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Yaskawa Auto Tuning

 

A Very Useful Calculator For The Formulas Described In This Manual Is Attached

Prerequisites

  • Have a tuning cable. USB MiniMicro Bb connector to fit the servo drive.
  • This MUST be a very good cable! under 15', heavily shielded, and with ferrite filters.

USB micro-b.png


    Make sure you have Sigma Win+ ver.7  installed

  • Download and updatedinstall withSigmaWin+ drivers.

      image.png

    • https://www.yaskawa.com/products/motion/sigma-5-servo-products/software-tools/sigmawinplus/-/content/_6c2e204d-20bc-475d-84a3-8f471d3ccaf7_DownloadSoftware


    Now
  • 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 thedrive drives
      using
    • If drive is not showing, go to device manager and find the USByaskawa port.drive

      image.png

      and


      update

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      drivers

      Click(found "Searchon Again"server: thisM:\Production\Products\Drives-Servo\Yaskawa\Software)

      • will
    refresh
  • Default drive parameters are on the selectionserver: toM:\Production\Products\Drives-Servo\Yaskawa\Drive showParameters, what's actually connected.

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    ___________________________________________________________________________________________________________________________________________

    If they don't have names add them soand you canshould tellnot themassume apart while logged into several at once

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    ___________________________________________________________________________________________________________________________________________





    Selectthat the drives youship wantwith andcorrect clickdefault connect.

    parameters.

    • image.png


    This is why you need the picture if connecting to multiple drives.

    image.png



Leave the drives in tuninglesstuning less mode (Pn170.0 set to 1) if cuttingrunning under 200ipm  or if precise profiling is not needed, however sometimes even slow machines will require motor tuning because of high inertia. A tune would not be of any benefit to slow cutting machines with moderate inertia ratios. Some machines even perform BETTER in tuningless than with a tune, due to tuningless mode's adaptability to varying loads at low speeds!needed. 

Waterjets are commonly left in tuningless mode due to slow cutting speeds, even if rapids are much higher than 200ipm.

Grinders will almost never benefit from a tune for the same reasons as a Waterjet.

Axis with widely varying loads and/or performing point to point moves, like tool changers or B axis on boring mills should usually be left in tuningless mode


Basic Auto-Tuning

Note: To tune a gantry,gantry Systemmode tuning is the only good way to go, since autotune only targets one motor at a time this is really only useful for single motor axis.

 (If you have to attemptusing auto tuning on slaved gantry motors try to tune an axis with a single motor and a similar drivetrain and then copy the parameters to the gantry axis after updating the inertia. alternativelytuning, you can decouple one of the motors on the gantrygantry. completely and try to autotune with only one motor engaged but this is very time consuming and often yields poor results.)


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, on an apollo system you can pull the control cable out from the CN1 board on the drive.
  3. Set In Position Parameter Pn522.  This will determine how tight or loose your autotunes will be.Pn522
    1. For RapidPath calculate (PnB02) x (Steps Per) x (Resolution) = Pn522
    2. For Apollo III calculate (Steps Per) x (Resolution)= Pn522
    3. Setting
    it to twenty thou has been yielding good results on routers

"Resolution" = Max Position Error that you want to see before CV get's applied, you won't actually see this amount of error in your parts.see.  Maybe 0.020001 Inch

you can also use this calculator convert to thou into encoder counts for Pn522 (also attached to the manual)

https://docs.google.com/spreadsheets/d/19xXUOK75FnIN3B1aj_EDSktX5nj8XN5OVXC3Y_g2d-E/edit#gid=0

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1: 

Input the value found in PnB02, (this is the numerator being applied to the encoder counts by the drive, it only exists on RP drives)

2:

Input "Counts Per Unit" from "Configure/Control/Motors" (you must do "Machine Calibration" for this axis first *See link below*)

https://support.machmotion.com/link/1231#bkmrk-on-the-menu-bar%2C-cli-3

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3:

This adjusts allowable deviation during the autotune. Higher number = looser autotune,  lower number = tighter autotune. In general we are shooting for a looser tune and then we will use Mach settings later to improve performance. (0.020-0.050 recommended currently)

4:

This is the result in motor counts, enter this into Pn522 before tuning.




