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Yaskawa Auto Tuning

 

Prerequisites

  • Have a tuning cable. USB Micro b connector to fit the servo drive.

USB micro-b.png

  • Download and install SigmaWin+
    • https://www.yaskawa.com/products/motion/sigma-5-servo-products/software-tools/sigmawinplus/-/content/_6c2e204d-20bc-475d-84a3-8f471d3ccaf7_DownloadSoftware
  • Copy over USB folder (M:\Production\Products\Drives-Servo\Yaskawa\Software\SigmaWinPlus570a)
    • Check device manager in the usb section or unrecognized device section to find the yaskawa drive. update the driver manually, looking in the USB folder copied over.
  • Open SigmaWin+ and connect to drive
    • If drive is not showing, go to device manager and find the yaskawa drive and update drivers (found on server: M:\Production\Products\Drives-Servo\Yaskawa\Software)
  • Default drive parameters are on the server: M:\Production\Products\Drives-Servo\Yaskawa\Drive Parameters, and you should not assume that the drives ship with correct default parameters.




Leave the drives in tuning less mode if running under 200ipm  or if precise profiling is not needed. 

Basic Auto-Tuning

Note: To tune a gantry mode using auto tuning, you can decouple one of the motors on the gantry. 

Tuning Setup
  1. Search and connect to the drive
  2. Keep hardware enable on, but turn off drive enable. Do that with one of the following methods: 
    1. For rapidpath systems, enable the machine. Then press the Disable button under the Service -> Maintenance page. 
    2. Set "Turn Off Enable Signals upon Disable" to "Drive Enable" in Interface Config or Configure->Plugins->MachMotion. 

      Press Save and disable the software. 
    3. Or if necessary, pull the control cable out from the drive.
  3. Set In Position Parameter Pn522
    1. For RapidPath calculate (PnB02) x (Steps Per) x (Resolution) = Pn522
    2. For Apollo III calculate (Steps Per) x (Resolution)= Pn522

"Resolution" = Max Position Error that you want to see.  Maybe 0.001 Inch

  1. Select Tuning --> Tuning to begin the tuning process
  2. Click the Execute Button.

  3. If it isn't in tuning mode already, you will have to enter tuning less mode. Press OK and then cycle power on the drive. image-1590097240103.png
  4. Click the Execute button to calculate inertia. NOTE: If worse than 400% (4:1 ratio), your motor will likely not work. Call MachMotion for engineering. 

  5. Select the No Reference Input Option in the Autotuning Area and then click the Autotuning
    Button.

  6. Configure Conditions

  7. StandardTuning.PNG


    1. Choose "1: A moment of inertia is not presumed" (We already calculated the inertia above)
    2. Choose "1: Standard"
    3. Choose appropriate mechanism. Default use Belt Mechanism even for ball screw unless you need very rigid tuning. 
    4. Edit distance if necessary (3 revs is default)
    5. Select "Start tuning using the default settings" (can be done without this option, but this is the typical way to do your first tune).
  9. Select "Next"

YaskawaAutoTuning2.jpg

Tuning Process
  1. Turn the "Servo ON"
  2. Select "Start Tuning"
  3. Software will run the motor through it's pre-programmed moves
  4. Click "Finish"
  5. The drive is tuned
  6. Click "Finish" again to exit tuning mode

If tuning fails it could be caused from one of the following reasons:

The position tolerance is too small. Increase Pn522 to allow for more position error.

Final Parameter Setup
  1. Turn off model following by setting Pn140 digit 0 to 0. 
  2. Set feed forward gain Pn109 to 0%. unless you are trying to work around very High inertia, then try 75%
  3. Check the following parameters on all axis that drive the tool usually X, Y and Z, (Exclude things like tool changers).
    1. Pn100 (Speed Loop Gain)
    2. Pn101 (Speed loop integral time constant
    3. Pn102 (Position Loop Gain)
  4. Pick the Highest value for Pn101 and the lowest for Pn100 and 102 from all axes values.
  5. Then make all included drives match each parameter. 

