation for productivity and dynamic capability 24
Figure 23. CNC controllers technologies architecture 25
Figure 24. Relationship between controller cost and machine attributes (performance index) 26
Figure 25. Application of Hurón KX-10 with a Siemens 840D controller 27
Figure 26. 3-D straight line processing times 28
Figure 27. Block per second for a 3-D straight line 28
Figure 28. 2-D straight line processing times 29
Figure 29. Bocks per seconds for a 2-D straight line 29
Figure 30. 1-D straight line processing time 30
Figure 31. Blocks per second for a 1-D straight line 30
Vil
Figure 32. Average feedrates for different Siemens controllers 31
Figure 33. Processing times for Siemens 802C, 802D, and 840D and their corresponding cost.. 32
Figure 34. Relative valué of different Siemens controllers technologies 32
Figure 35. Application of Milltronics VM16 with centurión VII controller 33
Figure 36. Average contour error comparison on VM16 for different programmed feedrates.... 34
Figure 37. Average feedrate comparison on VM16 for different programmed feedrates 34
Figure 38. Dynamic capability and productivity representation for DNC control option 35
Figure 39. UNC reference architecture 39
vin
CONTENTS
CONTENTS v
LIST OF FIGURES vii
LISTOFTABLES ix
LISTOFSIMBOLS x
GLOSSARY xi
SUMMARY xii
1. INTRODUCTION 1
1.1. Related Work 2
1.2 Motivation 5
2. TAXONOMY OF MACHINES 7
2.1 Controllers 8
2.2 Actuators 9
2.3 Mechanisms 9
3. METHODOLOGY 14
3.1 STEP I. APPLICATION 15
3.2 STEP ü. PERFORMANCE EVALUATION PROCEDURES 16
3.3 STEP El. TAXONOMY OF MACHINES 25
3.4 STEP IV. RELATIVE VALUÉ EVALUATION 25
4. EXPERIMENTAL RESULTS 27
4.1 CASE STUDY 1 27
4.2 CASE STUDY II 33
5. DISCUSSION 37
5.1 Machine tool selection and configuration 37
5.2 Machine tool development 38
6. CONCLUSIONS 40
6.1. Contributions 41
6.2 Future work 41
7.REFERENCES 42
APPENDIX A.- CNC Design 45
APPENDIX B.- Literature Review 48
APPENDIX C- Controller Specifications 53
APPENDIX D.- Actuator Specifications 79
APPENDIX E.- Drive Train Mechanisms Specifications 90
APPENDIX F.- Case Study I Results 101
APPENDIX G. - Case Study II Results 104
APPENDIX H.- UNC proposed scheme for connecting to Milltronics VKM3 118
VI
LIST OF TABLES
Table 1. Literature review of related work 4
Table 2. VKM3 and VM16 general comparison 13
Table 3. Software implemented algorithm classification 21
Table 4. Relative Valué of DNC control options 36
IX
LIST OF SIMBOLS
am (mm/s2) Axis Acceleration
c ($ USD) Controller Cost
Cs ( % ) Static Capability
Cd ( % ) Dynamic Capability
e (mm) Contour Error
ea (mm) Average Contour Error
d (mm) Cumulative Distance
Is (mm) Programmed Line Segment
P ( % ) Productivity
Pt (s) Processing Time
Ptv ($ USD/ms) Processing Time Relative Valué
t (s) Cumulative time
ta (s) Actual Cycle time
Vfp (mm/min) Programmed Feedrate
Vfa (mm/min) Actual Average Feedrate
GLOSSARY
ASME.- American Society of Mechanical Engineers
BPS.- Blocks per second.
CAM.- Computer Aided Manufacturing
CNC- Computer numerical control.
CL.- Control law
DSP.- Digital Signal Processor.
Feedforward.- Feedforward tracking control algorithm.
H.- High cost level
ISO.- International Standards Organization.
JIS.- Japanese Industrial Standard.
L.- Low cost level
Look-Ahead.- Look-Ahead control option for high speed milling.
M.- Médium cost level
PCI.- Peripheral Component Interconnect
PG.- Profile generation.
TG.- Trajectory generation.
UNC- Universal numerical control.
XI
SUMMARY
CNC controllers play a key role in the selection and configuration of a specific
milling machine tool. CNC controller technologies understanding and evaluation is
important in order to take reliable decisions for a required application selection or
configuration. This thesis presents a structured methodology for evaluating CNC
controllers in terms of dynamic capability, productivity, and a relative cost valué for
different performance indexes. Performance evaluation procedures are presented to
quantify different performance indexes for CNC technologies or CNC controllers
characteristics based on dynamic measurements. A qualitative scheme for different
machine tool taxonomies associated with each CNC technology is classified for three
markets to establish a technology cost reference. Experimental results using the proposed
methodology are presented for two case studies.
Xll
1. INTRODUCTION
Modern machine tools such as milling machines and machining centers are
complex mechatronic systems that intégrate mechanical components (structure, columns,
linear bearing systems, etc), electromechanical actuators (spindle, servomotors, servo
amplifiers, etc), and computer numerical controllers (CNC). The complete mechatronic
system has an overall performance that directly depends on the individual component
performance and interaction among components. Based on this integration, there are
many types of milling machines and machining centers that provide a wide range of
performance and prices (see Figure 1). Specifically, the computer numerical control,
whose principal function is to control the feed drive mechanism (see APPENDIX A for
more information), can be considered as the "brain" of the entire system and plays a key
role in the selection or configuration of a specific machine tool.
$ "0KUSD
S20KUSD
MANUFACTURENPRODUCT
MACHINE TOOLCOST DRIVERS•Spindle type andorientation•Number of axis•Size•Accuracy andrepeatability•Control type
S200KUSD
Figure 1. Example of machine tools with different price ranges and their cost drivers.
Machine tool selection is a complicated task due to the wide range of
characteristics to be considered. Previous studies [Bacre;2005] show that spindle type
and orientation, number of axis, size, static capability, and control type are the main cost
drivers on machine tool selection. Based on the product or the application, final users
seek attributes such as capabilities, productivity and most important cost, in order to
select an appropriate machine [Arslan; 2004]. Figure 2, shows how the cost increases for
higher productivity and capabilities demands for a given set of machine tool driver. In a
general scheme, capability can be measured with two performance indexes: quasi static
or dynamic performance [Amone; 1998], and productivity with cycle time, or average
feedrate [Shuett; 1996]. From the cost drivers, the focus of this work is concentrated on
controller technology, where the required performance index is dynamic capability.
Productivity.
/ \Production \
\
Molds
• = machines
MACHINE TOOLCOST DRIVERS
•Spindle type andorientation•Number of axis•Size•Accuracy andrepeatability•Control type
Capability
/ \Quasi *Static Dynamic
Figure 2. Machine tool cost tends for productivity and capability [Adapted form Arnone; 1998].
1.1. Related Work
In order to increase dynamic capability of milling machines, much research has
been done in developing new controls algorithms, for reducing contour errors at high
speed interpolation speeds [Altintas; 2001a], [Tomizuka; 2001], [Koren;1997]. In recent
years significant amount of effort has been put into developing more efficient profile
generation and trajectory planning algorithms that provide smooth feed motion to
increase productivity [Lambretchs; 2005] [Yang; 2004] [Altintas; 2001]. These
investigations focus just on the design of the CNC controller algorithms, and have been
tested with dynamic measurements on specific machine hardware.
Productivity of CNC machines integrating the complete machining process has
been widely studied by several authors [Rodríguez; 2003] [Monreal; 2003]. Other studies
and publications evaluated both dynamic capability and productivity comparing several
machines. These studies evaluated the productivity in terms of cycle time and dynamic
capability in terms of contour error for different machines, with different CNC controls,
changing control parameters [Ortega; 2004] [Hascoét; 2003]. The controller was not
considered as the main element of the overall dynamic performance. For more
information about some reference articles mentioned abo ve see APPENDIX B.
These related work (see Table 1) evaluated machine tool attributes like
productivity, capability or both, from different points of view. From the controller design
point of view, capability and productivity attributes are evaluated by imposing new
control and profile generation algorithms respectively. From machine tool comparison
point of view, capability and productivity attributes are evaluated for different machine
tools taxonomies.
From all the points of views the controller plays a key role in the evaluation of
machine tools. The controller can not be evaluated alone without considering the whole
mechatronic system and the whole machining processes, because productivity and
capability depends on other mechatronic components and also on the required application
(product) respectively.
[Altintas; 2001]
[Amone; 1998]
[Hascoét; 2003]
[Lambrechts;2005]
[Ortega; 2004]
[Schuett, 1996]
[Tomizuka;2001]
[Yang; 2004]
[Reyes; 2005]
PRODUCTIVITY
Model/Evaluation
s
s
AlgorithmDesign
s
s
CAPABILITY
Model/Evaluation
s
s
AlgorithmDesign
COST ANALYSIS
Jerk limitedtrajectorygeneration.Contouringcontrol of feeddrives.MachineEvaluation, Staticaccuracy,Dynamicperformance.Qualification ofparallelkinematicsmachines.Trajectoryplanning, andfeedforwarddesign.Contour errorevaluation,relationshipbetweenaccuracy andproductivity.Look-ahead,accurate control,processortechnology.Contouringcontrol ofmachine toolfeed drivesystems.Parametricinterpolator witha real timejerk-limitedaccelerationEvaluation ofCNC controllersconsidering costrelationship
Table 1. Literature review of related work.
Based on the reviewed related work there is not a specific methodology or
standard for CNC controller evaluation. Table 1 also shows that [Amone; 1998] is the
only one that considered cost, but none of the presented related work considered the term
cost in relationship with the evaluated attributes which is what the final user seeks for
The information provided by most manufacturers in their brochures only qualifies
positional accuracy, CNC block processing rates, and axis feedrates [Amone; 1998]. On
the other hand the standards ISO 230-2 and JIS B6201, evalúate positioning accuracy and
repeatability to qualify the entire machine tool by quasi static measurements. This study
aims at complementing the related work by developing a standard methodology that
integrates all the required elements for a consistent and reliable CNC controller
technology evaluation.
1.2 Motivation
CNC controller type represents an important cost driver in the selection of a specific
machine. There is an industrial need for adequate tools to configure and selected the
optimal machine tool for a specific application. Performance indexes such as average
feedrate or dynamic capability are directly related with the CNC controller design and
need to be tested to evalúate the real valué of different CNC controller technologies. Also
there is a need to clearly define some performance indexes that are commonly used in
industry.
1.3 Objective
The objective of this work is to evalúate the impact of different CNC technologies
in terms of productivity, dynamic capability, and cost. Three different markets have be
taken in consideration (see Figure 3):
• Low cost controller.- Motion control is performed in software by a personal
computer. A PCI board is the main communication hardware.
• Médium cost controller.- Motion control is performed by a Digital Signal
Processor (DSP).
• High cost controller.- Specialized hardware for each component of motion
control.
Controller ArchitectureSOFTWARE
Computer - > CNC. TG, PG,CL.
PCI, I/O Board
(a) HARDWARE
SOFTWAREReal Time Master procesingUnit, TG. PG, CL. TG, PG, CL
PCI. DSP CPU
(b) HARDWARE
SOFTWAREDNC, PLC's
Computer - > CNC. TG. PG, CL.communication task PLC's.
(c) HARDWARE
Figure 3. Controller architectures for different markets
2. TAXONOMY OF MACHINES
Machine tool configuration becomes a more difficult task because of the great
variety of components of the mechatronic system. Based on commercially available
machines and preliminary testing, a three level classification scheme (see Figure 4) is
proposed in order to group machines with similar cost, performance and capabilities:
• Low cost level.- low cost retrofitted machines were cost ís the most important
factor to consider is an example of this level. The controller and actuators are
from different brands.
• Médium cost level.- Milling machines and machine centers, where the machine
and the control are from the same brand.
• High cost level.- Machine center have a specialized controller, where the
controller and actuators are from the same brand.
Controllers
Conventionalmachine
CNU ] ^ n =A/IWA i ^ ^ P i ^~~~
Siemens: ^ ^ B L____
Actuators
£> ^ ^ k i L"
Mechanisms
—^ rV)
— • V
> 1 MI |
Figure 4. Three level classification scheme for controllers, actuators and mechanism.
Taxonomy of machines was proposed to distinguish controllers, actuators and
mechanism elements in order to establish a technology cost reference. This taxonomy
also establishes a reference of some performance indexes of different controllers,
actuators and mechanism elements in the proposed three level classification scheme. A
configuration scheme can be build from the cost and performance index reference.
2.1 Controllers
Many controller manufactures specify hardware capabilities in terms of CPU
speeds, other in terms of block processing time as shown in Figure 5. Unfortunately, like
positional accuracy, interpreting published blocks per second (BPS) valúes is not
straightforward and some manufactures do not necessary refer to the same thing when
they refer to this metric [Amone; 1998]. Valúes in parenthesis correspond to published
BPS valúes. For example 600 BPS, correspond to a block processing time of 1.6 ms, and
that processing time can be achieved by a high cost controller (for more information of
controller brochures and prices see appendix C.
•
•
•System
architecture
PCI Board
32 Bit-processor<256 Kb
32 Bit Processor16-32 Mb
32 Bit processor>128Mb
Blockproccesingtime(ms)
40-24-12**(600 bps)
6 ms-4ms**(1200bsp)
3.6 ms-0.5 ms**(>1200 bps)
PRICE($ USD)
<4000
4000 - 6000
6000- 9000
>10000
Figure 5. Block processing times and prices of different controllers.
2.2 Actuators
Low cost actuators (in this work the actuators are referred as the motors and
motors drives) such as stepper motors are generally used in low cost retrofitted machines,
for a point to point control scheme. DC motors are also used for low cost retrofitted
machines when speed control is required. In such systems an encoder and tachometer are
required for contouring applications. The big difference between pnces can be seen on
drives technologies (see Figure 6). In a médium to high range cost of actuators, the servo
motor drive generally is from the same brand of the motor. AC servo motors are
commonly used in most machine tools. In a high level cost, the controller, AC servo
motor and the drive are generally from the same brand (quotations and specifications for
some brands are presented in APPENDIX D).
Motors
Stepper motorsmDC Servomotors
AC Servomotors
AC Servomotors
Price
($ USD)
300 - 700
1000-1200
900 - 2000
900 - 2000
Drives
I
Description
PWM 20 KHz
PWM 20 - 30KHz
Microprocessorcontroller PWM400Hz speedloop frequency
>1000Hz speedloop frequency
Price($ USD)
<500
700-1000
1500-4000
>10000
Figure 6. Different motor types with their corresponding drives.
2.3 Mechanisms
The influence of the drive train mechanism over the CNC controller performance
is very difficult to quantify. As shown in Figure 7 ball screw accuracy vanes for
different cost levéis. Grounded ball screws are commonly used in mid-seized vertical
machines with C5 accuracy grade [Amone; 1998]. Nut technology is important factor for
high speed performance (ball screws producís and accuracy grades are presented in
APPENDIX E).
M )
Ball Screw Description
Acmé screw
Balls screw O.OO1in/ft {25um/300mm)
Ground ball screw 0.0005 ¡n/ft(12.5um/300mrn)C5=18um/300mm (0.00072¡n/ft)
C1= 5um/300mm (0.0002 ¡n/ft)C3 = 8um/300mm (0.00032in/ft)C5=18um/300mm (0.00072¡n/ft)
Nut / yoke
ftí35»
<
^V. Bal tae* fat H&
i.i*H« bJl " * - . * ) : rOOM
<Í..*5 *> te sí< »
Figure 7. Balls Screws accuracy performance for three levéis
The linear bearing system is one of the more critical aspects of machine tools
design. Solid ways, (commonly referred as hardened ground ways) are used in low to
médium cost machines range. Low friction pads, made from Diamant, or Turcite are
commonly used [Amone; 1998]. Rolling element bearings have about 80% less friction
resistance than solid ways (see Figure 8). Roller element bearings are constructed with
balls or rollers. Rollers have higher load capacities than balls. (Linear bearing systems
brochures are presented in APPENDIX E).
10
Linear Bearingsystems
Description
Solid ways. (Turcite)Friction (0.2-0.02)
Ball type wayFriction(0.002-0.003)
Roller type wayFriction (0.001 -0.0025)
Figure 8. Different bearing systems with their corresponding friction valúes.
This taxonomy does not include spindle technology. Its consideration is
important not only for taxonomy but for CNC control technology evaluation because
CNC controller technology towards better control of spindle torque and speed is under
constant development by several authors in order to increase productivity.
Example of different machine tools taxonomies
An example of two machines with the same controller and actuators is presented
in Figure 9. The objective of this example is to show two different machine tools
taxonomies and the effect of the drive train mechanisms over quasi static measurements.
Controller Actuators Mechanisms
3O
VKM3
M VM16
Figure 9. Taxonomy of VKM3 and VM16 machines.
11
The application of Milltronics VKM3 and VM16 are very different (see Figure
10). Milltronics VKM3 is a small vertical knee machine that is used for production. The
price of this machine is around US$ 25,000. Milltronics VM16 is a linear way machine
center that is designed for molds manufacturing. The price of VM16 is around US$
70,000. Both machines have the same controller, but for VM16 a software package can
be purchase for feedforward and look-ahead for high speed machining.
CONTROLLER
«TUATORS
MECHAIIISMS
PtoJu
#
•trvrty
• |
SBfl f iProdu ¿1 rvrf y
Figure 10. Application requirement comparison between VKM3 and VM16.
Milltronics VKM3 and VM16 are compared in Table 2. VKM3 (30"xl5"x5.35")
and VM16 (30"xl6"x20") have very different volumes valúes but the table travel área of
both machines is similar. Notice that both machines have the same Yaskawa motors and
servo amplifiers, but VM16 can raise higher feedrates. Higher feedrates valúes
(máximum feedrate and rapid movements) for VM16 are almost twice from VKM 3
because of the Balls Screw pitch lead. Both balls screws have the same diameters, but
VM16 has a damped coupling.
12
The significant difference in drive train technologies can be seen on the linear
bearing system. VKM3 uses a solid way bearing system and VM 16 used a ball type way
bearing system. The performance valúes given by the manufacturer are performed with a
Reinshaw láser and ballbar system. VM16 has twice of capability considering position
accuracy as a performance index. This performance valué corresponds to quasi static
measurements, where the controller does not play a key role as the mechanisms.
Controller
Actuator
Mechanism
Performance
VKM3 (V= 0.04 m3>Centurión Vil
•Yaskawa Ac servomotors:SGMGH-05AC A61•Servo Amplifier:SGDH 05 AE•Feedback Resolution: 0.001 mm400 ipm rapids XY 200 ¡pm (5080mm/min) feedrates
•Heavily Ribbed Cast I ronConstruction•Precisión Ground Double AnchoredBall Screws•Ball Screw grade C5.•Ball Screw Pitch lead 0.2 " (5.08mm)•Fully Ground Solid Ways with TurciteSurfaces
•Position Accuracy: 0.01 mm•Repeatability: 0.005 mm
VM16(V =0.156 m3)Centurión Vil
Feed Forward and Look-Ahead for HighSpeed Machining or 3-D Milling
•Yaskawa Ac servomotors:SGMGH-05AC A61•Servo Amplifier:SGDH 05 AE Y220•Feedback Resolution: 0.001 mm1000 ipm rapids XY300 ipm(7620mm/min) feedrates
•Massive Heavily Ribbed MachineTool Grade Cast I ron Construction•Precisión Ground Double AnchoredBall Screws With DampeningCoupling
•Ball Screw grade C5.• Ball Screw Pitch lead 10mm.•Ball type ways
•Position Accuracy: 0.005 mm•Repeatability: 0.0038 mm
Table 2. VKM3 and VM16 general comparison.
13
3. METHODOLOGY
The correct evaluation of CNC controller technology for a specific selection or
configuration has to consider the application or requirement that the user wants to
manufacture. The evaluation is based on the dynamic performance of the CNC controller
under certain evaluation procedures measurements for different performance indexes (see
Figure 11). A relative valué between different performance indexes are quantify in
relationship with their actual cost (see Figure 12). The proposed methodology is divided
into four steps:
• I. Application,
• II. Performance evaluation procedures,
• III. Taxonomies of machines,
• IV. Relative valué evaluation.
PERFORMANCE INDEX
I.APPLICATION EVALUATION
PROCEDURES
TAXONOMY
III.
PERFORMANCE INDEX
Figure 11. Method summary ,evaluation procedures for different performance indexes.
14
111o! * •S uiceaO zu. —ceuia.
IV.RELATIVE
VALUÉEVALUATION
Controller C |Characteristic
C1.C2
UI> UJ
_ l <UJ >
Controller B
CharacteristicB1.B2
Controller A
CharacteristicA1.A2
COST$ B/A C/B
Figure 12. Method Summary, relative valué evaluation.
