Manually Tuning a Servo Axis in a Logix 5000 Motion System

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

Objectives
After completing this lesson, you should be able to manually tune a servo axis.

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

Motion Applications Overview

High performance is required:
High speed High accuracy Repeatability

System has been properly sized and applied:

Load to motor inertia ratio in acceptable range Motion controller/drives can perform required tasks

Machine was properly built::

Compliance and machine resonance minimized Quality gearboxes and actuators/guides chosen

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

Inertia
Inertia is important for the following reasons:
Effect on dither in steady state AND in motion Effect on all other tuning calculations As inertia increases, gains are increased (scaling) Drive quantization increases Causes high frequency noise/heat in kHz of drive update Requires a notch filter, but doesnt eliminate (cascades) Compliance and backlash issues made worse by high inertia

Why does a high resolution encoder help?

Dither distance is reduced More information comes back (higher BW) per drive update

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

Tuning Terminology
Loop Pgain can do most of the work, but not all Use Integrals to help close the steady state error
Whether standing still or at constant speed Use velocity Igain if speed is crucial Use position Igain if steady-state position is crucial Use velocity Igain if path is important (this works)

Use Feed Forward values if following a path only

Velocity(ff) for constant speed portion Acceleration(ff) for blending velocities

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

Tuning Terminology

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

Tuning Terminology
Output filters
High integral gains can lead to low speed instability High derivative gains can lead to high speed instability

Torque offset
Compensation for vertical applications. Requires bi-directional tuning

Friction compensation
Used when not coming into end point tolerance due to stiction

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

Basic Servo Loop Diagram

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

Ziegler-Nichols Method to Tune a ClosedLoop

Ziegler-Nichols method of tuning for a closed control loop
Determines ultimate gain Determines ulltimate period

Requires the following steps

Create an instability on the control loop Continue decreasing the gain until a stable response is reached (do not want the system to be completely damped)

Tip: Ziegler-Nichols method recommended for schemes based on proportional control. The value of gain should be 1/2 to 1/3 the ultimate gain to obtain 1/4 wave response curve.
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Ziegler-Nichols Method to Tune a ClosedLoop

Over-damped Critically damped

Under-damped

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

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(3) Main Types of Motion Applications

Type 1

Type 2

Type 3

Constant Speed
Conveyor Line Shaft Crank

Tracking (Follower)
Winding Flying Shear Web

Point to Point
Pick-Place Packaging Cut to Length

Tip: Autotune works well if the inertia mismatch is less than 10:1. It is best to manually tune when the inertia mismatch exceeds 10:1.
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Tuning Tips
Compliant Manual

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

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Compliant Load Tuning Tips

For resonance below velocity loop bandwidth:
Natural resonance of machine is within drives velocity BW Must use BW reduction to detune (today), reduce Vel BW<machine BW.

For resonance above velocity loop bandwidth:

Audible noise, squealing and growling Add a low-pass output filter (x100 Hz) or notch filter (x1000 Hz)

How can you tell if its low or high frequency? Reduce BW:
If resonation follows = low frequency resonance No change in resonation = high frequency resonance

Tip: Reduce the auto tune bandwidth by a factor of the inertia (divide by ratio) as a starting point. Bring it back up until system is unstable, then reduce. This method keeps the Torque/Force Scaling assumption for gain normalization.
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Additional Manual Tuning Tips

Start out with box settings Use the RSLogix 5000 trend feature to monitor the motor position error. Set the velocity and acceleration feedforward parameters to 100% in the gains tab. Run the required motion profile. If necessary, gradually increase the torque/force scaling value until the position error becomes close to zero.

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

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Copyright 2008 Rockwell Automation, Inc. All rights reserved.

Copyright 2008 Rockwell Automation, Inc. All rights reserved.