Next step is to run an inertia calculation


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  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 disableenter tuninglesstuning less mode. Press OK and then cycle power on the drivedrive. or software reset.
  4. image-1590097240103.pngimage-1590097240103.png

Make sure your drive is in the proper state!

It should look like this, HBB or SVON will trip you up later.

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The easy way to do this on rapid path is to disable Mach without tripping the safety relay (Hit Reset, then Disable button, not the E-Stop button). 

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On Apollo III just unplug the Control cable from the CN1 board.



  1. Click the Execute button to calculate inertia. (OverNOTE: If worse than 400% is(4:1 generallyratio), consideredyour to be pretty high andmotor will probablylikely requirenot extrawork. timeCall toMachMotion tune.)for engineering. 

  2. image.png

  3. Configure Conditions
  4. Just leave this at defaults unless something doesn't look right, if it fails try adjusting things on this page starting withSelect the highlightedNo selection.
    5. Reference
  5. ClickInput "Next"
    6. Option
  6. in the Autotuning Area and then click the Autotuning
    Button.

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  7. ClickConfigure "Start",Conditions
    then

    click
    8. "Next"
  8. StandardTuning.PNG


  9. image.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. ClickEdit distance if necessary (3 revs is default)
    5. Select "ServoStart On".tuning (This may causeusing the motordefault to make rough humming or buzzing noise. This is common with untuned motors.)
    6. THIS STEP WILL CAUSE MOTION ON THE AXIS! Cycle clicking between "Forward" and "Reverse" buttons until the Inertia test completes.
    7. Click "Next"
    8. go ahead and run the software reset if you're only doing one axis, if you're tuning multiple axis then cancel out of the prompt and continue with the other axis. then reset all of them at the end. it will save you a lot of time






How To AutoTunesettings" (Onlycan attemptbe ondone singlewithout motorthis axis)

option,


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1:  No Reference Input but this is the besttypical optionway andto do your first tune).

  • Select "Next"

    • YaskawaAutoTuning2.jpg

    Tuning Process
    1. Turn the "Servo ON"
    2. Select "Start Tuning"
    3. Software will run a series of moves that are preprogramed into the drive.motor (similar to the inertia test)

      2: Position Reference Input This allows you to jog the machine from Mach while autotuning, only attempt this if Option 1 fails repeatedly. (In general system tuning has proved to be a better option.)


      Click the Autotuning button.

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      1: inertia

      "0" Will run an inertia calculation again as part of the autotune.

      "1" Will skip the inertia calculation: choose this option because we already did it earlier


      2: Mode selection 

      "1" Use this one by default

      "2" Use if 1 doesn't yield good results, in the pastthrough it's beenpre-programmed seenmoves

    4. Click "Finish"
    5. The drive is tuned
    6. Click "Finish" again to perform very closely to standard

      "3"  Use like Option 2


      3: Mechanism Selection

      Set to match the mechanics of the axis.

      "1" Belt mechanism refers to a long flimsy belt running the length of the axis with a pully on either end. (think of a light waterjet)

      "2" Ballscrew mechanism should usually be used by us, this will also apply to rack and pinion axis

      "3" Rigid Model refers to a weight directly coupled to the motor, (think rotory tool changer without any gearing)


      4: Distance

      This is how far the motor will go during the tune, usually default is fine. just be on the lookout for astronomical numbers.



      5: Defaults?

      Always check this on the first tune, only uncheck it if you are trying to stack tunes by picking up were the last one left off. (usually only done in a very high inertia situation)

      Click "Next"



      Click "Yes"

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      Click "Servo On"

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      Click "Start Tuning"

      THIS STEP WILL CAUSE MOTION ON THE AXIS! Click "Yes"  

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      Wait for the axis to finish it's preprogramed moves. (It might sound like death but that's ok)

      image.png

      Click "Finish"

      Go ahead and run the software reset if you're only doing one axis, if you'reexit tuning multiplemode

      7. axis
    then
    cancel out of the prompt and continue tuning the other axis. then reset all of them at the end. it will save you a lot of time

    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.

    Inertia could be too high.


    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. WriteCheck the inertiafollowing ratio into the install binder (Installer only)


    If you have a Sigma 5 drive this is your only good option image.png



    If you have sigma 7 drives don't use this section, skip down to "System Tuning".