3.1 STEPI. APPLICATION
As mentioned before the application for selecting or configuring a specific
machine tool is the starting point. Figure 13 show that certain performance indexes are
required for productivity and capability attributes quantification. For CNC controller
technology dynamic performance, in terms of contour error, is a critical factor to consider
for certain capability and product requirement. Thus for contouring applications such as
mold manufacturing the selected performance index for dynamic capability will be
contouring error. On the other hand if the application is production of manufactured
parts, the selected performance index for static capability will be repeatability and
aecuracy. Average feedrate and block per second processing are examples of
performance indexes to evalúate productivity attribute.
Actuators and mechanisms are important to consider in mold manufacturing, but
for production their consideration is more important to evalúate correctly the effect of the
controller. This thesis only considers dynamic performance evaluation for contouring
15
applications. It is important to notice that dynamic performance not only depends on the
controller performance, but also on the actuators and mechanisms.
Productivity Capability
CONTROLLER
ACTUATORS
MECHANISMS
Production Molds Static Dynamic
) VERY IMPORTANT
) IMPORTANT
Figure 13. Controller productivity and quality based on certain application requirement.
3.2 STEPII. PERFORMANCE EVALUATION PROCEDURES.
As mentioned before there is not a specific methodology for evaluating CNC
controllers. Different evaluation procedures are considered to evalúate dynamic
capability of CNC controller technology. Standards and machine specifications are based
on quasi static measurements for prismatic parts (see Figure 14). For dynamic capability
sculptured surfaces are considered to evalúate contour performance.
16
gQ O
¡I
CAPABILITY(CQNTOUR PERFORMANCE)
PRISMATIC PARTSSTATIC CAPABILITY
CONSIDEREDINEVALUATION
[Momeal;2003]
NOTCONSIDERED IN
EVALUATION
SPEC
[Amone; 1998]
SCULPTURED SURFACESDYNAMIC CAPABILITY
CONSIDERED INEVALUATION
ÁBPS
NOTCONSIDERED
IN EVALUATION
HEIDENHAIN
Figure 14. General evaluation procedures for productivity and capability quantification.
The proposed methodology evaluates productivity and capability attributes of
different elements that intégrate the controller architecture (see Figure 15). Two mayor
aspects that consider the controller hardware and software architecture are proposed to
evalúate a specific controller technology: Data processing performance (blocks per
second) and software implemented algorithms evaluation.
BPS \
\
/
/ f
ACRiATORS
CONTROLLERS
OONTROL\OPTION: \
LOOK-AHEAD\
\ \/ /
MOTOR / 1
MECHANISM
V E U X m .ACCELERATION
'BAIXSC:REW
DRIVE/
ACTUATl.
CONTROLLERS
\ \ < (INTROL U W :\ \ <ONTOVR
\ \
/ / / /
/ / / BEARDMU/ / / Si-STEM
RS MECRW1SMS
DYNAMICC.\PABnJTY
Figure 15. Ishikawa diagrams for productivity and dynamic capability
17
3.2.1 Data processing performance (BPS) Test
One of the more popular ways to measure CNC performance is block processing
time. Block per second (BPS) or block processing time (inverse valué of BPS) can be
considered as the performance indexes to evaluated productivity. As mentioned before
not all manufactures refer to the same thing when they refer to BPS. Some manufacturera
define a block as a single CNC "word" such as XI or Yl. Other manufacturers have
defined a block as whatever will fit on a line up to the carriage return. This definition is
important, because the block definition reveáis the actual processing speed of the control.
For this reason is necessary to defined a block. Some recommendations proposed
by [Amone; 1998] like stripping the program of all superfluous characters, including line
numbers are considered. Also is important to not include tool length or radius
compensation or any other features that might consume additional processing time.
From preliminary testing and reviewed related work one block for data processing
performance evaluation purposes is defined as a three word line (X,Y,Z coordinates)
without: line numbers, linefeeds ,character spaces, tool length and radius
compensations (see Figure 16).
g646546l?G90721G01X0YOZ0F500XO.01443Y0.01443Z0.01443XO.02886Y0.02886Z0.02886XO.04329Y0.04329Z0.04329l|(Pií¡^pl?2¥O.OS7?2Z0.05772 I
XO*. 08658Y0*. 08658Z0*. 08658XO. 10101 YO. ÍOIOIZO. 10101|XO.11544Y0.11544Z0.11544
~ ~ ^ _ _ _
Figure 16. Block definition.
To evalúate the block processing capability a simple straight line divided in
small segments is proposed. Three experiments were conducted using a 1-D straight line,
18
2-D straight line and 3-D straight line to evalúate the effect of using different block
words. All of the three lines have a total length size of 700 mm. Different line segments
(see Figure 17) were considered and tested under different feedrates with the look-ahead
control option. This length lines and segments were selected because first experiments for
a lOOmm total length line and a 200mm total length line show that for big segments (
>0.2mm) the effect of acceleration of the servo motors, affect the experimented obtained
valúes. For a correct block processing time measurement the acceleration effect must be
decoupled. This decoupled is obtained by making longer lines, with smaller segments.
¥> •
X(mm)
? '£>-
/
X(mm)
£
1^ yS. V X (mm)
1-D STRAIGHT LINE
•Total length: 700mm
•Line segments: 0.1 mm, 0.05mm, 0.025mm
2-D STRAIGHT LINE
•Total length: 700mm
•Une segments: 0.05mm , 0.025mm
3-D STRAIGHT LINE
•Total length: 700mm
•Line segments: 0.05mm, 0.025mm
Figure 17. Block processing time capability experiment of three different total length lines.
To determine the required block per second capability for different line segments
formula [l]can be used. For example for a 0.1 mm segment at 3000 mm/min a
processing time of 2 ms (500 BPS) is required.
19
L = length of a typical programmed segment [mm]
F = programmed feedrate [mm/min]
T = 6 0 X ( L H - F ) [seconds] [1]
^ [1/second]
The real BPS is obtained using a chronometer and measuring the time from when the
program begins until it ends. The actual average feedrate can be calculated for several
line segments experiments just knowing the processing time or the BPS valué (dividing
the total line length by the processing time for certain number of blocks). This valué
represents the máximum feedrate that the controller can achieve for a specific line
segment, and it is important because the final user can notice that for small program
segments (longer line segments might easily permit high feedrates [Shuett; 1996]), the
programmed feedrate can not be achieved. For contouring applications, a "bunching" of
data points are generated by CAM systems in many detail áreas for precisión cutterpaths
[Shuett; 1996], and the controller can not achieve the programmed feedrate.
Productivity in terms of processing time or BPS as performance indexes can be
compared for different controllers of the same or different brands knowing the real
processing time. Notice that valúes of BPS provided by the manufacturer should be taken
carefully [Amone; 1998], and not all manufacturers provide this valué in their brochures.
3.2.2 Software implemented algorithms evaluation
As block processing evaluation there is not a specific methodology to evalúate
software implemented algorithms. Software implemented algorithms are evaluated by
dynamic measurements generally using ball bars and grid encoders. Grid encoder has the
advantage that is not limited to a circle path. Heidenhain KGM-181 grid encoder and the
ACCOM Software are used to evalúate software implemented algorithms (Figure 18).
With the ACCOM Software it is possible to have a graphical representation of the actual
and the ideal tool path for several measurements. For a detail explanation of dynamic
20
measurements using the KGM-181 grid encoder and the contour error algorithm see
[Ortega; 2004].
Figure 18. Heidenhain KGM-181 grid encoder Set Up.
Software options are classified considering what implemented algorithm affect
most dynamic capability and productivity (see Table 3). Classification is based on
preliminary testing and the reviewed related work. This thesis only considered the
control law and profile generation evaluation.
Dynamic capability
Productivity
Software implemented algorithmsControl Law (CL):PID, Feedforward.Trajectory Generation (TG):Interpolation, spline interpolaron, polynomialinterpolationProfile Generation (PG):Trapezoidal velocity description, Trapezoidalacceleration description (acceleration withjerk limitation)
Table 3. Software implemented algorithm classification.
Control law (contour performance)
To evalúate contour error as performance index is important to consider how
other authors evaluated their developed control algorithms. [Altintas; 2001a] used
circular and diamond shaped paths, [Tomizuka;2001] [Koren; 1997] used circular paths
21
to evalúate the contour error of their proposed control schemes. All of these authors
used different feedrates ranges and path sizes to test their control schemes.
A 20 mm hexagon size path is proposed [Ortega; 2004] for testing the dynamic
capability at different feedrate ranges. A contour error algorithm developed by same
author was used to quantify the average contour error as a performance index. Figure 19
shows and example of the contour error on a 20 mm hexagon. Notice that contour error
presents a máximum valué at the hexagon corners. The average contour error is the
average of all the contour errors at the cumulative distance. For a complete evaluation at
all the tested feedrate ranges, an average of all average contour error is considered.
0.11•p. o íE 0.09E 0.08
w 0.07« 0.06i- 0.05S 0.04fe 0.033 0.01
C -0.01O -0.02ü -0.03
-0.04
(
Contour error, magnitude and location /
''1
JiJE
1
— ? •
í
i' i
- . _
- -
,v
>
) 20 40 60 80 100 120
Cumulative distance d, (mm)
Figure 19. Contour error graph of Milltronics VKM3 at 4000mm/min.
Profile generation evaluation
Controllers specify several Ínterpolation and profiling generation techniques in
their brochures. Several authors suggest that smoother feed motions at high speed
machining will increase productivity and reduce mechanical shock imposed on the servo
system [Yang; 2004][Altintas; 2001]. To quantify productivity the average feedrate as
performance index is obtained from the velocity profíles in a 20mm side hexagon at
different feedrates. Figure 20 and Figure 21, shows an example of a velocity and
22
acceleration profile respectively at a tested feedrate. Notice that this graph has 8 line
segments. The average feedrate is obtained considering the time of 6 segments of the
hexagon (120mm distance). For a complete evaluation at all the tested feedrate ranges,
an average of all average feedrates is considered.
Ve locity Profile
eed
rate
Vfp
,m
in)
H
Pro
gra
m
4000-3500-30002500
15001000500 j
ol
II /i n A h n ri\ i\ i\ i\ iIXix 11 n i
rÍREBí T f —M
4fi- —
T0.5 1.5 2 2.5
Cumulative time t, (s)
3.5
Figure 20. Velocity profile at 4000mm/min of Milltronics VM16 machine.
Acceleration Profile o^ 1500
s innn
•atio
n a
m, (
mnr
0
O
O
C
£ i
| -1000
x -1500 -
-2000-
' «I
• J ; II*Ufe
I I .wni
"ti fe **"T
— T
—^ H f
1 i
0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75
Cumulative time t, (s)
Figure 21. Acceleration profile at 4000mm/min of Milltronics VM16 machine.
23
Dynamic capability and productivity is represented in a percentage X-Y plañe
scheme as in Figure 22 for visualization of several controller options. To use this
representation same programmed feedrates have to be considered between control
options.
Dynamic capability e
%(Average Contouring error)
! • • =
i •-.i i
:
íi; :
| Í
4^
«a
í: : 111111
i : : : : :
S "1**r*r
I [ [ 11 ¡141 F ^
II: a
m
DYNAMIC MEASURMENTSCONSIDERATIONS
•Same Shape•Equal segment size•Same Feedrates
Figure 22. Percentage representation for productivity and dynamic capability .
The abscissa corresponds to the average contour error (better control option is
localized to the left of the plañe), and the ordinate corresponds to the productivity in
terms of the actual average feedrate, both of them expressed as a percentage. To deploy
several machines in the same graph, an average valué of productivity and its
corresponding average contour error valué can be calculated considering the same
programmed feedrates.
24
3.3 STEPIII. TAXONOMY OF MACHINES
Based on the proposed taxonomy of machines it is possible to determine an
approximate level of cost and performance of an specific controller and a machine tool.
From the controller point of view is important to consider the controller architecture in
order to take decisión for selecting or configuring a CNC controller technology. Figure
23, shows a schematic representation of the controller architecture and it relationship
between software and hardware for the three proposed markets.
Low Cost Controller CNU
Software
M ) Médium Cost Controller
High Cost ControllerSoftware
Hardware
Hardware
Hardware
Figure 23. CNC controllers technologies architecture.
3.4 STEP IV. RELATIVE VALUÉ EVALUATION
Relative valué evaluation was proposed in order to establish a cost reference
between different controllers or controller characteristics, to quantify the machine
attributes the final user seeks for (see Figure 24).
25
3.4.1 Relative valué cost between performance indexes.
After the performance indexes have been quantified, they are plotted in a X-Y
plañe (see Figure 24). The abscissa corresponds to the real cost (provided by the
manufacturer) and the ordinate correspond to the consider performance index. Relative
valué can be calculated using formula [2].
Relative Valué of B/A=Cost B - Cost A
ABS(ControllerB-ControllerA)[2]
The relative valué comparisons between software options or controller
characteristics have to consider the following aspects (see Figure 24): Controller's
comparison between machines in terms of dynamic capability performance can be
executed if the machine has the same volume, same application purpose and similar
actuators and mechanism taxonomies. Different controllers comparison can also be
executed if data processing time is taken as performance index and assuming that they are
tested on the same machine. To evalúate the relative cost of software implemented
algorithms of the same controller the cost of the control options is required.
UI
o< Xi
2 ui£°2^te.UJQ.
^ ^ ^ i Controller C j^ ^ ^ Characteristic
C1.C2
•
Controller B
CharacteristicB1,B2
^ ^ ^ | Controller A |
^ ^ ^ CharacteristicA1,A2
eosT$
ÍELA
TWE
VA
LUÉ
J\>
V /
B/A
*
///
C/B
Figure 24. Relationship between controller cost and machine attributes (performance index).
26
4. EXPERIMENTAL RESULTS
4.1 CASE STUDY I
Case study I was conducted on a Hurón KX-10 machine center. Hurón KX-10
main application is for molds manufacturing where dynamic capability in terms of
contour performance is the main factor to consider (see Figure 25). It has a Siemens 840
D controller, which can be considered as a medium-high cost controller. The objective of
this case study is to compare Siemens 840D controller with different Siemens (802C and
802D) controllers in terms of processing time capability. Siemens 802D and 802C best
processing time are of 24 and 12 ms respectively. (processing time data was provided by
the controller manufacturer. See appendix C for more information).
CONTROLLER
ACTUATORS
KECHANISMS
Productivity ifflSiJI
fMMtoi J « » « j | SU*
• » •
bWI)
O"
-
/ "
rme
Í
iI. II.
Machine: Hurón KX-10Controller: Siemens 840DWork Volume: 0.35 m3.
III.
f r
Figure 25. Application of Hurón KX-10 with a Siemens 840D controller.
The evaluation procedure is for data processing performance (BPS) of Siemens
840D controller. The selected performance index is BPS and processing time. The
results for the block processing times and blocks per second are illustrated in Figure 26
27
and Figure 27 respectively for a 3-D straight line. The processing time of 4.6 ms is within
expected valué for a médium high-cost controller (see Figure 5). The 0.025 mm line
segment has a saturation of 4.6 ms (218 BPS) at all programmed feedrate valúes. There is
an insignificant difference (measurement errors) between the 0.025mm programmed line
segment (Pt) and the 0.05mm line segment of 4 BPS at saturation. The graphs also show
the actual average feedrate when saturation occurs for the programmed feedrates (see
APPENDIX F for more details).
Siemens 840D
Control Option G64: ON
7.000
£ 6.000
3-D STRAIGHT UNE
5.000
4.000
3.000
--<1*
1 1
—
[• — • - — -
Vfa= 668.3 mm/mlnVfa= 327.3 mm/mln
4
—
ls= 0.05 mmls= 0.025 mm
)
O
•/
1 -
Measured Valué
Data Sheet
Models—•
t
1000 2000 3000
Programmed feedrate Vfp, (mm/min)
4000
• • - 0.05mm -0.025mm
Figure 26.3-D straight line processing times
Siemens 840D
Control Option G64: ON
250.000
a.&W 225.000o.m
200.000
175.000
150.000
3-D STRAIGHT UNE
^
, t
, ' T>
9
1
1. Vfa= 668.3 mm/mlnVfa= 327.3 mm/mln
ls= 0.05 mmls= 0.025 mm
® Nleasured Valué
• Data Sheet
/ Models
1000 2000 3000
Programmed feedrate Vfp, (mm/min)
4000
- • - 0.05mm -0.025mm
Figure 27. Block per second for a 3-D straight line.
28
Figure 28 and Figure 29 show the processing time and BPS values for a 2-D straight line
respectively. Compared with the 3-D straight line, there is not a significant difference
between the obtained Pt, and BPS values. For the 0.025 programmed line segment the
difference in terms of actual average feedrate is of 3.4 BPS for programmed feedrates
superior to 1000 mm/min.
7.000
,§.6.000
<D
F 5.000
4.000
3.000
Siemens 840DControl Option G64: ON
2-D STRAIGHT
1000 2000 3000
Programmed feedrate Vfp, (mm/min)
- • - 0.05mm -0.025mm
<V
1 1i
— —
Vla= 668.2 mm/minVfa= 330.7
imrrvmln
— —
I© Measured Value
• Data Sheet
/ Models
ls= 0.05 mmls= 0.025 mrr
4 1 |
4000
Figure 28. 2-D straight line processing times.
250.000
m225.000
200.000
8m
175.000
150.000
Siemens 840DControl Option G64: ON
1000 2000 3000
Programmed feedrate Vfp, (mm/min)
- • - 0.05mm -0.025mm
2-D STRAIGHT
<
f
*
t
t
t
\
1Vfa= 668.2 mm/minVfa= 330.7 mm/min
ls= 0.05 mmls= 0.025 mm
© Measured Value
H Data Sheet
/ Models
4000
Figure 29. Bocks per seconds for a 2-D straight line.
29
In a 1-D straight line there is no difference between the programmed line
segments (see Figure 30 and Figure 31). This is because the time was calculated from the
actual average feedrate obtained from the machine display. For 2-D and 3-D lines, there
was not possible to obtain the actual average feedrate from the machine display because
there was not a constant value of the actual feedrate.
13.0 -i
t, (
ms) b
ess
ing T
ime (
~i
tob
b
2 5.0
3.0
(
1
I
I\\ \
\\\
I 1
) 1000
Siemens 840D
Control Option G64: ON
Vfa= 1350 mm/minVfa= 675 mm/mlnVfa= 337.5 mm/min
o•
1
•]
I-D STRAIGHT UNE
IMeasured Value
Data Sheet
Models
ls=0.1 mmls= 0.0S mmls= 0.025 mm
1T2000 3000
Programmed feedrate Vfp, (mm/min)
—•—0.1mm - • - 0.05mm —•—0.025mm
4000
Figure 30.1-D straight line processing time.
250.0
en" 200.0a.mT3
8 150.0 •
J2 100.0
ffl
50.0
Siemens 840D
Control Option G64: ON1-D STRAIGHT LINE
1
1
1
*
• ' )
/
<
\*^
Vfa=Vfa=Vfa=
1350 mm/min675 mm/min
337.5 mm/min
s=0.1 mms= 0.05 mms= 0.025 mm
—•
9 Measured Value
S Data Sheet
/ Models
1000 2000 3000
Programmed feedrate Vfp, (mm/min)
4000
0.1mm - 0.05mm 0.025mm
Figure 31. Blocks per second for a 1-D straight line.
30
The programmed line segment vs. actual average feedrate is illustrated in Figure
32. Notice programmed feedrates and the actual average feedrate difference when the
controller saturates. This comparison is important because for high speed contouring
applications, higher average feedrate values are required to mill accurately at high speeds
[Shuett;1996].
Siemens controllers comparison
1400
1200
1000
800
600
400
200
(3) Measured Value
Data Sheet
Models
1-D STRAIGHT UNE
I Vfp > 2000 mm/mln I
0.025 0.05 0.075
Programmed line segment Is, (mm)
0.125
-Siemens 8400 (4.4 ms) - • - Siemens802D(12 ms) - Siemens 802C(24 ms)
Figure 32. Average feedrates for different Siemens controllers.
The cost relationship of Siemens controllers with their processing time (3-D
straight line with a programmed line segment of 0.025mm) as a performance index is
illustrated on Figure 33. Siemens 840D processing time was obtained by the above
experimentations on a specific machine. For that reason this comparison can be consider
with the assumption that Siemens 802D and 802C were tested on the same machine. The
cost of Siemens 840D was provided by the manufactured but it was not given in a formal
quotation format as for Siemens 802C and 802D. The price of $USD 12,000 for Siemens
840D can vary depending on the selected processor speed.