Pn100- Lowest 

Pn101- Highest 

Pn102- Lowest


System Tuning for Gantry

  1. Manually calculate the inertia (Pn103)
    1. Use the excel calculator to calculate it based on steady state torque.
    2. Yaskawa recommends setting Pn408.3 to 1 on the slave drive  
    3. Do a system tune. Ramp up till it gets noisy.  
    4. Example values: FF 170, FB 48.
  2. Pull back the tune till it sounds good.
    1. Try to minimize following error. 
  3. Graph following error.
    1. Check the following error both axes. 
    2. Increase the FF gain by 10s on the non gantry axis to make the following errors match. 


Custom Tuning

  1. Enable Tuning Mode
  2. Run Auto Inertia test (Pn103)
  3. Custom Tuning
  4. Make following errors match


Advanced Tuning

If additional tuning is required, you can run through the same procedure above but modify selections on Mode Selection and Mechanical Selection. 

You may have to play with Pn100-Pn102. But MachMotion strongly recommends keeping the parameters matching in both drives. 

  1. Pn100 (Speed Loop Gain)
    1. Increase to help make the machine more smooth. 
  2. Pn101 (Speed loop integral time constant
    1. Increase to reduce rigidity and noise. 
  3. Pn102 (Position Loop Gain)
    1. Increase till following error stops decreasing. 

You can also go through Chapter 8 (Tuning) of the attached manual ("Sigma-7 Manual Analog-Pulse.pdf"). 


If auto tuning does not work, you may have to try manual tuning. 


 9103




Current Processes

For system Tuning

first autotune all single motor axis like normal

Then check Position/following error on each axis at the max IPM of the slowest axis.

image.png

Calculate following error distance using this

(Steps per)/1000 = X

(Following Error) / X = Following error in thou


Following Error in Thou is the gold standard, all axis must match at the same IPM to have a tuned machine


Pick the Axis with the best result as the standard and adjust all other axis to match.

the easy way to do this on a single motor axis is to increase Pn109 until you reach the desired following error, be cautious with this as a value much over 75 can result in bad corners, under 50 is usually safe.


On a gantry axis or an axis that cannot complete an autotune, try system tuning


First name each axis so you can tell them apart while logged into several at once

image.png

image.png


Connect a USB cable to both gantry drives.


They should show up like this with the names you already gave them

image.png

Connect to both

it should look like this, (they will show up in the same order, X2 is on top)

image.png

Yaskawa recommends setting Pn408.3 to 1 on the slave drive 

Make sure an inertia ratio is set as well


image.png

Click ok

image.png


this will popup if you are still in tuningless mode, click ok to change the parameter

image.png

It should look like this

image.png

Next bring in the other drive by opening system tuning on the second drive.

image.png

next select the master Axis as "Base" and Slave axis as "Applicable" 

image.png

It should look like this with both axis adjusting equally

image.png


Use Mode 2 or 3 for CNC applications (Mode 3 is better, less overshoot)

When using mode 2 or 3 leave Friction compensation enabled

Use whichever Mechanism selection matches your machine


image.png


Next write some G-code that will bring the axis up to full speed for a bit and then stop, wait a couple seconds and the repeat going the other way. an M99 at the end will allow the program to keep looping until you stop it.

Example G-Code

G01 G90 X20 F200
G04 P2.
G01 G90 X-20
G04 P2.
M99
%

Push cycle start and let the machine start cycling

click "start tuning" and the DROs should turn green

Make your adjustments during the g-code pause, if you adjust while moving sometimes the drive will throw an error

image.png

watch following error and start increasing Feed Forward until following error reaches the target


image.png


next bring up feedback load until the machine get's noisy and then back off till it quiets again (usually 5 or so)

image.png


Click Finish



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