    First, autotune all single motor axis using the methods above.

    Then check position errorparameters on all axis atthat 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)
  • Pick the Highest value for Pn101 and the lowest for Pn100 and 102 from all axes values.
  • Then make all included drives match each parameter. 

    • Pn100- Lowest 

    Pn101- Highest 

    Pn102- Lowest

    System Tuning

    System Tuning for Gantry

    1. Manually calculate the inertia (Pn103)
      1. Use the excel calculator to calculate it based on steady state torque. 
    2. Do a system tune. Ramp up till it gets noisy. 
      1. Example values: FF 170, FB 48.
    3. Pull back the tune till it sounds good.
      1. Try to minimize following error. 
    4. 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 IPM.procedure (usuallyabove but modify selections on Mode Selection and Mechanical Selection. 

    You may have to play with Pn100-Pn102. But MachMotion strongly recommends keeping the maxparameters speedmatching 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 slowestattached axis) this reading should be taken with the machine performing a sustained feedrate movemanual (not"Sigma-7 duringManual theAnalog-Pulse.pdf"). accel or decel sections of motion)

    image.png


    If

    Convertauto followingtuning errordoes fromnot counts to inches using this formula or use the calculator in the link (also attached to the manual)

    (Counts Per Unit)/1000 = X

    (Position Error) / X = Position error in thou

    https://docs.google.com/spreadsheets/d/19xXUOK75FnIN3B1aj_EDSktX5nj8XN5OVXC3Y_g2d-E/edit#gid=0

    image.png

    1: 

    Input "Counts Per Unit" from "Configure/Control/Motors" (you must do "Machine Calibration" for this axis first )

    2:

    Input the max position errorwork, you observe during a sustained move, (not during the accel or decel sections of motion)

    3:

    Write this down and compare all the axis

    Since you don't have system tuning available on sigma 5 youmay have to adjusttry Pn109manual totuning. match the position errors however Pn109 tells the drive to add a buffer to it's commanded positions shrinking the following error.

    therefore you have to pick the drive with the lowest position error as the standard and then increase Pn109 on the other drives to match. hoping that they don't become too tight and start running poor motion and/or overshoots on corners. (try to stay below 75% )

    Position Error in thou is the gold standard, all axis must match at the same IPM to have a well tuned machine



     9103

    System Tuning (Sigma 7 Drive feature ONLY!)


    First, autotune all single motor axis using the methods above.

    Then check position error on all axis at the same IPM. (usually the max speed of the slowest axis) this reading should be taken with the machine performing a sustained feedrate move (not during the accel or decel sections of motion)

    image.png

    Convert following error from counts to inches using this formula or use the calculator in the link (also attached to the manual)

    (Counts Per Unit)/1000 = X

    (Position Error) / X = Position error in thou

    https://docs.google.com/spreadsheets/d/19xXUOK75FnIN3B1aj_EDSktX5nj8XN5OVXC3Y_g2d-E/edit#gid=0

    image.png

    1: 

    Input "Counts Per Unit" from "Configure/Control/Motors" (you must do "Machine Calibration" for this axis first )

    2:

    Input the max position error you observe during a sustained move, (not during the accel or decel sections of motion)

    3:

    Write this down and compare all the axis



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


    Pick the Axis with the best result (usually the loosest tune and highest position error) as the standard and adjust all other axis to match.




    If you have enough USB cables and ports connect all your drives at once, If you are tuning a gantry you must at least 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 all of them

    Yaskawa recommends setting Pn408.3 to 1 on the slave drive of a gantry (needs a bit more testing)

    Make sure an inertia ratio is already set


    Select "system tuning"

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    Click "OK"

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

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    It should look like this

    image.png


    Next bring in the other drives by repeating the process.