31
Performance Index comparison for Siemens controllers X-^ 2 5
£ 2 0
Pro
cess
ing
Tim
eo
yi
o
en
3-D STRAIGHT LINE
© Measured Value
• Data Sheet
/ Models
-
4,000 6,000 8,000 10,000Controller Cost c,($USD)
12,000 14,000
Figure 33. Processing times for Siemens 802C, 802D, and 840D and their corresponding cost
The relative value of Siemens 802D vs. 802C, is of $USD 213.5 for each
millisecond of reduction in processing time. This relative value is important because
with this comparison the final user can have an idea of what is the cost of processing time
in milliseconds per dollar from one technology to another (see Figure 34). The relative
value of processing time for a high performance controller (840D), between a medium
performance controllers is of $USD 681.75 for each millisecond.
Relative Value of Siemens Controllers
700
X-3-D STRAIGHT UNE
5 ^ID CO
EDi
2a.
600
500
400 -
300
200
100
^ Measured Value
H Data Sheet
/ Models
802D vs. 802C 840D vs. 802D
CNC Siemens Technologies
Figure 34. Relative value of different Siemens controllers technologies.
32
4.2 CASE STUDY II
Case Study II was conducted on a Milltronics VM16 machine center. It has a
Centurion VII controller, and a work volume of 0.156 m3. Milltronics main application is
for molds manufacturing where dynamic capability is the main factor to consider (see
Figure 35). The objective of this case study is to compare the relative cost of the
purchased software upgrade of feedforward and look ahead option for high speed milling
operations. The published cost of this software upgrade is of $USD 1,500.
a n
:ONTROLLER HIACTUATORS ^ A
MECHANISMS • HIn u
•JX •
PRISH»T!C PMTS
I.
Machine: Milltronics VM16Controller: CENTURION VIIWork Volume: 0.156 m3.
Figure 35. Application of Milltronics VM16 with centurion VII controller.
To activate feedforward and look ahead (see APPENDIX A for more
information), the DNC software option has to be used in the Milltronics controller.
Feedforward control strategy for machine has tools been tested by several authors
[Tomizuka; 2001][Altintas;2001a][Koren;1997], that reduce the contour error. The
results from dynamic measurements for contour error and actual feedrate are in Figure 36
and Figure 37 respectively (for more information see APPENDIX H). Notice that the
look ahead option is not evaluated in this case because the hexagon has only 8 program
blocks.
33
~ 0.008 -I
£ 0.007 -
8 0.006 -
8 0.005
- 0.004 -
% 0.003
° 0.002
2 0.001
3 0 -I
VM16 Average Contour Error Comparison / \
\ /
... ...
- ^
1 ^
2000 4000 7620
Programmed feedrate Vfp, (mm/min)
ffl DNC OFF • DNC ON
Figure 36. Average contour error comparison on VM16 for different programmed feedrates.
VM16 Average Feedrate Comparison
3000
2000 4000 7620
Programmed feedrate Vfp, (mm/min)
DNC OFF • DNC ON
Figure 37. Average feedrate comparison on VM16 for different programmed feedrates.
34
The proposed method for relating productivity and dynamic capability on the
same X-Y plane is illustrated in Figure 38. Notice that the dynamic capability percentage
of DNC OFF is 114%. This means that the contour error increases 14% ( dynamic
capability reduces 14). Centurion VI has not dynamic look-ahead, for that reason the
programmed feedrate has an insignificant reduction (0.06%) with DNC ON control
option.
Dynamic Capability vs. Productivity / \
\ /1 nn m n/
100.00% -
99.99%
Ig, 99.98%
£ 99.97%
Z= 99.96%
°" 99.95%
99.94%
— ——
--
^ ^ -
r_. .._.
- — —
^ — — — —
p- - -—
_.. — ._
.._ —
— _
,
_.
98% 100% 102% 104% 106% 108% 110% 112% 114% 116%
Dynamic Capability Ca, (%Contouring Error) ••
DNC OFF
DNC ON
Figure 38. Dynamic capability and productivity representation for DNC control option.
Considering a standard cost of Milltronics Centurion VII of $USD 8,000 for DNC
OFF (See APPENDDC C for more information of Centurion VII price), with the software
upgrade package the cost of Centurion VII, will be of $USD 9,500. DNC OFF has an
average contour error for the three tested feedrates of 6.7 um. With DNC ON the average
contour error reduces to 5.904 um. The relative cost of DNC ON vs. DNC OFF is of
$USD 1,826 per micron (see Table 4). This value is important because the final user can
evaluate the relative cost of two characteristics of the same controller. Software options
35
or upgrade control options are commonly presented in controller brochures. It is
important to note that the results presented here are only valid for the hexagon test.
DNC OFF 1
COST SUSD
8,000
Average AverageError(mm) Error (urn) Relative value SUSD/urn
DNC ON 9,5000.0067296 6.7296301 DNC ON vs. DNC OFF 1826.60285610.0059084 5.9084335
Table 4. Relative Value of DNC control options.
36
5. DISCUSSION
This section presents a discussion based on the presented methodology and the
case study results. Application and relevance of the proposed methodology for the
industrial need of selecting and configuring a machine tool can be discussed considering
the reviewed related work, proposed cost reference taxonomy and experimental results in
the case studies. In addition, a general scheme for machine tool development can be
considered based on the experience acquired with the development of thesis.
5.1 Machine tool selection and configuration.
A typical investment project for aerospace or automotive industry, with a given
target product cost, quality and lot size, requires the selection or configuration of specific
machine tools. From the controller point of view, machine tool configuration and
selection can be done with experimental testing. In this regards, this thesis defines
evaluation procedures to quantify the controller performance (BPS) and the machine tool
dynamic performance (average contour error). The selection of an appropriated CNC
controller for a specific machine is based on the controller performance and cost. Some
procedures such as software implemented algorithms evaluation do not evaluate the CNC
controller performance by itself, but the dynamic performance of the CNC controller and
its interaction with the actuators and mechanisms (machine tool dynamic performance).
For example, comparing the Milltronics VKM3 and VM16, they have the same
controller, actuators and balls screws, but a different kind of linear bearing system.
Based on some dynamic evaluation of these machines, the VKM3 was found to have
approximately twice as much error compared to the VM16. A possible reason for this
performance difference could be the friction characteristics of the different linear
bearings used with these machines. Assuming this explanation, there could be an
opportunity to use a lower cost controller with the VKM3, better matching the controller
with actuators and mechanisms, and therefore lower the total cost of the machine.
37
In a lower cost scheme for configuring a retrofitted machine tool, the principal
attribute that final user seeks for is cost. In this context, the CNC controller and actuators
are the bottle necks in configuring a low cost retrofitted machine. An optimization of the
required actuators (and some mechanisms if they are going to be changed) for
configuring a retrofitted machine tool can be done knowing the controller performance
and its compatibility with actuators and mechanism. This discussion is extended in the
next point.
5.2 Machine tool development
The proposed methodology can also be used as a reference framework for
machine tool development. This discussion will focused on machine tool development
with a low cost controller denominated "Universal Numerical Control" (UNC) that is
under development at ITESM. A brief description of the Universal numerical control
will be presented for a better understanding of the controller proposed architecture.
The UNC is a PC-based and open system control architecture, that is focused on
providing a low cost CNC technology for Small and Medium-Sized Enterprises (SMEs)
[Ramirez; 1998]. The UNC reference architecture (see Figure 39) is a conceptual model
that establishes rules and methods of integration and standard interfaces between its
components [Ramirez; 2004].
The most important element of the hardware layer is the PC bus, which is a
universal interface which connects all components of a PC system. The selected interface
is a standard PCI bus to communicate the software modules with a PCI board. All the
controller basic tasks (PG, TG and CL) are processed in software by a real time operating
system. The limitations of using only a PC for doing all basic tasks is evident for block
processing time performance. Comparing UNC with a medium cost controller, it is
possible to see that the significant difference in hardware is a DSP board. For example,
popular board as the Delta-Tau PMAC DSP board (medium cost card), can execute a
multiply-accumulate (MAC) instruction, a fundamental operation, in a single clock cycle.
38
This same operation on a current Pentium processor chip takes 11 clock cycles [Shuett;
1996].
Programming ApplicationInterface
Real Jime Operating System
HardwarePC^
Figure 39. UNC reference architecture.
Machine tool development with the UNC control will be focused on configuring
low performance actuators and mechanism for production machine tools. Since the
controller is the "brain" of the entire system, and has a relative low performance, some
elements can be developed in the house. For example it is possible to develop the UNC's
own driver for a low cost step motor. Dynamic performance will not be as important as
quasi static performance, for this reason solid ways can be considered in developing the
machine tool structure. For static performance low lead ball screw are recommend to
ensure high degree of accuracy and repeatability. It is important to notice that these
recommendations are base on the review related work, proposed cost reference taxonomy
and case studies of this work.
39
6. CONCLUSIONS
Machine and product application has to be considered to evaluate a specific CNC
technology. Evaluation procedures to evaluate some performance indexes were validated
and proved on two case studies. Evaluation of different CNC technologies and their
relationship with their cost in terms of dynamic capability and productivity was possible
considering constant volumes, similar quasi static capabilities and same tested
parameters. Characteristics of the same controller and their relative value can be
evaluated using the proposed methodology.
Taxonomy of machines was established in order to have a technology cost and
performance reference. Comparing different machine tools taxonomies, with the same
controller and actuators, the effect of the linear bearing system on the static capability
was evident
It was possible to compare Siemens 840D with Siemens 802C and 802D
controllers in terms of processing times as performance index assuming that those
controllers were tested on the same machine. A relative value between Siemens
technologies was presented.
The effect of the feedforward control algorithm over the dynamic capability was
evident by using the DNC command on Milltronics Centurion VII controller. The
measured dynamic error varies in 18% from the quasi static error specified by the
manufactured. Considering a hexagon the dynamic error is higher than quasi static error
and is within expected results. A 14% of dynamic error was reduced using a feedforward
control in a hexagon. The relative value of contour error as performance index was
compared between DNC control options.
40
6.1. Contributions.
A Structured methodology oriented to an application, considering different
machine tools taxonomies with relative cost values comparison between selected
performance indexes.
• Definition of a Block for block processing time evaluation purposes.
• Cost relationship between different performance indexes.
• Relative cost of processing time between different controllers of the same brand
• Relative cost of dynamic capability for a feedforward control option.
• Taxonomy of machine tool with a technology cost reference between controllers
and actuators. Reference performance values of the mayor elements that
integrated the drive train mechanism of a machine tool.
• Machine tool test bed proposal for evaluating UNC dynamic capability on VKM3
vertical knee milling machine (see APPENDIX I).
6.2 Future work
This work provides a basis for future research and development on a methodology
for CNC technologies evaluation taking into account the following aspects:
• Implement the propose methodology using UNC developed controller on a
Milltronics VKM3 milling machine, to quantify the dynamic capability of a low
cost controller.
• Study different profiles for dynamic measurements, for contour error evaluation.
Circular paths are used and recommended by many authors.
• Evaluation procedures for dynamic measurements using sculptured surface
profiles for a more reliable comparison between look-ahead control option.
• Include a cost reference for drive train mechanisms on the proposed methodology
• Evaluation and taxonomy considerations of spindle technology.
41
7. REFERENCES
[Altintas; 2000] Altintas, Yusuf; Manufacturing Automation, Cambridge
University Press, Cambridge, 2000.
[Altintas; 2001] Altintas, Yusuf; Erkorkmaz, Kaan; "High Speed CNC System
Design. Part I: Jerk Limited Trajectory Generation and Quintic
Spline Interpolation", International Journal of Machine Tools and
Manufacture, Vol. 41, pp.1323-1345, 2001.
[Altintas; 2001a] Altintas, Yusuf; Erkorkmaz, Kaan; "High Speed CNC System
Design. Part III: High Speed Tracking and Contouring Control of
Feed Drives", International Journal of Machine Tools and
Manufacture, Vol. 41, pp.1637-1658, 2001.
[Arnone; 1998] Arnone, Miles; High Performance Machining, Hanser Gardner
Publications, Cincinnati,1998.
[Arslan; 2004] Arslan, £agdas M.; Catay, Biilent; Budak, Erhan: "A decision
support system for machine tool selection", Journal oj
Manufacturing Technology Management, Vol 15, N 1, pp. 101-
109, 2004.
[Fan; 2001] Fan, Chun; Dong, Chensong; Zhang Chun; H P Wang; "Detection
of Machine Tools Contouring Errors Using Wavelet Transforms
and Neural Networks", Journal of Manufacturing Systems, Vol 20
N 2, pp. 98, 2001.
42
[Hascoet; 2003] Hascoet, J-Y; Dugas, Arnaud; Terrier, Myriam; "Qualification of
parallel kinematics machines in high-speed milling on free form
surfaces", International Journal of Machine Tools and
Manufacture, Vol. 44, pp.865-877, 2004.
[Koren; 1983] Koren, Yoram; Computer Control of Manufacturing Systems,
McGraw Hill, New York, 1983.
[Koren; 1997] Koren, Yoram; "Control of Machine Tools", Journal oj
Manufacturing Science and Engineering, Vol. 119, November
1987.
[Lambrechts; 2005] Lambrechts, Paul; Boerlage, Matthijs; Steinbuch Maarten; "
Trajectory planning and feed forward design for
electromechanical motion systems", Control Engineering
Practice, Vol. 13, pp. 145-157,2005.
[Monreal; 2003] Monreal, Manuel; Rodriguez Ciro A.; "Influence of tool path
strategy on cycle time of high-speed milling", Computer-Aided
Design, Vol. 35, Issue 4, pp. 395-401, 2003.
[Ortega; 2004] Ortega, Carlos; Algorithm development for contour error
evaluation - analytical relation ship between accuracy and
productivity on high speed milling machining, Research modality
investigation thesis, CSIM, 2004.
[Ramirez; 1998] Ramirez, Miguel; Desarrollo de un control numerico Universal de
bajo costo basado en software y sistemas abiertos, Tesis de la
Maestria en Sistemas de Manufactura, Instituto Tecnologico y de
Estudios Superiores de Monterrey, Diciembre 1998.
43
[Ramirez; 2004] Ramirez Cadena, Miguel de Jesus; Jimenez Perez, Guillermo;
Molina Gutierrez, Arturo; Noriler , Maria A.. "Design
Methodology for CNC Applications Based on Open Systems". 7th
IFAC Symposium on Cost Oriented Automation COA 2004.
CANADA, pp: 153-158. June. 2004
[Rodriguez; 2001] Rodriguez, Guadalupe; Evaluacion de Tiempo en Operaciones de
Freasdo de Alta Velocidad - Impacto del Perfil de Aceleracion,
Tesis de la Maestria en Sistemas de Manufactura, Instituto
Tecnoldgico y de Estudios Superiores de Monterrey, Diciembre,
2001
[Shuett;1996] Shuett, Todd; Advance Controls for High Speed Milling, SME
Conference, Chicago Illinois, May, 1996.
[Tomizuka; 2001] Tomizuka, Masayoshi; Chiu, George; Contouring control of
machine tool feed drive systems: A task coordinate frame
approach", IEEE Transactions on control Systems Technology,
Vol. 9, No.l, pp. 130-139, January, 2001.
[Yang; 2004] Yang, Min-Yang; Nam, Sho-Ho; "A study on a generalized
parametric interpolator with real-time jerk-limited acceleration",
Computer-Aided Design, Vol. 36, Issue 1, pp. 27-36, 2004.
44
APPENDIX A.- CNC Design.
A very basic three axis CNC milling machine requires the fine coordinated
feeding velocity and position control of all three axis and the spindle speed
simultaneously. This type of control is known as control of contouring system, and
almost all milling machines are based on this scheme. In the market there are also
retrofitted milling machines with point to point control scheme, were only control of final
position is required. In both schemes the controller has to perform three basic tasks
(motion control): interpolation/trajectory generation (TG), profile generation (PG) and
control law (CL). Current CNC systems tend to employ multiple CPU's depending on the
number of computational tasks [Altintas; 2000] [Shuett;1996]. In such multiprocessor-
based CNC systems additional CPU can be added to extend CNC intelligence and
functions.
In this lower level there are three crucial times that depend on the hardware
capability of the CNC: the block transfer time, interpolation time and servo cycle time
[Shuett;1996]. Each of these times are distinctly different, and each has the potential of
limiting the CNC from meting its requirements.
Trajectory generation
Generate trajectories must not only describe the desired tool path accurately, but
must also have smooth kinematic profiles in order to maintain high tracking accuracy ,
and avoid exciting the natural modes of the mechanical structure or servo control system
[Altintas; 2001]. At high speeds, small discontinuities in reference path result in high
frequency harmonics in the reference trajectory which end up exciting natural modes. On
some complex shapes, employing only linear and circular interpolation techniques has
serious limitations in terms of achieving the desired part geometry and productivity
[Altintas; 2001]. To address these problems a lot of research has been done in recent
years in developing new trajectory generation algorithms that provide smooth feed
motion to high speed machining systems.
45
Velocity command generation
The acceleration (A), deceleration (D), and jerk (J) values are either set to default
values within the CNC or given by the NC programmer within the NC part program.
The acceleration and deceleration of the axis is controlled by imposing a trapezoidal
velocity profile on the position command generation algorithm.
The trapezoidal velocity profile is simple to implement, computationally advantageous,
and suitable for most low speed, low cost machines, however the trapezoidal velocity
profile employs constant acceleration, (the jerk or the derivate of acceleration is zero),
which leads to various oscillations and noise on the feed and acceleration when
interpolating along complex tool paths [Altintas; 2000].
Contour error
The contour error is defined as the orthogonal deviation from the desired toolpath,
arises due to the tracking errors in the individual axes [Korem; 1983]. The main reasons
behind the tracking errors are: The dynamics response of the feed drive system to the
reference trajectory; disturbances, such as friction and cutting forces; nonlinearities, such
as backlash and saturation in the actuator system; modeling errors and axis dynamics
mismatch [Altintas; 2000]. The existence of contour error definitely indicates the
existence of tracking errors, the opposite is not always true.
Two mayor approaches have emerged for reducing the contour error in high speed
drive systems, The first approach, known as the tracking control concentrates on only
reducing the tracking error in each axis (feedforward Control). The second approach
known as contouring control (Cross Coupling Control, and Optimal Control) aims at
estimating the control error in real time and using these estimates in the feedback control
law [Altintas; 2001a].
Feedforward
The principle of design of Feedforward control is simple to implement. A transfer
function G0~l(z) that is the exact inverse of the one of the real control loop G(z). For
46
example if Go~' (z)G(z) = 1 then the actual position becomes equal to the required position.
This Feedforward controller is the inverse of the feedback control loop, which consist of
the controller and the drive. However if Gox(z) includes unstable poles, it cannot be
implemented as a feedforward controller and must be modified To address this problem,
a feedforward controller entitled "Zero Phase Error Tracking Controller (ZPETC)" was
proposed by [Tomizuka; 2001].
Look-Ahead
Look-Ahead is control software option that medium and high cost controllers have.
This software option depends on the hardware capabilities of the CNC controller. Look-
ahead in now offered by some companies either as a pre-processing step or as a part of
the DNC system. The amount of look ahead varies based on contours, feedrates and
machine performance. Look-Ahead must evaluate data ahead in several different way.
The most obvious check is whether or not the next point deviates from the current path.
With today's dense data for 3-D forms, many blocks of CNC data must be checked to
foresee vector changes [Schuett; 1996].
47
APPENDIX B.- Literature Review
High Speed CNC Speed System Design. Part I: Jerk Limited Trajectory Generation
and Quintic Spline Interpolation [Altintas; 2001].
If the feed drive acceleration command produce by the trajectory generator is not
smooth, the resulting acceleration torque for ball screw and force for linear motor drives
contain high frequency components that excite the structural dynamics of feed drives an
cause undesired vibrations. To obtain smooth velocity and acceleration profiles as in
Figure B 1, jerk -limited trajectory generation algorithms are used .
T,
©
y©
time
time
Urns
(a)
Traptfzoktal Velocity ProWe
- TrApe'oical Acceteratnn Profte^.-^*r (Jork Umitod Traiectory)
0 0.02 O.W 0.06 006 0 1 0.12 O H 0.16 0.18
0 002 0.04 0.06 OOfl 0.1 0.12 014 0.16 0.18
0 0.02 0.04 0-06
- 2x10*; i Jerk
O 002 004 006 0.08 0 1 0.12 0.M tt16 CMSTime (sec)
I . I . ^ . - - , - , , - , - .0 SO 100 150 2 0 0 2 5 0 3 0 0 3 5 0 4 0 0 4 5 0 5 0 0
Frequency JHi]
(b)
Figure B 1. (a) Kinematic profiles for Jerk-limited feedrate generation, (b) Comparison between jerklimited and trapezoidal velocity profiles [Altintas; 2001].
Important considerations:
To impose this jerk-limited generation algorithm, the following parameters need to be
known:
48
• The control loop sampling period
• The total distance of travel
• Total number of interpolation steps
• Initial, desired and final federates
• Desired acceleration, deceleration magnitudes
• Desired Jerk magnitude.
Reference trajectories generated from the interpolator need to be resample at control
loop frequency. Is recommendable to have an interpolation without federate fluctuation,
to allow jerk limited federates profiles to be realized as they are planned, without
degradations arising from feedrate fluctuations (quintic spline interpolation).
Altintas introduce a new quintic spline interpolation technique to maintain constant
position increment at each step, and eliminate feedrate fluctuations.
The proposed curves are inappropriate as CAD models for designing complex shapes
[Yang; 2004].
High Speed CNC System Design. Part III: High Speed Tracking and Contouring
Control of Feed Drives [Altintas; 2001a].
High speed machining techniques required faster feed motion between the tool
and work piece, in proportion to increased spindle speed. However, due to the limited
bandwidth achievable by using only P, PD, or PID types of servo controllers, which are
the most common ones used in industrial CNC,s there will be tracking errors in each axis
as the closed loop control system is not able to follow the rapid varying position
commands. [Altintas; 2001a].
In this paper the authors, adapt a feed forward control scheme, with Cross
Coupling Control scheme, for minimization of tracking and contour errors
simultaneously. This scheme has a large computational complexity for designing a third
order Kalman filter, a second order state feedback gain, and a third order feedforward
49
filter (see Figure B 2). This required the axis controllers to be coupled among
themselves, in accordance with the kinematic configuration of the machine tool which
has to be very accurately known.
i t AzPETC ]Feedforward L*.
Axis Dynamics ,Compensation
1 z-1
rg T,z
FeedforwardFriction Compensation
O/> r 1 1— I """HI
State
>c
Gain
DACResolution
yy -*-
A t
A
0)
AJ:
FilterState and
DisturbanceEstimator
\ 1 d Axis Dynamics i
" • to
1'Ir'i
CO
5
X
Tachometer
Encoder
1
11
Figure B 2. Axis tracking control scheme [Altintas; 2001a].
This is not very practical because actual machine tool design is toward building standard
feed drive modules with digital motors which can easily be reconfigured and used in
different production arrangements [Altintas; 2001a].
A study on a generalized parametric interpolator with real-time jerk-limited
acceleration [Yang; 2004].
Parametric curves, are used together with the traditional linear/circular blocks in
modern CAD systems. Yang proposed a new interpolation algorithm that produces
smooth kinematic profiles for parametric curves that have no relationship between
parameter and arc-length. For this approach, each linear/circular block should be
defined as a pseudo-parametric curve by the simple parameterization. The results of
mixing linear/circular blocks and NURBS blocks as in Figure B 3,with the jerk limited
profile are shown in Figure B 4.
50
0 10 20 30
V' (CO, 0,0.1.2.3.4, 5,6. 6. 6. 6}
P- HI. 1».(IO, J 429). ([5. 1.8575).(20. 2.727). (25. 5), (28. 10),(29, 15). {29 5, 20), (30. 3O)|
50 60
Figure B 3. Toolpath example of mixed blocks [Yang; 2004].
«yo
h.
seE
I4O00-,12000-I0O00-8000-6000-4000-2000-
0-
ft = 10000 [mm/min]
/ \ // \ /
/ B> \ /
/ VCVB,
/ . = 12000 (mm/min]
\\
B \\
f * I *
0 4 0 S I 0
g J^-1000-< -2000H
0 0 04 0 6lime [sec]
0 8 1 0
Figure B 4. Jerk-limited profile for mixed blocks [Yang; 2004].
Important considerations:
• The simulation for jerk limited acceleration profile for a parametric curve was
using a third order NURBS parametric curve.
• The NC blocks are interpreted using a real time operating system, were each
block is interpreted and stored in a buffer with lower priority than the
interpolation thread.
51
Algorithm development for contour error evaluation - analytical relation ship
between accuracy and productivity on high speed milling machining [Ortega; 2004]
Dynamic measurement of the contouring accuracy of the machining centers with
the HEIDENHAIN KGM-181 Grid Encoder is presented. An algorithm for contour errors
estimation is developed based on vector theory for a hexagon. Experimental results for
dynamic measurements for different programmed feedrate on two machines are presented
with different control options. Is possible to compared velocity and acceleration profiles
for the two tested machines. Machine A have a jerk limited acceleration profile.
Important considerations
1. This study evaluates dynamic capability of two different machines with very
different taxonomies.
2. Both machines were tested at same programmed feedrates, but machine A
considered a programmed feedrate of 16m/min too.
3. Other prismatic parts and a sculptured surface contour error algorithms have to be
developed.
52
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192.00
295.00-
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The Milltronics Centurion Control
Centurion VI Control
•Memory - Data Storage•3-1/2" 1.44 MB - Standard
100 MB Zip ® Drive - OptionalHard Disk 2 + Gig - OptionalRAM Memory - Volatile 16 MB - Standard32 MB - OptionalRAM Memory - Program Storage 6 MB - Standard
140 MB-OptionalRAM Memory - Operating System 2 MB
•Dual Processor Control Utilizes Latest Computer Technology•I t is estimated that 90% of all computer related engineering efforts are directed
towards the rapidly advancing PC arena. Centurion controls take advantage of theseadvances by utilizing a PC based Pentium processor to handle the operator interfaceand a robust 32 bit Motorola processor to handle the motion control. These combinedprocessors provide data throughput and features unsurpassed in the industry.
Because Centurion controls are based on a PC platform, expandable data storage,memory and communications are possible. You can also rest assured that the open PCarchitecture of the Centurion CNC controls will allow service and upgrades to beperformed well into the future and at substantially less cost than other dedicatedsystems. Additionally, all Centurion controls are five axis standard - allowing quickand inexpensive installation of an additional axis.
•Flexible Communications•Anyone who has struggled transferring programs with a CNC in the past will
appreciate the IBM format 1.44 MB floppy disk drive and RS232 communicationsport, both standard on the Centurion controls. Networking and Iomega Zip® are alsooffered as options to further enhance the file transfer ability of the control.
•Networking•Due to the Centurion control's PC architecture it is possible to connect to a Local
Area Network. Networking offers numerous advantages over RS232 communicationsas it provides transparent transfer of data at speeds of up to 100 MB/sec - more than50 times faster than typical RS232 communications. Features built into the softwarealso enhance the network connectivity by allowing the user to easily save and loadfiles to and from the network.
•Zip® Drive
•Fully compatible with Iomega Zip® Drives, which allow the user to transfer up to 100MB files via Zip disk to and from the machine seamlessly.
• A Front Panel Designed For The Operator•An operator will spend thousands of hours working with the front panel of any CNC,
this is why we have designed our front panel around an oversized high resolutionactive matrix LCD color screen rather than the tiny monochrome monitor often foundon other CNC's.
But we did not stop with the screen either. We listened to operators frustrated withinsensitive flat keypads and added a sealed full travel keypad. Machine functionbuttons such as flood, mist and spindle illuminate when selected. In fact buttons thatrequire operator response, such as Cycle Start, flash as needed to prompt the operatorthrough the task at hand.
•Conversational Programming
• A menu based question and answer format prompts the operator through programcreation. In most applications there is no need to memorize complex G and M codes.
Conversational programming is not only quick and easy, it's extremely powerful. Infact, many operations available in conversational programming are nearly impossibleto duplicate with G and M code programming. For instance the simple task ofincrementing a tool to depth with G and M codes usually involves complex looping ofsubprograms or many redundant commands. With conversational programming thistask is reduced to simple statements where only the cut increment and depths need tobe entered.
•Text Programming•All Centurion controls accept the G and M codes recognized as industry standard. If
you currently program in code, utilize a CAD CAM system, or are considering addinga CAD CAM system in the future, you can rest assured that compatibility will not bean issue.
A full word processor style editor is utilized on all CNC controls and offers helpfulfeatures such as search, search and replace, cut, copy and move. Programs as large as8 Mb can be edited concurrent to program execution.
•This useful feature allows an operator to take total control of machine movement andrun complex programs with confidence.
With this feature enabled program movement only occurs while the handwheel isbeing turned; stop turning the handwheel and machine movement stops immediately.The faster the handwheel is turned the faster the feedrate.
Ask any experienced CNC operator if they have ever crashed a machine and theanswer most likely will be yes. The usual cause is that the operator simply could notreact fast enough to the situation at hand. With this feature an operator can avoidcrashes and safely work near rotating lathe chucks or expensive fixtures.
•High Speed Control•All Centurion CNC controls have addressed the complex dynamics required for a
CNC to truly be categorized as high speed. The end result is that Centurion CNC'shave set the standard for performance in their class. Milltronics will benchmark ourcontrol against any other control in the industry!
Processor SpeedThere are literally thousands of calculations required for each and every axismovement. When trying to machine complex geometry, often the microprocessor ofthe control creates a bottleneck restricting the attainable feedrate. To minimize therisk of this processing bottleneck, Centurion CNC controls utilize two 32 bitprocessors providing over 150 megahertz combined processing speed. With these twoprocessors working together, over 1250 blocks per second can be achieved.
Intelligent Axis Acceleration And DecelerationControlling how an axis decelerates and accelerates is one of the most crucial factorsrelating to machine speed. Understanding that it is impossible for a servo motor tostop and start a heavy machine slide anywhere close to 1,000 times per second leavesthe only hope of achieving speed through greater intelligence of the acceleration anddeceleration slopes. All Centurion controls search ahead in a program as much as 255moves to determine the directional changes that lay ahead. Once these directionalchanges are known the CNC will dynamically adjust the deceleration and accelerationslopes to minimize stopping and starting.
AccuracyServo motors cannot instantaneously respond to a given command. This lack ofresponse negatively effects accuracy and only deteriorates as the feedrate increases.To counter the disastrous effects of servo response, Centurion CNC controls utilize anelaborate "Feed Forward" error correction algorithm that reduces inaccuracy withoutcompromising speed. Until now feed forward error correction has been found only ona handful of the world's most expensive CNC controls and should in no way beconfused with inferior error correction systems that rely on slowing feedrates tomaintain accuracy.
•Long List of Standard Features
on-line help.
If an operator has a question about a conversational programming screen, pressing theHelp button will pull down an illustration defining the operation at hand.
•Manual Operation with Teach Programming•The SLS control not only supports full manual operation of the machine, it also
allows a program to be constructed as the machine is operated manually.
When manually machining a part for the first time an operator simply needs to press abutton after each manual move and the present machine location is stored in anexecutable CNC program. The program is stored in both conversational and ISOformat making future editing easy.
•Dual Handwheel Operation (Option)•An electronic dual operator station can be added to any SLS control. This option
places the X and Y axis handwheels in a convenient location to reduce operatorfatigue.
•Manual Operation•The Centurion T CNC control fills the hole between manual engine lathes and
difficult to use CNC turning centers. Operation in full manual, simple MDI and fullyautomatic is standard.
For full manual operation a conveniently located remote panel places the necessarycontrols at the operator's fingertips. Single operations that cannot normally be madeby simply turning handwheels, such as tapers, radii and threading, can be madequickly and easily with conversationally prompted MDI screens.
•Teach Mode Programming•Teach mode programming allows an operator to construct a program through a
combination of manual and MDI commands.
Other teach systems only allow manual machine movements to be recorded into aprogram. These systems are highly restrictive in that it is impossible to cut threads,radii and tapers by simply turning a handwheel. The Centurion T control allows notonly manual moves to be recorded directly into a program, but also a series ofconversationally prompted MDI events including threading, tapers and arcs.
•Automatic Operation•Like the other Centurion CNC controls, the Centurion T has all of the advanced
features you could ask for: Conversational programming, Trig Help, Graphics andmore are all standard.
Virtually any part can be programmed quickly and easily with conversationalprogramming.
•Digitizing•Digitizing option permits quick, easy and cost effective duplication of parts with
unattended operation.
In lathe applications a digitized 2D part profile is ready to run at the CNC with no
additional processing. Output file is standard ISO G and M code. Not only can it beedited with any text editor, it can also be input into other CNC controls to maximizeproductivity.
In milling applications both 2D part profiles and complex 3D surfaces can becaptured. Output is standard ISO G and M code as well. With the use of the off-lineDigiscan software a digitized file can be inverted (male to female), cuttercompensated, scaled, rotated, mirror imaged and more It can also translate the fileinto a DXF or CDL format for input into popular CAD CAM systems.
Even if your needs do not call for Digitizing now it can be installed on all Centurioncontrols at a later date - installation is a simple four wire connection.
•Off-line Software^Off-line software of all Centurion CNC controls is available. Off-line software allows
programs to be created and graphically verified the same as they are at the machine.
The software also serves as a storage library for part programs and supports RS232communications for trouble-free communication with the CNC.
An additional feature allows import of DXF or CDL CAD files which expandsdifficult part programming capabilities.
•Increased Data Storage•Battery backed up SRAM program storage can be increased to 512K or 720K, or add
a hard disk to increase program storage to over 1 Gig.•Tool Offset Probing
• A table-mounted probe allows tool radius and length offsets to be set quickly andconsistently. The probe can be used in-process to determine tool breakage.
•Workpiece Probing•The Workpiece Probing option aids in setup of difficult parts. It provides the ability
to automatically set and correct work coordinates, tool offsets, rotation angle andmore after inspection of a fixtured part.
•General•Microprocessor - 32-bit IBM compatible PC based 1000 blocks/sec DNC with up to 5
axis of control Multi processor/parallel processing capability. Feed Functions: Jogfeed, rapid and incremental. Electronic handwheel, Feedrate override, Programmableacceleration and deceleration, Excess error fault protection, Minimum programmingresolution 0.0001", Mid program restart, Automatic start, stop, reverse, RPMoverride on Spindle, Tool Functions: 99 tool length and radius offsets, One buttontool setting routine.
Graphics Functions: Large color LCD screen, Full 3D view with rotational, iso,zoom, and window. Program verify, Runtime display (excellent forestimating). Feedrate, rapid rate, part and offset toolpath display.
Distinctive Programming Functions: Built-in engraving Linear, circular & helicalinterpolation Advanced trig help Part rotation Scaling (each axis individually if
ILL1R0NI.Manufacturing Company
CENTURION IV USERSGo From This - TO THIS1
CENTURION 7 PC Based CNC
CNC is self-contained in thecompact operator's station
AFF0RDABLY11
SPECIFICATIONS
FEATURES Centurion 7
Absolute / Incremental StdInch / MetricConversational ProgrammingTrigonometry Assist ('Trig Help")Corner Chamferinq And RoundingCutter CompensationColor Graphics - Tool Path and
Part ProfileCanned Drilling CyclesDiagnosticsExcess Error ProtectionFull Language Errors MessageBacklash CompensationBall Screw Pitch Error CorrectionMirror, Scale And RotateEIA/ISO Code (Fanuc®)
Compatibility*Macro ProgrammingSubprogram Looping And Nesting3 Point Circular InterpolationPolar CoordinatesAuto / Block OperationProgrammable DwellBlock SkipConcurrent ProqramminqHard Tapping (Optional)Digitizing ReadyProgram Interrupt And ResumeGraphics Based Mid-Program StartProgram Start from Block or Tool #Hand wheel RunTeach ProgrammingFeed Forward Error CorrectionSelectable Corner AccuracyAutomatic HomingCircular InterpolationAxis JogSoftware LimitsUnidirectional ApproachDry RunAutomatic Tool Setting ProgramSelectable LanguagesMultiple Work Offsets1 Button Tool / Fixture Offset Entry8 Mb Text Editing with Cut, Copy,Move and Search/ReplacePocketing and Framinq CyclesTapered And Round Walls3D Sweep RoutineHelical InterpolationBolt Hole Drill CycleEnqraving, with SerializingSpeed And Feed CalculatorOnline Help ScreensIrregular Pocket ClearingAuxiliary Keyboard JackCurrent MeterTrue Spindle Speed FeedbackNetwork CapableElectronic HandwheelPolygon Milling Cycles60 Work OffsetsParts Counter
StdStdStdStdStdStd
adStdadStdadadadad
adadadadadadadadOpt.adadadadadNAOpt.adadadadadadadadadadadad
adadadadadadadNAOpt.adadOpt.Opt.adadadad
* Compatibility varies with control version
Centurion 7 SLS
StdStdStdadStdStdStd
StdStdStdStdStdStdStdStd
StdStdStdStdStdStdStdStdOpt.StdStdStdadStdStdOpt.StdStdStdStdadStdStdStdStdStdStdStd
StdStdStdStdStdStdNAStdOpt.StdOpt.Opt.Opt.StdStdStdStd
CONTROL
Processor: Motion ControlProcessor Operator Interface
Program ThroughputAxis Control
Motorola 32 bitPentium 130 Mhz(Or greater)
Over 1300 blocks/sec4Axes- Standard
MEMORY - DATA STORAGEFloppy Disk 3 1/2" 1.44 Mb - Standard100 Mb Zip® DriveRAM Memory - Volatile
Optional16 Mb Standard32 Mb Optional
RAM Memory - Program Storage 12 Mb StandardNon-volatile 256 Mb - Optional
"SLS" Skill Level SelectFor machines without automatic tool changers, thisinnovative feature allows the CNC control to beconfigured to match the skills of the CNC operator.We have worked with a number of first-time CNCoperators and have recognized that the more fea-tures, screens and selections a CNC control has,the more intimidating it is for the operator. Oftenthese selections overwhelm the new operator,undermining confidence and lengthening thelearning curve. Skill Level Select solves this byallowing the operator to enable/disable features toa comfortable level. Operate the CNC in an easy touse two axis format, step up to a simplified threeaxis operation and, when ready, turn on all thefeatures to maximize productivity. In the highestskill level you will be ready for even the mostchallenging programs — from custom codes toparametric programming. Truly a control thatmeets all needs of toolroom milling!
A TRUSTEDNAME IN CNCFOR 30 YEARS!
PROPOSAL
UPGRADE PACKAGECPU assembly, PC based with upgrade adapter kit $6,995Operator's Station with new LCD screen, electronic handwheel and tactile keys 1,995Subtotal $8,990Less Milltronics User Special Discount - 2,490TOTAL $6,500
PARTS REUSED - Typically Reusable Unless Defective
Servo plate (if not reusable add $455 per axis for a used or reconditioned unit)Servo motors (if not reusable add $600 per axis for a used or reconditioned unit)Magnetics (will propose replacement of defective parts)Encoders (if not reusable add $200 per axis)
INSTALLATION - In The Field
Field installation will be arranged by Milltronics and performed by Milltronics or acertified dealer. A customer should not attempt to install this himself.
Installation $1,100.00PLUS
Expenses - air, auto, lodging Actual costsOr
Flat fee anywhere in the USA $1,900.00 + Air Ticket(Air ticket can be proposed prior to order)
INSTALLATION - In Our FactoryInstallationCustomer pays machine
ACCESSORIES
freight each way, estimated at $500.00 to. .$900$1,000
00.00
Upgrade to 12" Color LCD with Discrete Pushbutton Keys $900.00Off-line FastCAM Software $400.00Large Program Package $4,000.00
Includes: 256 Mb solid state non-volatile memory upgrade, Zip® drive,additional 16Mb extended program execution memory,feed forward and look-ahead for high speed machining or 3-Dmilling, and networking option with 30 day phone support
DRIVE SYSTEMConversion of Reeves drive system to an inverter or controlled direct drive system, upto 7 V2 HP (Must be done at the factory) $2,800.00
Centurion 7 Upgrade includes the following:Large color LCD display with 3D graphicsOperator's controls, pushbuttons, and panelElectronic handwheel with handwheel verifyKeyboard jack for PC keyboardCPU, PC-based with 1300 block/sec processing and 12 Mb parts storage
memory plus large program editing/execution capabilitySoftware features including conversational, G & M code programming,
3D part and tool path graphics, engraving, helical interpolation, autoroutines, user-definable macros with trig assist, coordinate rotation,scaling, mirror image, irregular pocket clear and much, much more.See the Centurion full catalog for a complete description.
3 V2" 1.44 Mb floppy driveInterface cable and hardware
WARRANTYAll new or replaced parts have a one-year parts warranty for normal usage. Originalreused parts have no warranty.
SPECIAL NOTEBecause we have concerns on the reusage of some machines, special softwarerequirements or other unusual circumstance, we reserve the right to refuse the sale ofthis upgrade package.
TERMSAny freight or rigging is not included with proposal. Customer should be prepared toincur additional expenses if original parts are found not to be reusable. This proposaldoes not include any replaced machine parts or repairs. New parts have a one-yearwarranty for normal usage. Original reused parts have no warranty.
Payment: 80% down with order20% net 30 days after installation
Make The
^HlLLlRONICSContact the factory for special offers or financingoptions. Subject to credit approval and approval by 1400 Mill Lane • Waconia • MN • 55387
your local distributor. 952-442-1410 • 952-442-6457 (Fax)www.milltronics.net
Milltronics reserves the right to amend or change without notice.Centurion 4 Upgrade Rev. 2 9-17-03
SINUMERIK 840D:The Digital System for Almost All Applications ..