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    If tuning a gantry click "Adjust Equally" if no gantry Click "adjust individually"

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    If you picked "adjust equally" you must select the master Axis as "Base" with the first click and Slave axis as "Applicable" with the second

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    It should look like this with both axis adjusting equally

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    If you are adjusting individually it should look like this

    image.png




    Now click "ChangeModifiy" to set the tuning parameters on each drive (On a gantry the slave drive will mirror the master)

    image.png

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    Use Tuning Mode 2 or 3 for CNC applications (Mode 3 is better, less overshoot, turns on Modal Following Control)

    When using mode 2 or 3 leave Friction compensation enabled

    Use whichever Mechanism Selection matches your machine

    feed forward level (FF) is the same as Pn141 (which uses an assumed decimal 500 = 50)


    Next write some G-code that will bring the all the axis up to full speed for the same distance and then stop, wait a couple seconds and then repeat, going the other way. An M99 at the end will allow the program to keep looping until you stop it. Make sure you use G90 for the safest results!



    Make sure all axis are traveling the same distance!! otherwise Mach will interpolate the move and slow the axis traveling the shorter distance and your tune will be inaccurate!!!


    Example G-Code using block deletes to select which axis will move or be ignored.

    ___________________________________________________________________________________________________________________________________________

    M1

    /1 G01 G90 X20  F500 
    /2 G01 G90 Y5   F500 
    /3 G01 G90 Z2   F500 
      
    G04 P3.

    /1 G01 G90 X35  F500
    /2 G01 G90 Y-10 F500
    /3 G01 G90 Z-13 F500

    G04 P3.

    M99

    ___________________________________________________________________________________________________________________________________________


    Ensure every axis is in fact reaching the commanded feedrate before matching the position error!!


    Push cycle start in Mach and let the machine start cycling

    click "start tuning" on each axis and the DROs should turn green

    image.png

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


    Use this calculator to determine the proper position error target for each axis.

    https://docs.google.com/spreadsheets/d/19xXUOK75FnIN3B1aj_EDSktX5nj8XN5OVXC3Y_g2d-E/edit#gid=0

    image.png

    1: 

    Input the max position error In inches! you observed earlier during a sustained move, (not during the accel or decel sections of motion)

    2:

    Input "Counts Per Unit" from "Configure/Control/Motors" (you must do "Machine Calibration" for this axis first)




    Watch "Position Error" in Diagnostics>RapidPath>Motors and start adjusting "Feed Forward Level" until Position Error reaches the target produced by for that axis 

    Next bring up "Feedback Level" until the axis get's noisy and then back off till it quiets again (usually 10 units or so)


    image.png

    Next bring up feedback load until the axis get's noisy and then back off till it quiets again (usually 10 units or so)


    Press feed hold to stop motion.

    Click Finish on each axis

    image.png


    Cycle drive power or software reset to finalize the new parameters



    CV Feedrate and theory

    The theory's applied in the creation of this manual are simply trying to match the lag of each axis in inches! so that in theory one could cut a circle at high speeds and while it might be smaller than programed it would still be a circle and not an egg. The job of the drives to provide smooth motion at the required speeds with equal lag in inches.

    We are therefore depending on Mach to provide the precision to that allows said circle to be the proper size, that is not the drives job.

    Mach has two tools for this, acceleration and CV feedrate. on a fast rigid machine (like a good router) acceleration should be pretty high, probably over 60 and ideally match across all coordinated axes, though this doesn't appear to be completely necessary.

    CV feedrate is needed to obtain part precision by overriding the commanded feedrate during angle changes since most post processors don't slow feedrates for angle changes. 

    It is turned on and scaled  the MachMotion plugin and can be viewed in the "Wizards" tab

    advanced CV (G64.2) is necessary once you start cutting above about a couple hundred IPM since corners start rounding.




    Without advanced CV motion is smooth, just not accurate at high speeds. We also see a pronounced entry mark from the Z, the tool appears to be finishing the ramping leadin while cutting

    G5.1 R0 is full CV mode,  activates G64   (full gas, does not slow for angle changes, use on files trying to program arcs with only G01 moves)

    G5.1 R1 slows some for corners, activates G64.2   (Uses the full "path error tolerance" amount in the MM plugin, is full gas within G64.2)

    G5.1 R10 slows completely for corners, activates G64.2   (Slows down much more than than an R1 will, is full brakes within G64.2,  this is a nice middle ground between R1 and G61)

    G5.1 R5 is halfway between R1 and R10

    sometimes it's nice to use a pound variable and let the operator adjust it as needed on the dashboard.   G5.1 R#501

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