The SINUMERIK 840D offers a convincingrange of innovative technology-specificfunctions.
Standard cycles are available for frequentlyrecurring machining operations in the drilling,milling and turning technologies.
And even extremely exacting applications, like5-axis milling in the manufacture of tools andmolds, are no problem for the SINUMERIKgeneration. The continuity from the CADsystem right through to the workpiece andintelligent motion control allow fast, preciseproduction of even highly complex parts. Theseparation of geometry and technology withRTCP (remote tool center point) and 3D tooloffset simplifies alterations. And the promptmachine stop facility, in the event of toolbreakage, for example, protects both machineand workpiece.
Solving digital tasks fast andprofessionally
The standard SINUMERIK 840D control in-cludes tailor-made functions for high produc-tivity and precision for grinding, flexible axismovements with the aid of positioning axesand reciprocating functions, short machiningtimes using multiple feed values in a blockand fast set-up by means of handwheel over-lay.
Time-critical process signals are connected todirect CNC inputs/outputs and programmedby synchronous actions. Special axis couplingscan be defined using cam tables, e.g. forswing-frame grinding. Transformation of aninclined axis also permits inclined bed appli-cations, and tool compensation is includedon-line to permit simultaneous grinding anddressing (continuous dressing).
In conjunction with adaptive control, theSINUMERIK 840D enables optimum utili-zation of spindle power, prevents overload,protects the workpiece, reduces machiningtimes and improves surface quality withoutthe need for additional hardware.
Handling tasks, such as work-piece mani-pulation, machine loading, packaging andpalletizing, can be easily performed byconnecting the handheld terminal (HT 6).
In the same way, an "electronic gear with non-linear coupling" is also possible. In additionto the manufacture of convex gear tooth sur-faces, it is thus possible to compensate fornonlinear characteristics of the process.
Technical Specifications:Impressive Performance Data
Control typeModular 32-bit microprocessor CNCcontinuous-path control for turning,drilling, milling and grinding machinesand handling with integrated powerfulPLC.The control consists of a 50-mm-widemodule and a choice of external intel-ligent operator panels to meet all typesof operator requirements.
Function overviewx Drilling, turning, milling, grinding,
nibbling, punching, laser machiningand handling technologies
x Optimum, complete digital solutionwith SIMODRIVE 611 digital
o Up to 10 mode groups, 10 channelsand 31 axes/spindles
o Channel structure: Simultaneousasynchronous processing of partsprograms
o OA open-ended NCK softwarex Feedrate and rapid traverse:
103 mm/min to 999 m/minx Endlessly rotating rotary axesx 2D+n helical interpolationx Spindle package with extensive
range of functions, for example,various thread cutting functions,variable pulse evaluation, orientedspindle stop
o 5-axis machining package with5-axis transformation, 5-axis toolcompensation, oriented tool retrac-tion (RETTOOL) remote tool centerpoint (RTCP)
o Spline interpolationo Polynomial interpolation of the
third degreeo Control value linking and curve
table interpolationo Electronic gearboxo Link axiso Axis containero Electronic transfero Axis and spindle movements from
synchronous actionso Speed-dependent analog value
outputo Sensor-controlled 3D distance con-
trol
o Evaluation of internal drive variableso Continuous dressingx Acceleration with jerk limitationx Programmable accelerationx Synchronized actions (SYNACT)x Coordinate transformation and
inclined-surface machining withFRAME
o Fast retraction from the contourwith RETT routines
x Direct/indirect measuring systemswitchover for high degree ofprecision and fast positioning
o Extensive motion control for veryfast machining with Look Aheadfunction and dynamic feed-forwardcontrol
x Travel to limit stop with adaptableforce or limited torque
x Follow-up modex Advanced detection of contour
violationso Tool-oriented RTCPx Configurable number of inter-
mediate blocks with tool radiuscompensation
x Tool radius compensation withapproach and exit strategies andcalculation of intersection
o Tool length compensationo Interpolation leadscrew error com-
pensation and measuring systemerror compensation
o Multidimensional sag compensationx Backlash compensationx Quadrant error compensationo Automatic quadrant error compen-
sation with neuronal networkx Safety routines permanently active
for measuring circuits, overtemper-ature, battery, voltage, memory,limit switch, fan monitoring, EPROM
x Working area limitationx Software limit switchx Contour monitoringx Spindle monitoringx Diagnostic functions from interface,
PLC and NC with plaintext displayson screen
o Interrupt routines with fast retrac-tion from the contour
o Safety Integrated
PLCx Integrated SIMATIC S7-compatible
CPU 315-2DPor314C-2DPo Program and data memory expand-
able to 288 KB or 460 KBx Programming language STEP 7o I/O modules expandable to 2048
digital inputs/outputsx Max. 4096 flags, 128 or 256 timers,
64 or 256 counters, 256 FBs/FCsand 399 DBs
o Servo or step motor PLC positioningaxis
o S7 HiGraph programmingo Distributed I/Os via PROFIBUS-DP
Operating componentsThe operator panels are modular instructure and can be assembled to pro-vide specific levels of performance.
o OP 01 OS operator panel (310 mmwide), 10.4" TFT display, VGA(640 x 480), mechanical keys
o Machine control panel (310 mmwide) with 16 customer keys,1 slot 22 mm dia. and 6 slots16 mm dia.
o Full CNC keyboard (310 mm wide)o OP 010 operator panel (19" wide),
10.4" STN color display, membranekeyboard
o OP 010C operator panel (19" wide),10.4" TFT color display, mechanicalkeys
o OP 012/OP 015A operator panel(19" wide), 12.1715" TFT color dis-play, membrane key board and in-tegral mouse, vertical soft keys canbe used as direct keys in the PLC
o OP 015 operator panel (19" wide),15" TFT color display, membranekeyboard
o TP 012 touch operator panel(400 mm wide)
o Machine control panel (19" wide)with 30 customer keys and key-switches
o MPI interface module for customermachine control panel
o Full CNC keyboard (19" wide)
o MFII PC standard PC keyboardo OP 030 slimline operator panel
(280 mm wide)o Handheld control terminalo HT6 handheld terminalo PCU 20
- COM 1 (V.24/TTY), COM 2 (V.24)- PS/2 keyboard- Multipoint interface (MPI)- USB, 2 channels (1 x internal/
1 x external)- Ethernet 10/100 Mbit/s (optional)- Cardbus (max. Type III)- Disk drive interface (option)
o PCU 50Industrial PC with 566 MHz/128 MBSDRAM or 1.2 GHz/256 MB SDRAM- Removable hard disk with trans-
portation lock (1 Gbyte for userdata)
- Microsoft Windows NT 4.0 (US)or XP operating system
- COM 1 (V.24/TTY), COM 2 (V.24)- LPT1 parallel port- PS/2 mouse, PS/2 keyboard- Multipoint interface (MPI)- USB, 2 channels (1 x internal/
1 x external)- Ethernet 10/100 Mbit/s (option)- Cardbus (max. type III)- Disk drive interface- Expansion slots:
1 x PCI/ISA + 1 x PCIo PCU 70
- Expansion slots: 1 x PCI/ISA +3 x PCI (otherwise the PCU 70is exactly as the PCU 50)
Operation and displaysx Clear operation with operating
areas with 8 horizontal and verticalsoftkeys each
x Operator panel disablex User-oriented hierarchical access
protectionx Supplement operator interface
(user-specific)o OA Windows operator interface
configurableo Control unit management (up to
8 PCUs to max. 8 NCUs)
Operating modes:x AUTOMATICx JOG (set-up)x TEACH IN (program generation
interactively with the machine)x MDA (processes manually entered
block)x The operating modes are supple-
mented by the machine functions:- PRESET to set a new coordinate
reference point- Simultaneous traversing of axes
with up to 2 handwheels- Overstoring machine functions in
setup mode and AUTOMATIC mode- Program selection via directory
Displays:o Screen text in several languages
(English, German, Spanish, French,Italian), other languages on request
x Program window for block displayx Positional actual values, 2- to 5-fold
character sizex Screen saverx Plaintext display for operating status
Programming:x User-friendly programming language
editor to DIN 66025 with comprehen-sive range of high-level languageelements
o Technology cycles for drilling, turningand milling
x Tapping without compensation chuckx Dimension input metric, inch or mixedx Extensive parameter technologyx Program generation parallel to
machiningx Reference point approach ace. to
programo Measuring cycles, measurement in
JOG modex Fast NC-PLC data exchange via
dualport RAMx Contour and cycle programmingx Simulation for turning and millingo AutoTurn - programming software
for simple turned partso ManualTurn - simple operating and
programming interface for turningo ShopTurn - convenient operating
and programming interface forturning and milling
o ShopMill - convenient operatingand programming interface formilling and drilling
o SinuTraino On-line ISO dialect interpretero CAD reader, converts DFX files into
drilling patterns and contoursx Dynamic block buffer (FIFO)x Configurable number of zero offsetsx Up to 2.5 MB NC user memory (RAM)
for parts programs, tool offsets, offsets
Communicationx RS232C (V.24)/TTY universal opera-
tor interface, configuration viaplaintext screenforms
x Read in/read out via universal inter-face during machining
x Extensive archiving procedureso Serial data transmission with
SinuCom PCINo Archive and transmit data with
DNCNT2000o Data transmission via standard
network with SinDNCo Communication of tool require-
ment via SinTDIo Communication to host computer
via SinCOMo Data exchange between production
planning and manufacturing viaWinBDE
x Program coordination via CNChigh-level language
x CNC-PCU multipoint interfacex 2nd serial interface (HMI via
external PC)o I/O interface via PROFIBUS-DP
(master or slave)
Keyx CNC functions included in the basic
configurationo Option or Accessory
HMI - Human machine interfaceMPI - Multi Point InterfaceNC - Numeric controlOA - Open architecturePLC - Programmable logic
controller
SIEMENS
SINUMERIK 802S & STEPDRIVESINUMERIK 802C & SIMODRIVE
Catalog September 2001
•*
J 1 ?••'
Mill UK
•
Function OverviewSINUMERIK 802S/SINUMERIK 802C
CNC memory (non-volatile) for programs and data, 256 KBPart program memory, up to 50 programsMax. 3 axes + 1 spindleSpindle positioningIncremental encoder RS 422Additional spindle encoder RS 422Resolution 1 jim/0.00001 inches
Look ahead, 1 block
Programming language, DIN 66025 and SINUMERIKhigh-level languageInch/metric dimensionsContour programmingAbsolute/incremental programmingX axis diameter/radius programmingArithmetic and trigonometric functionMenu programmingSubroutine callSkip functionChamfer/radius transitionPlane selectionWorkpiece coordinate system
Linear interpolation, max. 3 axesCircular interpolationHelical interpolation
RS 232 C serial interfaceData transmission from ECU to ECU
Slimline operator panel, monochrome, 5.7*Full CNC keyboard2 electronic handwheels can be connectedGraphical cycle support2 languages available in the system/switchable online,English/customer-specific (German/Chinese etc.)8 access protection levelsProgram execution via external DNC
AutomaticDNC modeMDA modeJOG modeTeach inReference point approach manual/via CNC programIncrement weighting with handwheelManual mode interruptJOG and handwheel simultaneous modeIncremental axis approachDry runSingle block
Block number searchProgram number searchBackground editing
Graphical displayStatus displayCurrent position displayProgram displayProgram error displayParameter displayOperator error displayAlarm displayServo setting displaySpindle displaySelf-diagnostics functionStatus signal output(NC ready, servo ready, automatic operation, etc.)
Length/radius compensationTool management15 tools30 tool offsetsTool radius offset in the planeCollision monitoring, machining areaTool tip radius compensationTool position compensationGeometry/wear compensationTool length measurement
Standard features at no additional costs
Option or accessory
Siemens Catalog SINUMERIK 802S/802C • September 2001
Function OverviewSINUMERIK 802S/SINUMERIK 802C
Zero offsets, adjustable, max. 4Zero offsets, programmable
Cycles for turningCycles for drilling/milling
Limit switch monitoring2 software limit switchesContour monitoringPosition monitoringClamping monitoring
Stored leadscrew error compensationBacklash compensationMeasuring system error compensationDrift compensation for analog set points
Velocity (max. default 100,000 mm/min / 40,000 inch/min)Feedrate override, 0% to 120%Feedrate per minFeedrate per revolutionTangential velocity constant controlJerk limitationJOG override
Miscellaneous function M (2 digit)Max. 3 auxiliary functions per block
Spindle speed, programmable (max. 999,999.9 rpm)Spindle override 0% to 120%5 gear stagesAutomatic gear stage selectionOriented spindle stopConstant cutting speedThread cuttingTapping/rigid tapping
SIMATIC S7-200 software CPUUser memory, 4000 instructionsLadder programmingDigital inputs/outputs, 16/16Digital inputs/outputs, 64/64 in 16/16 steps1024 flags16 timers32 countersTypical processing time for bit commands 1.8 p.s
Diagnostics basic functionsPLC status
Alarms selectable in the part programAlarms and messages from PLC
Start-up tools, running on external PCSeries start-up via serial interface
The manual machine version contains in additionthe following functions:
Constant oriented spindle stop for material changeThreading with constant cut profile at working spindleCutting of multiple threadsCutting of conic threadsCutting of transversal threadLimit stop turning in X and Z axisConic turning over the complete working areaRepair thread cutting
Standard features at no additional costs
Option or accessory
Siemens Catalog SINUMERIK 802S/802C • September 2001
System OverviewCNC Control
SINUMERIK 802D panel control unit, keyboards
The SINUMERIK 802D combines all CNC, PLC, HMI and com-munications tasks in a single component. The maintenancefreehardware integrates the PROFIBUS interface for the drives andthe I/O modules with the slimline operator panel in a ready-to-install unit.
The SINUMERIK 802D can digitally control up to 4 axes and1 spindle. The SIMODRIVE 611 system, which is modular indesign and PROFIBUS compatible, is used as the drive system.Consequently the drive power can be individually structured inevery respect. Alternatively, the spindle can also be connectedvia an analog interface, which means that universal solutionscan be implemented even for simple machines. The SIMATICS7-200 facilitates straightforward adaptation to the machine.
Workpiece programming can not only be carried out universallyon the SINUMERIK, but also allows the use of non-SiemensG codes.
The following components can be connected to theSINUMERIK 802D:
Full CNC keyboard (vertical format or horizontal format)I/O module PP 72/48 via PROFIBUS connectionConverter system SIMODRIVE 611 universal E via PROFIBUSElectronic handwheels (max. 3)Mini handheld unit
I/O module PP 72/48
The I/O module is connected to the PROFIBUS and offers72 digital inputs and 48 digital outputs (24 V, 0.25 A).The 3 connectors for the I/Os comply with MIL-C-83-503 (flatribbon cables).
The I/O module provides:3 x 24 digital inputs and 3 x 1 6 digital outputsIntegrated power supply 24 V DC with electrical isolationbetween I/Os and PROFIBUS
Machine control panel MCP
The machine control panel offers a simple and cost-effectivestandard solution for turning and milling machines. In addition to6 customized keys (with LED) all the keys and switches that areneeded to operate a machine are provided.
All wiring work for mode type selection, 2 override switches, NCstart/stop, spindle function and reset are taken care of by simpleconnection to the PP 72/48 I/O module using 2 ribbon cables.The EMERGENCY STOP switch is fitted with a break contact anda make contact.
aaaaaao
GDOS ana
SINUMERIK 802D panel control unit with full CNC keyboardvertical format (beside) or alternatively horizontal format (below)
I/O module PP 72/48
Machine control panel
• Siemens Catalog SINUMERIK 802D June 2000
SINUMERIK 802DFunction Overview
CNC user memory (non-volatile) for programs and data,256KBPart program memory, up to 100 programsMax. 4 axes + 1 spindleSpindle positioningIncremental encoder sin/cosAbsolute encoder EnDatAdditional spindle encoder RS 422Resolution 0.1 nm/0.00001 inches
Look ahead, 10 blocksFRAME concept (mirror image, scaling, rotation)1 measuring probe, with/without delete distance-to-go
Programming language, DIN 66025 and SINUMERIKhigh-level language, online interpreter for other G codesInch/metric dimensionsContour programmingAbsolute/incremental programmingX axis diameter/radius programmingDirect drawing dimension programmingArithmetic and trigonometric functionMenu programmingSubroutine callSkip functionChamfer/radius transitionPlane selectionWorkpiece coordinate system
Slimline operator panel, monochrome, 10.4"Slimline operator panel, color, 10.4"Full CNC keyboard3 electronic handwheels can be connectedGraphical cycle supportDIN simulation2 languages available in the system/switchable online,English/customer-specific (German/Chinese etc.)6 access protection levelsWorkpiece counterProgram execution via external DNC
AutomaticDNC modeMDA modeJOG modeReference point approach manual/via CNC programFollow-up modeIncrement weighting with handwheelManual mode interruptJOG and handwheel simultaneous modeIncremental axis approachDry runSingle block
Block number searchProgram number searchBackground editing
Linear interpolation, max. 3 axesCircular interpolationHelical interpolationPolar coordinate interpolation
RS 232C serial interfaceData backup and start-up with PC cardPROFIBUS
Graphical displayStatus displayCurrent position displayProgram displayProgram error displayParameter displayOperator error displayAlarm displayServo setting displaySpindle displaySelf-diagnostics functionStatus signal output(NC ready, servo ready, automatic operation, etc.)
Standard features at no additional costsOption or accessory
• Siemens Catalog SINUMERIK 802D June 2000
SINUMERIK 802DFunction Overview
Length/radius compensationTool management32 tools64 tool offsetsTool radius offset in the planeCollision monitoring, machining areaTool tip radius compensationTool position compensationGeometry/wear compensationAutomatic tool length measurement
Zero offsets, adjustable, max. 6Zero offsets, programmable
Working area limitationLimit switch monitoring2 software limit switchesContour monitoringPosition monitoringZero speed controlClamping monitoring
Spindle speed, programmable (max. 999,999.9 rpm)Spindle override 0% to 200%5 gear stagesAutomatic gear stage selectionOriented spindle stopConstant cutting speedThread cuttingTapping/rigid tapping
Cycles for turningCycles for drilling/milling
SIMATIC S7-2OO software CPUUser memory, 6,000 instructionsLadder programming languageWindows programming toolMax. 144/96 digital inputs/outputs2048 flags32 timers32 countersTypical processing time for bit commands 0.4 us
Stored leadscrew error compensationBacklash compensationMeasuring system error compensationFeedforward control
Rotary axis turning endlesslyVelocity (max. default 100,000 mm/min / 40,000 inch/min)Feedrate override, 0% to 200%Feedrate per minFeedrate per revolutionTangential velocity constant controlJerk limitationJOG override
Miscellaneous function M (2 digit)2nd auxiliary function H (6 digit)Max. 3 auxiliary functions per block
Diagnostics basic functionsPLC status
Alarms and messages selectable in the part programAlarms and messages from PLC
Axis limitation from PLCProtection zone
Start-up tools, running on external PCSeries start-up via serial interfaceSeries start-up via PC card
Standard features at no additional costsOption or accessory
Siemens Catalog SINUMERIK 802D • June 2000
*hriM \ * 1X111. Page 1 of4
De: Guerrero Roger <[email protected]>A: '"[email protected]"1 <[email protected]>Cc:Asunto: RV: Presupuesto RetrofitFecha: Tue, 26 Apr 2005 10:27:23 -0500
David,Anexo la respuesta por parte del desarrollador de producto.Saludos cordiales, Roger
Mensaje originalDe: Schneider WolfgangEnviado el: Martes, 26 de Abril de 2005 10:13 a.m.Para: Guerrero RogerAsunto: AW: Presupuesto Retrofit
Hi Roger,
Following situation:Our best block cycle times are:802C bl - 24 milli sec802D - 12 miili secBut more important for the processing are the time the processor realy hasto do the interpolation. If you have a one processor controller. Thiscontroller has to do all the work.If the partprogram is also well prepared via a post processor you can alsosave steps and get a higher speed.Next point is the requested or realiced accuracy of the part. I f accuracyis not necessary or not possible by the controller you very often get muchbetter surface.Last but not least is important how good is the optimisation of the mechanicparts of the machine.
If you have more questions please contact me again.
Best regardsWolfgang
Urspriingliche NachrichtVon: Guerrero Roger [mailto:[email protected]]Gesendet: Freitag, 22. April 2005 16:05An: Schneider WolfgangBetreff: RV: Presupuesto Retrofit
Hi dear Wolfgang. How are you? Long time since have talked each other.
A university of Mexico is interested in doing a retrofit with 802C BL and802D. They have a question that I couldn't answer. They are asking me howmany blocks per second are able to process?
RegardsRoger
Mensaje originalDe: David Reyes Luna [mailto:[email protected]]Enviado el: Jueves, 21 de Abril de 2005 05:57 p.m.Para: Guerrero RogerAsunto: RE: Presupuesto Retrofit
Roger,
Gracias por las propuestas. Pienso que la mejor opcion seria el 802C.
http://mailserver 1. itesm.mx/mail/MessagePrintView?sid=6ED0683EEB7C68452D7E 17F1173 A8... 5/20/2005
POS.
1
3
6
CANT.
2
1
1
MLFB
1FK7042-5AF
6FC55000AA
6FC55480AC
DESCRIPCION
SERVOMOTOR SINCRONO 1FK7COMPACT,3,0 NM, 100 K, 3000 R/MINREFRIGERACION NATURAL,IM B5 (IM V1, IM V3)CONECTOR POTENCIA/SENALESCONECTOR GIRABLE 270 GRADOS,SIS. CAPTADOR RESOLVER 2 POLOS;(RESOLVER P=1);EJE CON CHAVETA, TOLERANCIA NSIN FRENO DE MANTENIMIENTO;GRADO PROTECCION IP64;
SINUMERIK 802C BASE LINEPAQUETE BASE COMPUESTO DE:CONTROL DE PANEL MANDO INCL:PANEL DE MANDO DE MAQUINAPERIFERIA 48/16 E7S DIGITALESTOOLBOX LOGBOOK
SIMODRIVE BASE LINECONVERTIDOR PARA DOSSERVOMOTORESCON RESOLVER 2 POLOS 6+3NMDEL TlPO 1FK7 INTENSIDAD 2X5 A
PRECIO
737.59
4,393.58
2,887.65
1,475.19
4,393.58
2,887.65
POS.
1
3
4
CANT.
2
1
1
MLFB
1FK7042-J
6FC5600-C
6FC5603-C
DESCRIPCION
SERVOMOTOR SINCRONO 1FK7COMPACT,3,0 NM, 100 K, 3000 R/MINREFRIGERACION NATURAL,IMB5(IMV1,IMV3)CONECTOR POTENCIA/SENALESCONECTOR GIRABLE 270 GRADOS,SISTEMA CAPTADOR INCREMENTAL;(ENCODER I-2048);EJE CON CHAVETA, TOLERANCIA NSIN FRENO DE MANTENIMIENTO;GRADO PROTECCION IP64;
SINUMERIK 802D PAQUETE BASE 1:-TECLADO CNC COMPLETO VERT.-1 X SIMODRIVE 611 UNIVERSAL E-1 X MODULO MOTION CONTROLCON PROFIBUS-DP-1 X MODULO PERIFERIA PP 72/48-3 X CONECTORES PROFIBUS-SINUMERIK 802D TOOLBOXSINUMERIK 802DPANEL DE MANDO DE MAQUINAFORMATO ELEVADOMONTAJE JUNTO A LA PANTALLA24V, CONEXION CABLE PLANOADAPTADO 6FC5611-0CA01 -0AA06FC5611-0CA01-0AA0
PRECIOUNITARIO
1,117.96
6,955.20
607.03
TOTAL
2,235.91
6,955.20
607.03
11
16
1
1
6SL3000-0
6SN1145-'
SINAMICS / SIMODRIVE 611PAQUETE FILTRO RED 16KWENTRADA: 3AC 380-480V, 50/60HZCOMPUESTO DE: BOBINA DE RED HFTIPO 6SN1111-0AA00-0BA1 YFILTRO DE REDTIPO 6SL3000-0BE21-6AA0SIMODRIVE 611MODULO E/R, 16/21 KWREGULADO,EVACUACION DE CALOR INTERNA,PROTECCION DE RED CONCONTACTO ABIERTO
1,280.81
2,468.48
1,280.81
2,468.48
The Powerful HEIDENHAIN Contouring Control
iTNC 530
Built for the workshopThe machine operator can programhis operations in dialog with thecontrol. For simple work it is easyto operate the machine manuallywith the iTNC 530.
Fast block-processing times andoptimum motion control make theiTNC the perfect choice for HSCmachining
Automated manufacturingOn machining centers the iTNC 530manages tools and pallets. Overthe data interfaces you can eveninterrogate operating conditions oroperate the machine remotely.
For 20 years, TNC contouring controls have been proving themselves in daily use on milling machines,drilling and boring machines, and machining centers. This success is due in part to its shop-orientedprogrammability, but also to its compatibility with the programs of its predecessor versions. TheiTNC530 is also compatible in its operation and programming with its predecessor models.
The machinist who has already worked with TNC does not have to relearn. On the iTNC 530 heimmediately uses all of his previous experience with TNCs, programming and machining as before.
The iTNC 530 features a new, more powerful processor architecture, to enable you to finish your jobsin the workshop even more quickly:. With its sophisticated closed-loop control methods and short block processing times, the iTNC
530 mills your workpieces faster then ever., With the fast editor of the iTNC 530 you can edit and add to you existing programs in seconds.. You can verify even complex programs quickly and simply with the iTNC 530 through its optimized
graphic buildup.
# Over its Fast Ethernet data interface (100 megabaud) you can transfer long programs quickly froma remote programming station to the control.
The new iTNC 530 therefore combines modern technology with the well-known user friendliness of aTNC.
Specifications
Components
Program memory
Input resolution and display step
Input range
Interpolation
Block processing time(3-D straight line without radiuscompensation)
Axis feedback control
Traverse range
Spindle speed
Error compensation
Data interfaces
Ambient temperature
# MC 422 main computers CC 422 controller unit. TE 420 keyboard unit# TFT color flat-panel display with soft keys: BF 120 with 10.4
inches or BF 150 with 15.1 inches
Hard disk
. To 0.1 urn for linear axes# To 0.0001° for angular axes
Maximum 99999 999 mm (3.937 inches) or 99999.999°
# Straight line in 4 axes. Straight line in 5 axes (export permit required)
^•software option 2# Circle: in 2 axes
in 3 axes with tilted working plane„ Circle in 3 axes with tilted working plane
^-software option 1. Helix:
Combination of circular and linear motion, Spline:
Execution of splines (3rd degree polynomials)^•software option 2
# 36 ms# Option: 0 5 ms
^software option 2
, Position loop resolution: Signal period of the positionencoder/1024
, Cycle time of position controller: 1.8 ms» Cycle time of speed controller: 600 us# Cycle time of current controller: minimum 100 MS
Maximum 100 m (3937 inches)
Maximum 40000 rpm (with 2 pole pairs)
, Linear and nonlinear axis error, backlash, reversal spikesduring circular movements, thermal expansion
„ Stick-slip friction
# One each RST232-C / V.24 and RS-422 / V. 11 max. 115 Kbfe. Expanded data interface with LSV2 protocol for remote
operation of the iTNC 530 through the data interface with theHEIDENHAIM software TNCremo
# Fast Ethernet interface 100BaseT
. Operation- 0 "C to +45 °C (32 "F to 113 °F)
. Storage: -30 "C to t-70 °C (-22 °F to +158 *F)
Software Option 1
Machining with a rotary table
Coordinate transformations
Interpolation
v Programming of cylindrical contours as if in two axes# Feed rate in mm/min
* Tilting the working plane
# Circle: in 3 axes with tilted working plane
Software Option 2
3-D machining
Interpolation
Block processing time
# Motion control with minimum jerk, 3-D tool compensation through surface normal vectors. Tool Center Point Management (TCPM): Using the electronic
handwtieel to change the angle of the swivel head duringprogram run without affecting the position of the tool point
. Keeping the tool normal to the contoura Tool radius compensation normal to the direction of traverse
and tool# Spline interpolation
a Straight line: in 5 axes (export permit required)# Spline:
Execution of splines (3rd degree polynomials)
. 0.5 ms
www.DanaherMotion.com
HoUmorgen ServoMotors & Drives
Pacific ScientifStep Motors
& Drives
Pnctfic ScientificSynchronous
Motors
Servo & StepMotors and Drives
Sttmims,DANA HERMOTION
Product Selection Tree
Specialty Motors
Call 1-866-993-2624 or [email protected]
Step, Sync, PMDC
DDL - Ironless _
DDL • Ironcore —I
Call 1-866-993-2624 or email
[email protected] 1-866-993-2624 or email
www.DirectDriveRotary.com
Conventionalwww.ServoMotorProducts.comwww.DirectDriveLinear.com
0.18-16.8 0.18-41.6 0.84-16.5 | 1.2-53 ! 0.70-124
Encoder, Resolver Encoder, Resolver Encoder, Resolver ! Encoder, Resolver j Resolver
SERCOS interface™ SERCOS interface™ SERCOS interface™ i SERCOS interface™ I SERCOS interface™PROFIBUS PROflBUS PROflBUS ! PROFIBUS i
CANOpen, DeviceNet CANOpen, DevlceNet CANOpen, DeviceNet I CANOpen, DeviceNet I
Online Product Selector
Go to www.DanaherMotion.com/advisor to use our intuitive, one-of-a-kind.Online product selector. This product attribute search engine allows you toexamine our vast database of produas to choose from the many solutionsKollmorgen and Pacific Scientific products offer.
10
Introduction 2
2.1 FlexDrive77 features
Throughout this manual, both the FlexDrive11 and the Flex+Drive11 will be referred to simply asFlexDrive11. Where there is a difference in specification it will be clearly marked.The FlexDrive77 is a versatile compact control, providing a flexible and powerful solution forsingle axis rotary systems. Standard features include:
• Single axis AC brushless drive• Wide range of models with continuous current ratings from 2.5A to 27.5A• Direct connection to 115VAC or 230VAC single-phase or 230-460VAC three-phase
supplies (model dependent)• Resolver or encoder feedback• Velocity and current control, with pulse and direction input for position control• Auto-tuning wizard (including position loop) and software oscilloscope facilities• 8 optically isolated digital inputs• 3 optically isolated digital outputs• 1 general-purpose analog input (can be used as a speed or torque command reference)• 1 control relay• Selectable RS232 or RS485 communications
Flex+Drive^only:• Integrated motion controller for rotary and linear positioning systems• Programmable in Mint• Up to 16 programmable preset moves (expandable to 256 with factory-fitted CAN and I/O
option)• Position control using preset moves, software gearing and point to point moves• Flash memory for program storage (64k).• Motion controller for rotary and linear positioning systems
Factory-fitted options expand the I/O capabilities of the FlexDrive77 and provide CANopen,DeviceNet or Profibus connectivity. See Appendix A for details about options. FlexDrive77 willoperate with a large number of brushless servo motors - for information on selecting Baldorservo motors, please see the sales brochure BR1202 (BR1800 for linear motors) availablefrom your local Baldor representative.
This manual is intended to guide you through the installation of FlexDrive77. The sectionsshould be read in sequence.
The Basic Installation section describes the mechanical installation of the FlexDrive77, thepower supply connections and motor connections. The other sections require knowledge ofthe low level input/output requirements of the installation and an understanding of computersoftware installation. If you are not qualified in these areas you should seek assistance beforeproceeding.
MN1902 Introduction 2-1
B.1.3 Position control (Pulse and Direction)Setting the control mode to Position Control (Pulse and Direction) configures the FlexDrive77
as a positioning system, as shown in Figure 45, capable of following a position commandsignal.
The profiler interprets the pulse and direction signals and uses them to generatecorresponding position, speed and acceleration demand signals.
The position and speed demand signals are fed into a position controller and used, togetherwith the position measured from the feedback device, to generate a suitable speed demandsignal. If the position controller is tuned correctly, the measured position will accurately trackthe position demand.
The speed demand signal from the position controller is fed into the speed controller and used,together with the speed measured from the feedback device, to generate a torque demandsignal. If the speed controller is tuned correctly, the measured speed will accurately track thespeed demand. To improve the tracking performance of the speed controller, the profileracceleration demand is fed in at this point.
Finally, the torque demand signal is fed into a torque controller, which determines theappropriate amount of current to apply to the windings of the motor. This demand current iscompared with the actual winding current measured from sensors, and a suitable pulse widthmodulation (PWM) signal is generated. This PWM signal is fed to the power electronics in thedrive.
Position reference(Pulse and Direction)
n n_n t
Profiler
}tAccnSpeeiPosrti
- J PositionlEJ controller
. Speed[demanc
.I Speedcontroller
Torquedemanc I ToI?HPcontroller
tPWM Power stage!
+ motor r~"l
Measured current I IMeasured speed 1Measured position
Figure 45 - Control structure in Position control (Pulse and Direction)
B-4 Control System MN1902
DJ\ NA HERMOTION
Ing. David Reyes LunaAsistente de Docencia Dpto. MecanicaITESMTel. 8358-2000 ext. 5454mail. [email protected]
APPLIEDMexico, S. A. de C. V. ®
Mexico D.F. a 15 de Febrero 2005
Ponemos a su consideracion la siguiente cotizacion, esperamos vernos favorecidos con su pedido
QtY11
111
1
1
1
1
11
1
1
ModelAKM21E-ANCNC-00S20360-VTS
CP-102AAAN-03-0CF-DA0111N-03-0PMA22B-00100-00
PC832-001-T
PFC-010101-010
PPC-010101-010
S30361-NA
BAR-300-66BSM50N-133AA
FDH1A02TB-RN20
CBL030SP-SF-MHMALMAKM21E-ANCNC-00S20360-VTSCP-102AAAN-03-0CF-DA0111N-03-0
BrandKollmorgenKollmorgen
KollmorgenKollmorgenPacificScientificPacificScientificPacificScientificPacificScientificKollmorgen
KollmorgenBALDOR
BALDOR
BALDOR
DescriptionAKM series brushless servomotorS200 series brushless servo drive, alimentacion de 115 vac, 3amp.Power cableFeedback cablePMA series brushless servomotor
PC800 series brushless servo drive, alimentacion de 115 vac.2.5 ampMotor Feedback Cable
Motor Power Cable
S300 series brushless servo drive. Opcional en lugar de la serieS200300 Watt, 66 ohm regen resistor. OpcionalSERVOMOTOR SIN ESCOBILLAS CON RESOLVER
SERVOANPLIFICADOR ALIMENTACION DE 115 VAC,CORRDSNTE DE 2.5 AMP. CON FUENTEINTEGRADA DE24 VDC, RESISTENCIA REGENERATIVA, 8 ENTRADAS,3 SALIDAS CONFIGURABLESJUEGO DE CABLE DE FUERZA Y RESOLVER DE 3METROS DE LONG.
Unit Price Net Price581.00797.75
124.40124.40737.65
1173.50
205.75
205.75
1016.50
250.75496.90
974.65
190.75
Total amount
EL TIEMPO DE ENTREGA para la marca BALDOR DE 4 semanas, para Kollmorgen y Pacific Scientific de 6-7 semanas UNA VEZCONFIRMADA LAORDEN DE COMPRACONDICIONES DE VENTA LAS GANADAS POR SU EMPRESA.LAB. ALMACEN MEXICO. Los precios antes mencionados son netos en Dolares Americanos y se les cargara el 15 % de I.V.A. almomenta de facturar en pesos al tipo de cambio vigente en esa fecha.
Atentamente,
Ing. Jose Juan Ortiz V.
200V Three-phase Sigma II Servo Systems
General PurposeS G M G H S e r V O m O t O r S -With Incremental /Absolute Encoder
Rated Output: 0.45kW, 0.85kW,1.3kW,1.8kW, 2.9kW,4.4kW, 5.5kW, 7.5kW,11kW, 15kW.
For Additional Information
SGMGH Ratings & SpecificationsSGMGH Speed/Torque CurvesSGMGH DimensionsSGMGH Selection/Ordering InformationSGDH Ratings & SpecificationsSGDH Dimensions
Page(s)
585960 - 6263 - 6899 -100
101 -112
Design Features
1. Compact• Small sized motor
Compatible with previous generation G series motorsTen types of rated outputs ranging from 0.79 to 1988in • Ib of peak torqueOptional built-in holding brake available
2. Higher Speed and acceleration• Up to 3000rpm maximum• High torque to inertia ratio
3. Encoders• 17-bit (32,768 ppr x 4) incremental encoder (standard)• 17-bit absolute encoder (optional)
4. Enhanced Environmental Resistance• Totally enclosed, self-cooled IP67 (excluding shaft)• Shaft seal (optional)
5. Application Emphasis• Machine tools and woodworking machines• Packaging machines• Gantry Robots• Press Automation• Thermoforming
6. Certified International Standards• UL, cUL recognized (File #: E165827) CE compliance
200V Three-phase Sigma II Servo Systems
Servomotor Ratings and SpecificationsTime Rating:Insulation:Vibration:Withstand Voltage:Insulation Resistance:
ContinuousClass F15nm or less1 5 0 0 ^10MQ minimumat 500Vnc
Enclosure: Totally-enclosed, self-cooledIP67 (except for shaft opening)
Ambient Temperature: 0 to 40°CAmbient Humidity: 20 to 80%
(non-condensing)Rated Speed*: 1500rpm
Maximum Rotational Speed*:
Excitation:Drive MethodMounting:
0.45to7.5kW: 3000rpm11and15kW: 2000rpmPermanent magnet
: Direct driveFlange-mounted
Values when the servomotor is combined with an SGDH servo amplifier
MOTORS:SGMGH-
05ADA
09ADA
13ADA
20ADA
30ADA
44ADA
55ADA
75ADA
1AADA
1EADA
RatedOutput*
kW(hp)
0.45(0.6)
0.85(1.1)
1.3(1.7)
1.8(2.4)
29(3.9)
4.4(5.9)
5.5(7.4)
7.5 (10)
11(15)
15(20)
RatedToque'
N«m
2845.39
8.34
11.5
18.6
28.4
35.0
48.0
70.0
95.4
b f in (KG* cm)
25(29)
48(55)
74(85)
102(117)
165(190)
252(290)
310(357)
425(490)
620(714)
845 (974)
Instantaneous PeakTorque*
N«m
89213.8
23.3
28.7
45.1
71.1
87.6
119175224
Ibf in(KG-cm)
79(91)
122(141)
207(238)
254(293)
400(460)
629(725)
775(894)
1053(1210)
1550(1790)
1988(2290)
RatedCurrent*
A * .387.110.7
16.7
23.8
32.8
42154.7
58.6
78.0
InstantaneousMaximumCurrent*
An , ,
111728425684110130140170
MOTORSSGMGH-
05AOA
09ADA
13ADA
20ADA
30ADA
44ADA
55AQA
75ADA
1AAOA
1EAOA
Values when the servomotor is combined with an SGDH servo amplifier.
TorqueConstant
73(0.82)
7.3(083)
7.4(0.84)
6.5(0.73)
7.3(082)
8.0(0.91)
7.8(0.88)
8.2(0.93)
11(1.25
11.7(1.32)
Moment of Inerta
Ib-in'S2
xitr3
6.41
12.3
18.2
28.1
40.7
59.8
78.8
111
249
279
KC'tn2
xVt*
7.24
13.9
20.5
31.7
46.0
67.5
89.0
125
281
315
Hddhig Brake (at 20*C)
Capacity
W
9.85
18.5
23.5
320
35.0
Torque
N-m
441
12.7
43.1
726
84.3
115
Col.Resistance
W
58.5
31.1
24.5
18.0
16.4
RatedCurrent
A
0.41
0.77
0.98
1.33
146
AddionalInertia
Ib-in-s2
x1O*
1.85
7.75
7.75
16.7
33.2
AllowableLoadInertia
KG-rn 2
x io 4
36.2
69.5
103
159
230
338
445
625
1405
1575
RatedPowerRate*
kW/s
11.2
20.9
33.8
41.5
75.3
120
137
184
174
289
RatedAngular
Acceleration*
ratfs2
3930
3880
4060
3620
4050
4210
3930
3850
2490
3030
InorksTime
Constant
ms
5.0
3.1
2.8
2.2
1.9
1.3
1.3
1.1
1.2
0.98
InductiveTime
Constant
ms
5.1
5.3
63
128
125
15.7
16.4
18.4
226
27.2
* Values when the servomotor is combined with an SGDH servo amplifier at an armature winding temperature of 20°C." These characteristics can be obtained when the following heat sinks (steel plates) are used for cooling purposes:
Type 05ADA to 13ADA: 15.75 x 15.75 x 0.79 (in) (400 x 400 x 20 (mm))Type 20ADA to 75ADA: 21.65 x 21.65 x 1.18 (in) (550 x 550 x 30 (mm))Type 1AADA to 1EADA: 25.59 x 25.59 x 1.38 (in) (650 x 650 x 35 (mm))
56
100/200V Sigma II Servo Systems
S G D H SerVO A m p l i f i e r - For Speed, Torque, & Position ControlWith Incremental or Absolute Encoder
Single-phase Three-phase
For Additional Information
SGDH Ratings & SpecificationsSGDH DimensionsSGDH Internal ConnectionsConnection Diagram, Single PhaseConnection Diagram, Three PhaseConnector Terminal Block UnitTerminal Block Pin NumbersAmplifier/Encoder ConnectionsCable Specs and PeripheralsSGMAH Sigma II Servo SystemSGMPH Sigma II Servo SystemSGMPHGearmotorSGMGH Sigma II Servo SystemSGMGH GearmotorSGMSH Sigma II Servo System
Page(s)
99-100101-112113-114115116117118119121-12511 -2829 -4647 -5657 -6865 -8485 -96
Design Features
1. Improved Performance• Higher bandwidth response (400Hz speed loop frequency response)• Positioning settling time shortened to 1/2 to 1/3• Smooth control at low rpm made possible by Sigma II servomotors'
high resolution feedback2. Easy Operation
• All-in-one model (speed, torque, and position control)• PC monitoring function available including graphical tuning and file storage• Adaptive-tuning function
Online auto-tuning• Multi-axis communication provided as standard
One PC can communicate with up to 14 SGDH units by parameter setting• Built-in parameter setting device• On-board storage of alarm history• Automatic determination of motor settings at connection
3. Additional functionality with ready-to-install application modules• Configurable single axis controls including serial networking capability• Fieldbus connectivity (Devicenet™, Profibus™, etc.)• Full closed loop (optional position feedback)• Yaskawa MP940 single axis motion controller
4. Certified International Standards• UL, cUL listed (File #: E147823), CE compliance
95
100/200V Sigma II Servo Systems
SGDH Amplifier Ratings and Specifications
Bas
ic S
peci
ficat
ions
Spe
ed/T
orqu
e C
ontro
l Mod
e
Inpu
t Pow
erS
uppl
y Main Circuit*
Control Circuit*
Control Mode
Feedback
Loca
tion Ambient/Storage Temperature**
Ambient/Storage Humidity
Vibration/Shock Resistance
Structure
Per
form
ance
Inpu
t Sig
nal
Speed Control Range
Spe
edR
egul
atio
n*** Load Regulation
Voltage Regulation
Temperature Regulation
Frequency Characteristics
Accel/Decel Time Setting
Spe
edR
efer
ence
Tor
que
Ref
eren
ceIC
onta
ct S
peed
Ref
eren
ce
Reference Voltage*"*
Input Impedance
Circuit Time Constant
Reference Voltage"**
Input Impedance
Circuit Time Constant
Rotation Direction Selection
Speed Selection
Three-phase (or single-phase) 200 to 2 ^ ^ +10% to -15% 50/60 Hz,or single-phase 100 to 1 ^ +10%to -15% 50/60 Hz
Single-phase 200 to 2 3 0 ^ (or 100 to 115^) +10% to -15% 50/60 Hz
Three-phase, full-wave rectification IGBT PWM (sinusoidal commutation)
Serial incremental encoder, absolute encoder
0to55°C/-20to85°C
90% or less (no-condensing)
4.9m/s2/19.6nVs2
Base mounted (duct ventilation available as option) and flat mount type
1:5000 (The lowest speed of the speed control range is the speed at which the servomotor will notstop with a rated torque load.)
0%to100% 0.01% max. (at rated speed)
Rated voltage ±10%: 0%(at rated speed)
25 ± 25°C: 0.1% maximum (at rated speed)
400Hz(atJL = . y
0 to 10s (Can be set individually for acceleration and deceleration).
±6VQC (variable setting range: ±2 to ±10VDC) at rated speed (forward rotation with positivereference); input voltage: ±12V (maximum)
Approximately 14k&
—
±3VDC (Variable setting range: ±1 to ±10V) at rated torque (forward rotation with positivereference), input voltage: ±12VQC (maximum)
Approximately 14kQ
Approximately 47us
Uses P control signal
Forward/reverse rotation current limit signals are used (1st to 3rd speed selection). When bothsignals are OFF, the motor stops or enters another control mode.
Notes: * The power voltage must not exceed 230V +10% (253V). If it is likely that it will exceed this limit, use a step-downtransformer. For types SGDH-08AE-S and SGDH-15AE-S, voltage is 200 to 230V + 10% -5%.
** Use the servo amplifier within the ambient temperature range. When enclosed, the temperatures inside the cabinetmust not exceed the specified range.
*** Speed regulation is defined as follows:
Speed regulation = (no-load motor speed - full-load motor s p e e d ) x 1 0 0 %
rated motor speed
**** Forward is clockwise viewed from the non-load side of the servomotor, (counterclockwise viewed from the load andshaft end).
97
APPENDIX F.- Case Study I Results
Data Processing test
1-D STRAIGHT LINE
Control Option:G64ONProgrammed Feed Rate Vfp (mm/min)
Total Time (s)Calculated time (s]Feedrate (mm/minBlock time(ms) jBlock /s (BPS)
500
84.084.0
500.012.083.3
1000
42.042.0
1000.06.0
166.7
2000
31.131.1
1350.04.4
225.0
3000 4000
31.131.1
1350.04.4
225.0
31.131.1
1350.04.4
225.0
1-D STRAIGHT LINE
Control Option:G64 ONProgrammed Feed Rate
Total Time (s)Calculated time (s]Feedrate (mm/minBlock time(ms)Block /s (BPS)
500
84.084.0
500.06.0
166.7
1000
62.262.2
675.04.4
225.0
) Vfp (mm/min)2000| 3000
62.262.2
675.04.4
225.0
62.262.2
675.04.4
225.0
4000
62.262.2
675.04.4
225.0
1-D STRAIGHT LINE
Control Option:G64 ONProgrammed Feed Rate Vfp (mm/min)
2503
Total Time (s)Calculated time (s)Feedrate (mm/min)Block time(ms)Block /s (BPS)
500
124.4124.4337.5
4.4225.0
1000
124.4124.4337.5
4.4225.0
20001 3 0 0 0
124.4124.4337.5
4.4225.0
124.4124.4337.5
4.4225.0
4000
124.4124.4337.5
4.4225.0
Figure F1.1-D Straight line results.
101
Control Option:G64 ONProgrammed Feed Rate Vfp (mm/min)
500| 1000J 2000| 3000| 4000
Total Time (s)Calculated time (s)Feedrate (mm/min)Block time(ms)Block /s (BPS)
84.584.0
500.0006.033
165.759
62.562.9
668.2164.464
224.000
62.562.9
668.2164.464
224.000
62.562.9
668.2164.464
224.000
62.562.9
668.2164.464
224.000
—
2-DS
Line
TRAIGI
700
•IT LINE
mm
•
28012 blocks
Controller BControl Option:G64 ON
Total Time (s)Calculated time (s)Feedrate (mm/min)Block time(ms)Block /s (BPS)
127.0127.0330.7
4.5220.6
127.0127.0330.7
4.5220.6
127.0127.0330.7
4.5220.6
127.0127.0330.7
4.5220.6
127.0127.0330.7
4.5220.6
Figure F 2.2-D straight line results
3-D STRAIGHT LINE
Control Option:G64 ONProgrammed Feed Rate Vfp (mm/min)
Total Time (s)Calculated time (s)Feedrate (mm/min)Block time(ms)Block /s (BPS)
5001,24.34
84.384.0
500.0006.020
166.121
10001,02.96
62.862.8
668.3644.487
222.852
2000
62.862.8
668.3644.487
222.852
30001,02.84
62.862.8
668.3644.487
222.852
4000
62.862.8
668.3644.487
222.852
102
3-D STRAIGHT LINE
Control Option:G64 ONProgrammed Feed Rate Vfp (mm/min)
250 500 1000 2000[ 3000 4000
Total Time (s)Calculated time (s)Feedrate (mm/min)Block time(ms)Block /s (BPS)
2,08128.0128.3
327.3584.6
218.8
2,08128.0128.3
327.3584.6
218.8
128.0128.3
327.3584.6
218.8
2,08128.0128.3
327.3584.6
218.8
128.0128.3
327.3584.6
218.8
Figure F 3.3-D straight line results.
Average Feedrate calculation Siemens 802D and 802C
SIEMENS 802DController Price (US$) 6,955.20Simodrive 611 U(US$) _[ 5,048.73Processing time** i 12
Line Segment (mm)
0.10.05
0.025** Manufacturer
Saturationfeedrate
(mm/min)
msTotal linedistance
(mm)700700700
Blocks
70001400028000
Calculedfeedrate
(mm/min)500250125
SIEMENS 802CController Price (US$)Simodrive Base Mne(US$]Processing time**
Line Segment (mm)
0.10.05
0.025
4,393.582,887.65
24Saturationfeedrate
(mm/min)
msTotal linedistance
(mm)700700700
** Manufacturer
Blocks
70001400028000
Calculedfeedrate
(mm/min)250125
62.5
Relative Value Evaluation for 3-D straight line
83J33I802D vs. 802C41.6
103
APPENDIX G. - Case Study II Results.
Data Processing test
For block processing evaluation DNC function was used. Centurion VII internet
brochure specifies that the two32 bit processors working together can achieve 1250
blocks/s. (For more detail specifications of hardware and software features see
APPENDIX C). Results for the block processing times are illustrated in Figure G 1.
£
seco
nd
,is
per
Blo
c)
500 •
400
(
300
200
(
1
500
- •
0*
00
00
00
1000 1500
- 0.1mm_DNC ON 255 LookAhead
CENTURION VII
X0
0
0
0
0)
„ . <0
2000 2500 3000
Programmed Feedrate Vfp, (mm/min)
\3•I
3500 4000
- ^ — 0.05mm_DNC ON 255 LookAhead • 0.025mm_PNC ON 255 lookahead
Figure G 1. Centurion VII block processing times for DNC On function.
Is not possible to quantify a real block processing time because the obtained
values didn't arrive to a saturation point.. The best value of BPS is 498, and corresponds
to a 2 ms processing time. Comparing with the manufactured brochure value of 1250
BPS, we find that a 60.1% of incredibility between the manufactured given value and the
obtained value from line segments experimentation.
104
Dynamic Measurement Results.
Contour error graphs, velocity and acceleration profile graphs were taken form [Ortega;
2004].
Programmed Feed Rate Vfp (mm/min)2000
Control OptionDNC ON | DNC OFF
4000Control Option
DNC ON | DNC OFF
7620Control Option
DNC ON | DNC OFF
I 4,0356 I 4.0356 I 2.76 | 2.7612 | 2.659 I 2.6622 I
AVERAGE FEEDRATE (mm/min)
Programmed Feed Rate Vfp (mm/mm)2000
Control OptionDNC ON | DNC OFF
4000Control Option
DNC ON | DNC OFF
7620Control Option
DNC ON | DNC OFF
Programmed Feed Rate Vfp (mm/min)2000
Control OptionDNC ON | DNC OFF
4000Control Option
DNC ON | DNC OFF
7620Control Option
DNC ON | DNC OFF
0.006243^010052721 0.0058771 0.0073681 0.0056051 0.00755
105
Co
nto
ur
erro
r (m
m)
o (D Q. 55" 8 o 3
O 00 O O O O
1
—
_Ci li
il
1 I 1 f-
.1 1-• 4
I !
1 1 I••I
_i
1\ \ 11•- iw
- •• t 1 • _0 M
•— M _
o o 3 c (D O 0) (Q 3 Ml Q.
(D 0) 3 o" o 0) o' 3
< o
• •
^^
^
jo
mo
<
0 ^
3 a
3 o
1 g
3 O
MACHINE VM16 DNC OFF
Vfp: 4,000 mm/min
iIoo
0.060.055
0.050.045
0.040.035
0.030.025
0.020.015
0.010.005
0-0.005
-0.01-0.015
-0.02-0.025
-0.03-0.035
-0.04-0.045
-0.05-0.055-0.06
Contour error, magnitude and location
% IMMmmM i
J• I4
j
|
L
IL
—i—'—'
J
11M
11
, •• i
S—i—
*1
111
1
20 40 60 80 100 120
Cumulative distance d, (mm)
107
Co
nto
ur
erro
r (m
m)
• O
ip
iO
ip
iO
iO
O
O
O
O
O
O
be
nb
-t»
.bc
ob
iob
-'b
o
ob
-'b
Na
bc
ob
-ii.
bc
nb
cnen
enen
-en
eoen
ioen
-en
oen-
enio
enco
en-
enen
encn
o
O c (D | o (D
o 00 o o o
1 I rr I I I F i A •!F r I 1 1»>
ft
T --« r TTTT
ft 11 I I 1I 1
1M
fl __
• _
-* •1 L
id
i m Ik
» to •
•
o o I Q o 0) Q.
(D 0) O O 0) o" 3
< o
•3"
5
o 3 5'
m a D O O
o oo
MACHINE VM16DNC ON
Vfp: 2,000 mm/min
Contour error, magnitude and location
0.06 n0 055 -0.050.045 -0.04 -
0.035-P 0.03= 0.025e 0 02"r* 0.015O 0.01C 0.005 -fc 0 -•_ -0 0053 -0.01 -O -0.015 -C -0.02 -O -0.025 -O -0.03
-0.035 --0.04
-0.045 --0.05 -
-0.055 --0 06 -
(
/>
i m
ii
!i i
JJ
1
M i
i i 1
J1114
Jt-— I — 1-1
) 20 40 60 80 100 120
Cumulative distance d, (mm)
109
Co
nto
ur
erro
r (m
m)
.6
.6
,6
.6
,6
,6
o o
o
o
o
o
Pd
Pd
°d
Pd
Pd
°d
d
Pd
°<
Dod
Pd
c>d
o
Otf
lOA
OO
OM
O-'O
O
00
-'O
I\)O
UO
A0
01
0a>
wovif
oic
ooi\
30io
iooiO
irooiw
oiu
oio
ioio
>
o c 5* <" Q.
| O (D Q. 3
00 o
r 4 vi fl
g
1 1 1 • I F 1
• •
•M ff
L 1
11 1
• T I 1 rrfl 1 1L
M • •-- ii J i!
• • »
o o (D o 0) CD a (D 0) o o 5" 3
O
<O
^
3 5"
O 2 O O
MACHINE VM16DNC ON
Vfp: 7,620 mm/min
0 06 -0.055 -0.05 i
0.045 -i0.04 -
0.035 -' ? 0.03 -C o 025E 0.02 1^ 0.015O 0.01 'fc 0.005 -o oZ -0.005 -3 -0 01 -O -0.015 -C -0.02 -O -0.025 -Q "0.03 -
-0.035 --0.04 -
-0.045 --0.05 -
-0.055 --0 06
(
Contour error, magnitude and location
t111m
t
mmm
J11I1 Jk
|111X4
J
!
\
i
1
/
•
•1 I
) 20 40 60 80 100 120
Cumulative distance d, (mm)
111
1000
800
600
400
200
0
-200
-400
-600
-800
-1000
MACHINE VM16 DNC OFF
Vfp: 2,000 mm/min
Velocity Profile
2000 - M M I
mno 1
oi
irIfV II11
ir11I I! "I
4-II1
IfiIIKT1
1
0.5 1.5 2 2.5 3 3.5
Cumulative time t, (s)
4.5 5.5
Acceleration Profile
9 L]l
I1 i• •1 1
••
•r•
f•
f•
8""rt
i1f I17
• i
IIIr•ni
0.5 1.5 2 2.5 3 3.5
Cumulative time t, (s)
4.5 5.5
112
S1 120°% 1000g 800g 600 !ra
400^200
0-200-400-600-800
-10001200
MACHINE VM16DNC OFF
Vfp: 7,620 mm/min
Velocity Profile Om
in)
1
Feed
Rat
e
5000
3000
2000
1000
ol
A/ \
i A •.it
A it iiL1
w\ r
\
i
\
1-MiI
\\
A aAA i\ nt-V-i w Vht-II 10 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75
Cumulative time t, (s)
Acceleration Profile
1. . . i 1
r s. i i • i •. I » k..
= 3*1
i—j
•
f I B "j*rw
I I »
1 j " •
0.25 0.5 0.75 1 1.25 1.5 1.75 2.25 2.5 2.75 3.25 3.5 3.75
Cumulative time t, (s)
114
^ 600 j
£ 400.
MACHINE VM16DNC ON
Vfp: 2,000 mm/min
Velocity Profile
0 0.5 1 1.5
Acceleration Profile
-400
-600
-800
-1000
o2000 l § m
1500-P
1000 |
0 *
f•
•
-ir*H 11
-1-111 11 w
If Tf
i•
442 2.5 3 3.5 4 4.5 5 5.5
Cumulative time t, (s)
r • IF
If 1* tI If9 i
f1
f**
1|
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5
Cumulative time t, (s)
115
MACHINE VM16DNC ON
Vfp: 4,000 mm/min
Velocity Profile
4500
4000
3500
3000
2500
2000
i 1000
500
|-/1IIf
f
i\
r lifi//
li
1
ft-ft1
Mlf i / i i i fIf if 11 ififat
if iiV_T
If
"In•
1It
//IT1
r\\\
|-ii/I
Tii\
40.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75
Cumulative time t, (s)
3.25 3.5 3.75
Acceleration Profile
-20000.25 0.5 0.75 1.25 1.5 1.75 2 2.25 2.5 2.75
Cumulative time t, (s)
3.25 3.5 3.75
116
MACHINE VM16DNC ON
Vfp: 7,620 mm/min
6000
0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75
Cumulative time t, (s)
Acceleration Profile
2000
~ 1500
1000
°
500
-500
-1000
-1500
-2000
1
J IV1
JAmi
f 11 11
t0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75
Cumulatime t, (s)
117
1. Ball Screw Products
Horizontal machining cento
NSK ball screws combine low friction characteristics and screw mechanismsto ball screw applications in facilitate conversion between linear rotarymotions, precise linear positioning, and force amplification.
Machine tools (Horizontal type machining centers)FeaturesSmooth motion and high accuracy, even with large cutting forces
Reasons for adoptionHigh accuracy, smooth motion, high load capacity, and high durability
• HMC Series: High-Speed; High Ridigity; High Load Capacity• HTF Series: High Load Drive Ball Screws• Hollow Shaft Series: Reduces Effects of Thermal Expansion; provides
stable, precise positioning• Custom Ball Screws: Let our Mechanical Engineering Department assist
you in designing a ball screw to fit your unique application• NDT Series: Rotating Nut Ball Screws• Rolled Ball Screws: Interchangeable screw shaft and nut; lower cost
due to shaft rolling process• Precision Rolled Screws: Compact Nut Design; High Speed; Tighter
Tolerances than standard rolled ball screws; Can be Preloaded
B-I-4 Procedures to Select Ball ScrewB-I-4.1 Flow Chart for Selection
There are several methods to select a ball screwwhich is most suitable both in type and size for aspecific use. The chart below is one of the selectionmethods. To take advantage of prompt delivery andreasonable prices, this method focuses on the
standardized series that are available in stock.NSK offers a ball screw selection program, and alsohas a service to select appropriate items using datafile compiled by our knowledge and experience.
NG
NG
Use conditionsLoad, speed, stroke, accuracy,required life (environment)
Basic factorsAccuracy grade (CO-CtiO)Screw shaft diameterLeadStroke
Pages B17 and B445
Is it a standard series and available in stock? The following arerecommendations for different needs.
A Series : If accuracy is important, and if you desire to use the ballscrew as it is delivered.
S Series : If accuracy is important, and if you desire a certain shapeof the shaft end.
KA Series : If you are concerned about rust.V Series : If you desire accuracy and low cost.R Series : If you desire low cost. Pages B19-22
NO
YES
Basic safety checks(D Limitation of buckling load(D Critical speed® Life expectancy
Page B451
Page B455
Page B461
Is it in the dimension table forcustom made ball screws? Nutshape, shaft end
OK
Factors to be checked to satisfy a need<D Heat displacement and lead accuracy@ Rigidityd> Drive torque@ Lubrication, rust prevention, dust
prevention, safety system(£> Consideration to assembly
OK
Summary of technical data for ordering
Page B447
Page B465
Page B469
Page B471
Page B475
Page B31
\ / Y E S
See Page B23
NO
Consult NSK
NSK
B16
B-1 -4.2 Accuracy Grades
Table 1-4*1 shows examples of how to select
accuracy grade for a specific use. These practical
cases are based on NSK's experience. Circle
indicates the range of the accuracy grade in actual
use. Double circle indicates accuracy grades most
frequently used among cases marked with a single
circle. These symbols help to identify general
information on the accuracy grade of ball screws. To
confirm whether a specific ball screw accuracy grade
satisfies requirements in positioning accuracy in
actual use, refer to "Technical Description" and
"Mean travel deviation and travel variation." (Page
B445)
App
licat
ion
Name of axis
grad
eac
ycc
ur
<
CO
C1
dzC3
G5
Ct7
CtflO
Table 1-4•1 Accuracy grades of ball screw and their application
NC machine tools
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e
X
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O
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1
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ng c
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XY
O
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p
i
Dril
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mac
hine
XY
O
0
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0o
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borin
g m
achi
ne
XY
O
o
zoo
Grin
der
XY
O
O
o
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C)
oo
Ele
ctric
dis
char
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mac
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XY
O
O
o
z
oo0
Wire
cutti
ng
mac
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Ele
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dis
char
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mac
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O
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grad
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C0C1
c?C3
C5
Gen
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, I
Mac
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Lith
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hem
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pro
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O
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O
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Pro
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O
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B17
Technical Description of Ball ScrewsB-1 -1 AccuracyB-II-1.1 Lead AccuracyThe lead accuracy of NSK precision ball screws (C0-C5 grades) conforms to the four characteristicsspecified in JIS Standards. These characteristics areexpressed by codes ep, vu, v3mi and v^ .Fig.I-1'1 explains the definition of each characteristic,
and shows allowable value of each. Leads areclassified into two categories: C system forpositioning; Ct system for transportation. Table E-1*2, 3 and 4 show tolerance of each characteristic.
Travel length (/»)
Actual travel (la) Nominal travel (to)
Mean travel (lm) Specified travel (Is)
7 /
Fig. 1-1*1 Definition of lead accuracy
Table I -1*1 Terminology in lead accuracy
Term
Specified travel
Travel compensation
Actual travel
Actual mean travel
Tolerance on specified travel
Travel variation
Code
75
T
la
lm
ep
vu
U300
Description
Travel after the adjustment of thermal expansion and deformation
by the load have been made relative to the nominal travel.
Value obtained by subtracting the specified travel from the nominal travel basedon the effective length of thread. The value is to compensate the errors causedby thermal error and deformation by load.This value is determined by tests andexperience (See Page B447).
Actually measured travel
A straight line that demonstrates the direction of actual travel. This straightline is obtained from the curve that shows actual travel volume by least-squares method or by resemblinq approximation.
Obtained by subtracting the specified travel from the actual mean travel.
Maximum range of the actual travel which is between the two straightlines drawn parallel to the actual mean travel. There are three categoriesas shown below.• Maximum range relative to the effective length of thread.• Maximum range relative to the length of 300 mm anywhere within theeffective length of thread.
• Maximum range which corresponds to any single rotation (liurad.) withinthe effective length of thread.
Tolerance
Table 1-1-2
Table n-1-2
Table 1-1-3,4
Table 1-1-3
B445
Table 1-1*2 Tolerance on specifiedball screws
travel (±ep) and travel variation (vu) of the positioning (Ctype)Unit: fim
Accuracy grade
E
leng
thth
read
tive
o
LU
over
—
100
200
315
400
500
630
800
1000
1250
1600
2000
2500
3150
4000
5000
6300
8000
10000
or less
100
200
315
400
500
630
800
1000
1250
1600
2000
2500
3150
4000
5000
6300
8000
10000
12500
CO
±ep
3
5.5
4
5
6
6
7
8
9
11
3
3
3.5
3.5
4
4
5
6
6
7
C1
+ ep
3.5
4.5
6
78
9
10
11
13
15
18
22
26
30
vu5
5
5
5
5
6
7
8
9
10
11
13
15
18
C2
±ep
5
7
8
9
10
11
13
15
18
21
25
30
36
44
52
65
vu7
7
7
7
7
8
9
10
11
13
15
18
21
25
30
36
C3
±ep
8
10
12
13
15
16
18
21
24
29
35
41
50
60
72
90
110
uu8
8
8
10
10
12
13
15
16
18
21
24
29
35
41
50
60
C5
±ep
18
20
23
25
27
30
35
40
46
54
65
7793
115
14p170
210
260
320
t>.
18
18
18
20
20
23
25
2730
35
40
46
54
65
7793
115
140
170
Table II -1*3 Tolerance of travel variation relative to 300 mm (u ,) and onerevolution (vj of the positioning (C type) ball screws Unit ^
Accuracy grade
IV-,
Vat
CO
3.5
2.5
C1
5
4
C2
7
5
C3
8
6
C5
18
8
Remarks 1. JIS B1192 sets C type and Cp type standards for positioning ball screws. NSK uses thespecification of C type only.
2. Colored sections conform to JIS B1192 standards. Values in other areas are IMSK standards.
Table I -1*4 Travel variation (ux>) relative to 300 mm of transportation (Ct type) ball screwsUniti/im
Accuracy grade
vm
Ct7
52Ct10
210
Remarks 1. Tolerance on specified travel (ep) of the transportation (Ct type) ball screws is calculated asfollows.
2. JIS B1192 sets Ct1, 3, and 5 grade standards. NSK standards are integrated by C type only. Referto Table 1-1*2 for C type standard tolerance.
B446
//5 to/es Precision Hardened Way SlidesSaddle Widths: 7" to 32"Standard & Custom HS Series SlidesSlide Options & Accessories
US Series
Single Guide Rail Design (standard)All HS slides provide a single guide rail design for superior tracking accuracy. The single raildesign maximizes accuracy because the saddle movement is controlled by one support sidewall for smoother positioning.
As standard, all HS-series slideshave a guaranteed straightness oftravel(side-to-side and up-and-down)not to exceed 0.0005" in 12 inches,and with an accumulation not to exceed0.00025" in each additional 12" of travel.
Guide Rail
i
1
ft
1 — Reference Edge
Low-Friction Turcite™ Material (standard)As standard, HS-series slides are equipped with low friction, self-lubricating Turcitebound to the gib and saddle way surfaces to reduce the effects of friction on the slideassembly. This low-friction bearing material minimizes "stick-slip", and makes wearnegligible on guiding and sliding surfaces.
The use of a low-friction Turcitedoubles the load carrying capacityof a slide. The coefficient of frictionwith low-friction is 0.10; this dropsto 0.05 when combined with aforced lubrication system. (Whenneither is used, the coefficient offriction is 0.30.)
2. Linear Guides Machine ToolHorizontal machintig center
NSK Lineat guides
NSK linear guides are roller guides which utilize balls and are used forsupporting load and guiding precise linear motion with low friction.
Machine tools (Horizontal machining centers)FeaturesSmooth motion and high accuracy even with large cutting forces
Reasons for adoptionHigh accuracy, high load capacity, high speed, smooth motion, and highdurability
• LA Series: 6 Row Design; Shock Resistant; High Rigidity; ModerateFriction; High Load; High Accuracy
• LH Series: 4 Row Design; Shock Resistant; Self-Aligning;Interchangeable (Retained Balls); High Load Capacity
• LS Series: Low Profile; Shock resistant; Self-Aligning, Interchangeable(Retained Balls); High Load Capacity
• LY Series: 4 Row Design; High Stiffness; Equal Load Rating in AllDirections; High Dampening Characteristics
• Translide: 2 Row Design; High Load Capacity; High Dust-ProofCapability; Maintenance Free
A-1 -3 Procedures for Selecting Linear GuideA-1 -3.1 Flow Chart for Selection
The flow chart below indicates general steps for selection.
Set conditions for use
Select model
Select accuracy grade
Lubrication,dust protection,
surface treatment
Selection completed
• Machine structure• Guide installation space• Installation position• Stroke length• Load to be imposed• Speed
Required life, rigidity andaccuracyFrequency of use (dutycycle)Use environment (considermaterial, lubricant, andsurface treatment first forspecial environment)
Select based on theinstallation spaceSelect through experienceUse simple calculation
Select lubricant andlubrication methodDust prevention design (seal,bellows)Rust prevention, surfacetreatment
•PageA7
•Page A15
•PageA129
• P a g e A 2 1 ,119
•Page A 2 0,115
•Page A141
A14
A-1 -3.4 Accuracy and Preload
(1) Accuracy grades and types of preload
0 Accuracy grades• The accuracy grade which matches the
characteristic of each series is set for NSK linearguides.
• Table 1-3*1 shows accuracy grade set for eachseries.
• See Page A115 for accuracy specifications of each
series.Refer to "(2) Application examples of accuracy!grades and preload" which shows cases offappropriate accuracy grade and preload type for)specific purpose.
Table I -3*1 Accuracy grades and applicable series
Series
LH
LS
LA
LY
LW
LE
LU
LL
Preloaded assembly (non-interchangeable)
Ultra precision
P3
O
O
0
0
Super precision
P4
00
0
0
o
High precision
P5
0
00
0
00
0
Precision
P6
0
0
0
0
00
o
Normal grade
PN
00
0
0
o0
Interchanaeableassembly
Normal grade
PC
O
0
o0
0
A20
APPENDIX H.- UNC proposed scheme for connecting to Milltronics VKM3.
General system identification:
The studied system is the interface connection between the controller Centurion 7 to
Yaskawa Sigma II servo amplifiers in a Milltronics Knee Milling machine (Model
VKM03). This identification has the objective of to provide the information for a future
connection of the UNC to Yaskawa Sigma II amplifiers. First is necessary to identify all
the parts that involve the current control system:
• Servo motors• Drive (servo amplifier)• Controller
AC Servo Motors:The motor for the Z axis is a 900 watt Ac servomotor. The motors for X and Y axis are
both of 500 watts. (The present document just focuses on the control of X-Y axis). The
general parameters of X and Y axis which are:
Motor: AC servomotor
Type: SGMGH-05AC A61
Incremental encoder
450 W
3.8 A
2.84 Nm
200V
1500 r/min
InsF
Figure H 1 Nameplate of SGMGH Servo motor.
Servo Amplifiers:
Both axis servo amplifiers are equal. The Main power supplies, control supplies and
servo terminals (see Figure H 2 ) are provided by Milltronics current connection.
Servo Amplifier model:
SGDH 05 AE
118
SGDH Servo Amplifier Identification
.Version NumberM E M H U S Servo Anptfc. hanhnre Kfffcm aMsolware version (See -AmpMer Version Number")
Battery HolderUsed to house «ha bsduv battery for anabsoUe encoder
CN5 Analog Monitor ConnectorIked to monaor rotor epecd. tuM ie refer*ertoe. and other values tirouah a special cable.
KCM8 Battery Connector
Used lo cornea lo tw tac»v baaery tor anabsolulsnasier.
Panel DisplayRn-oUft 7-sojmenl «spar/ p a M u• -•- — - - rannalalut.ar>
used ». and dhor
Panel KaysIfted to aet pararheiert
Power ON IndicatorUgra* when If* eonrat aower *u&0ty is ON.
Charge IndicatorUahkt wrnn s » mam drcul poMer «««*/i«Cm and ataya aa rona aa trat oonvonenracaMdUnrnama craned Therefore. fflMa
taOtt doatdmuHttttmivoA ff >
M10 Connector for Option UnitCorvwcls oplian urtt fe» dpandrng Ute
N3 Connector to PC or Digital Operator
oorvwcl to art optional digHaf operator.
11/O Signal Connector
iked rbr bottt reference Input and sequence I O signals
-NameptateIndxies Ihe r a w arnpttfer model and Ksspedllc rabigs
Encoder ConnectorJslotneeno
Tenninal
"Main Circuit Power Supply TerminalUsed far ma main circUK power aicpry inpu
'Control Power Supply Terminal
Cbmw* to ma conM oo«er supply and lo eulernalrymounw ntenerattw roiator (where appfeaUe)
-Servomotor TerminalCoflnools toths aetvomokjr power ine.
Figure H 2. SGDH Servo amplifier identification
CNl I/O signal connector is plugged to Centurion 7 interface panel. Is necessary to
determine Yaskawa I/O wiring setup for speed control mode and compare this scheme
with Milltronics scheme. Figure H 2, shows all the connections required to set up the
servo amplifier as speed controller, were the reference speed is set by a host controller.
119
4WILL1RONICS Electrical ManualCEMB With Centurion 7
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
Yaskawa Axis Drive ParametersSigma 2 Axis Drive Parameters For MB/VKM Series
The following table lists the axis drive parameters changed by Militronics. All other parameters remain setto the Yaskawa factory default settings.
p#\000
100
101
201
300
408
409
40A
600
MB11&12X
0000H
130
400
1968
720
0
Y0000H
110
400
1968
72CL
0
Z0001H
55
400
1476
543
10
MB18/19X
0001H
75
700
1000
362
0000H
1000
70
0
Y0001H
75
700
1000
362
0000H
1000
70
0
Z0001H
75
700
500
183
O00OH
1000
70
10
MB20X
0000H
75
700
1000
362
0000H
1000
70
0
Y0001H
75
700
1000
362
0000H
1000
70
0
Z0000H
75
700
500
183
0000H
1000
70
10
P#\
000
100
101
201
300
408
409
40A
600
MB25X
0000H
75
700
985
362
0
Y0000H
75
700
985
362
0
Z0001H
75-
700
738
270
10
MB30X
0000H
75
700
985
362
0
Y0000H
75
700
985
362
0
Z0001H
75
700
738*1
270
10
VKMX
0000H
70
400
m000OH
350
50
0
Y0001
70
400
1000
369
0000H
1000
50
0
Z0000
50
400
1000
369
0000H
1000
70
10
28RRV 15
CNl Terminals layout is shown in Table H 1.
2
4
8
S
10
12
14
IS
IB
20
22
74
SG
SEN
SG
/PULS
SG
JSK3N
KLR
PL3
/PCO
BAT*-)
GNO
SEN signalinput
GND
Referencepuba Input
GNO
RefBranoftsymbol input
Clear input
Opea-oolec-lor referencepower apply
PGdtvtfed
C-ptana
Battery (•)
1
3
5
7
9
11
13
15
17
IS
21
23
25
SG
PL1
V-Rff
puts
T-REF
SIGN
PL2
CLR
PCO
BATH
/V-CMP+(COIN*)
GMD
Opea-cctec-Mrrefereeeepower aappV
Refareacaspeed inpui
RafBreacapulse input
Torquereference
input
Raferaacasign input
Opearcolec-janafauaui
Clear input
PG dividedodpat
C-phase
Battery H
Speed coina-dance detec-
tion outpal
77
7fl
31
«
37
>
41
41
45
47
4fl
/TOON+
S-RDY*
AIM*
PAO
PBO
AtOI
AIA3
^
NM3T
JP-Ct
+24V4N
IPSO
TOON sig-nal output
Servo readyoutput
Servo atomoutput
POdMdedoutput
PGdMdedOUtDUt
AJBTBIOOdeoutput
kroutpat
P oparsbonInput
Reverseowartravat
Input
Faward cur-rant I M ON
input
Externalinput power
Sitaaean-nal output
28
28
30
32
34
36
38
40
42
44
46
48
S3
rV-CM>-(JCOIN-)
/TGON
ALM
/PAO
.P80
ALD2
mm
P-OT
IfiiM-RST
IHCi
PSO
Spaed ooavndanoe
detactknoirtput
TGONslj-naloutwt
Senmreedyoinput
Servo alarmou^iut
PGdMoedOU|)Ut
A-phese
PGdMdadoinput
B-fhase
Alarm codeoufiut
SerwOMInput
Forward
Input
AtarrafasaiInput
Ftaveraecurrant Imt
ONinpat
&fhases i j a a t o *
put
Table H 1. CNl Terminal layout
121
Output Signals
Signal Name
Common
Speed
Position
Not used
ALM*ALU-
/TGON*flQQH-
/S-RDY+/SHRDY-
PAO/PAOPBO/PBOPCO/PCO
PSO/PSO
ALO1ALO2ALO3
F<3
A/-CMP+/V-CMP-
/CCHN*
Pin
Number
3132
2728
d30
H^35361820
4849
3738
39{1)
Shell
2526
2526
1fi17232450
Function
Servo alarm: Turns OFF when an error e detected.
tetection during servomotor rotation: detects wheBwrlhe servomotor Brotating at a speed higher than the motor speed selling. Motor speedBtectmn can be set via parameter
Servo ready: ON if tiiere is no servo alarm when the controMmaln circuittower supply »turned ON.
i phase signal(phase signal
C phase signal
S phase signal
Converted two-phase putse {A and B phase) encoderoutput signal and origin pulse (C phase) signal: RS-422or B>e equivalent
With an absolute encoder: outouts Bertal datacorresponding to 8w number of revokitionB (RS-422 orequivalent).
Alarm code output Outputs 3-brt alarm codes.Open-cofector: 30V and 20mA rating maximum.
lormected to frame ground If the ahieJd vwre of the UD signal cable isconnected to fte connector shel.
Speed coincidence {output in Speed Control Mode): detects whether thenotor speed ts wnMn the setting range and if it matches the refers nee* » e d value.Positioning completed {output in Position Control Mode): turns ON whenlie number of error putees reaches the value sat The setting is thelumbar of error pulses set in reference units (input putse units defned bylie electronic gear).
rtiese termnafs are not used.>o not connect relays to these terminals
Refersnc*
5.5.1
5.S.5
S.5.6
5.2.3
5.5.1
554
5.5.3
—
Note f. Pin numbers in parenthesis Q indkaJa signal g
2. The functions allocated to /TGON, /S-RDY. and Ar-CMP (/COLN") can be changed viaparameter* Functions CUT, ATCT, /BK, AVARN. and /NEAR signals can also be changed. (See5.3.4 Output Circuit Signal Allocation >
122
Input signals
Signal Name
Common
SpeedReferenceTorqueReference
PositionReference
S-ON
/P-CON
P-OTNOT
/P-CL/N-CL
/ALM-RST
•24V,N
8ENBATTf*}BATTM
V-REF
T-REF
PULS/PULSSIGN/SIGN
CLR/CLRPL1PL2PL3
PinNo.
40
41
4243
4546
44
47
4 P)2122
5(6)
»(10)
7a1112151431318
Function
Servo ON: Turns ON the servomotor when the gate Mock in the inverter isreleased.
* Function selected via parameter.
Proporkonat opera-ion reference
Direction reference
Control modeswitching
Zero-damp reference
Reference pulseblockForward RuntrahlbitedReverse Run
prohibited
Forward current limitONleverse current limit
ONInternal speedswitching
3wrtches the speed confroi loop from Pi (proportonaVntegral) to P {proportional} control when ONLIMtti internal reference speed selected: switches thedirection of rotation.
Position -» Speed)
Speed " Torque > Enables control mode switching
Torque « Speed j
Speed control with zero-clamp function: referencespeed is zero when ON.Position control wrth reference pulse stop: stopseference pulse input when ON
Overtravel prohibited: stops servomotor whenTKJvable part travels beyond the allowable range ofnotion
Current imit function used when ON.
rtrtti mtemal reference speed selected: switches thentarnal speed settings
Alarm reset Releases the servo alarm state
Control power supply input for sequence signals: users must provide the+24V power supply.Initial data request signal when using an absolute encoder.
Connecting pins for the absolute encoder backup battery
Speed reference Input ±2 to ±1 OV/rated motor speed (Input gain can bemodified with a parameter.)Torque reference input ±1 to ±1 OVfrated motor speed {Input 9am can bemodified wtti a parameter.)
Corresponds to refer-ence pulse inputLine-wvarOpen-collector
nputmode• Code + putoe string> CCWrCWpute«• Two-ptiase rxite« (90° phase cSffcrential)
Error counter dear: Clears the error counter during position control.
+12V pull-up power supply when PULS, SIGN and CLR reference signalsare ogen-collector outputs (*12V power supply is butt into the servoamplifier).
Reference
5.5.2
5.2.15.2.7
5.21
9J2.6
5.2.7
5.4.3
5.2.10
5.1.2
5.13
5.2.6
5-5.1
5 2 4
5.23
5.2.3
5.2.1
5.2.1
5.2.1
5.2.1
5.2.1
Note t. The funclions allocated to /S-(W,/P-CON. P-OT, hMK,/ALM-RiST,/P-CL, and/Nl-CL inputsignals can be changed with parameters. (See 5.3.3 Input Circuit Signal Alloeauon.j
2. Pin numbers in parenthesis ( ) indicate signal ground*.& The voltage input range for speed and torque references is a maximum of ± 12 V
123
Controller connections
Is important to identify the panel layout of Milltronics machine. Figure H 4 shows
the connections of the servo amplifier with Centurion interface panel.
Figure H 4. Milltronics VKM layout
Experimental tests
The experimental measurements were conducted on the Yaskawa Y axis servo
amplifier as shown in Figure H5. The plastic cover of the amplifier was removed for
measuring CN1 I/O signals.
124
(a) (b)
Figure H 5. (a) Y axis Servo amplifier, (b) CN1 connector close up.
Input Signals measurements
Before measuring input signals Pins 1,2, 6 were tested for ground continuity. Once
ground continuity was tested a common ground to connect the oscilloscope ground was
used. Table H 2, show the measured values for input signals.
Signal Name/S-ON Servo ON
Common + 24V INV-REF
Pin No.40
475(6)
Measured Value0 V when servo is ON24 V when servo is OFF24 VSpeed reference input +- 2 V to +- 10 V
The measured values for output signals are in Table H 3
Signal NameALM +ALM-PAO/PAOPBO/PBOPCO/PCO
Pin No.313233(1)3435361920
Measured ValueOV
ov
2.5 V
Table H 3. Output signals. Pins numbers in parenthesis ( ) indicate signal grounds..
125