JP2004103031A - Malfunction detection/diagnosis method and device for servo control system, and automatic rectification method and device therefor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a high-reliability servo control system by facilitating cause investigation in trouble occurrence by generating a parameter abnormality alarm when a detector type designated by a parameter is different from that of a detector actually connected. <P>SOLUTION: Transmission-side connection states of a plurality of receiving circuits for detectors are detected to automatically determine the type number of the detector actually connected in turning power on, and when the detector type designated by a parameter is different from that of the detector actually connected, the parameter abnormality alarm is generated. <P>COPYRIGHT: (C)2004,JPO

Description

The present invention relates to an abnormality detection / diagnosis method and an automatic optimization method of a servo control system used in a numerical controller for controlling a machine tool, a robot, and the like, and an abnormality detection / diagnosis apparatus and an automatic optimization method of a servo control system. It concerns the device.

FIG. 43 shows a general servo motor driving device used in a servo control system. The servo motor driving device is supplied with a rectifier circuit 2 for rectifying three-phase AC supplied from a three-phase AC power supply 1, a smoothing capacitor 3 for smoothing a rectified output of the rectifier circuit 2, and a DC that is smoothed by the smoothing capacitor 3. A semiconductor switching circuit 4 serving as an output part of a PWM circuit for outputting the PWM-converted three-phase alternating current to the AC servomotor 8, and shunting the U-phase and V-phase current values flowing from the semiconductor switching circuit 4 to the AC servomotor 8. The current detection unit 5 detects by the resistance CT, the A / D converter 6 that converts an analog voltage signal proportional to the current value detected by the current detection unit 5 into a digital signal, and the A / D converter 6 outputs. The digital signal is fetched as a current feedback signal, and predetermined arithmetic processing is performed based on the current feedback value and the speed command value. And a CPU7 for outputting a signal to each phase of the base terminal of the semiconductor switching circuit 4.

In this specification, a circuit constituted by the rectifier circuit 2 and the smoothing capacitor 3 is hereinafter referred to as a converter.

FIG. 44 shows a general servo control system. The servo control system includes a position control unit 11 that generates a speed command based on a deviation between a position command value output from the NC device 10 and a position feedback value from a motor end or a machine end, and a speed command value from the position control unit 11. A speed control unit 12 that generates a current command based on a deviation from the speed feedback value, and a current that generates a current that flows through the servomotor 8 based on a difference between the current command value from the speed control unit 12 and the current feedback value based on the shunt resistor CT. And a control unit 13. The servo motor 8 drives the feed screw 16 to rotate by the reduction gear 15 and linearly moves the table 17 which is the control object.

In the case of a semi-closed loop, a motor end detector 18 connected to the servo motor 8 and detecting the number of rotations, the rotation angle, and the position of a magnetic pole of the servo motor 8 is used. A load-side detector 19 for detecting the position is used, and a feedback signal is obtained by these detectors.

FIG. 45 shows a current control unit of the AC servomotor. The current control unit limits the q-axis current command value output by the speed control unit 20 to protect a semiconductor element forming a PWM modulation unit 25 described later, and a speed control unit 20 that outputs a q-axis current command value. Limiter 21, a d-q coordinate converter 22, which converts U-phase and V-phase currents output to the AC servomotor 8 into d- and q-axis currents, a d-axis current command value and a d-q coordinate converter. A current controller 23a for generating a d-axis voltage command such that a deviation from the d-axis current value output from the output 22 is zero and a q-axis current command value output from the speed control unit 20 and d-q coordinates A current controller 23b for generating a q-axis voltage command such that the deviation from the q-axis current value output from the conversion unit 22 is reduced to zero, and d and q-axis voltages output from the current controllers 23a and 23b. Converts the command into three phases and converts the U, V, W phase voltage commands And 3-phase conversion unit 24 for forming, is constituted by a PWM modulator 25 to generate a three-phase alternating current to be output to the AC servo motor 8 from each phase of the voltage command output from the 3-phase conversion unit 24.

In the configuration as described above, when the NC device 10 outputs the position command value, the position feedback value by the motor end detector 18 in the case of the semi-closed loop and the position feedback value by the machine end detector 19 in the case of the full closed loop is represented by the position command value. A speed command is generated by the position controller 11 so as to match the speed command, and the q-axis current command is generated by the speed controller 12 so that the speed command value matches the speed feedback value detected by the motor end detector 18. You. Normally, 0 is given to the d-axis current command with respect to the q-axis current command.

The three-phase AC current for driving the AC servomotor 8 so as to follow the command is supplied by the q-axis current command and the d-axis current command, and finally by the semiconductor switching circuit 4 shown in FIG. It is output after PWM modulation.

Next, the operation of the protection function in the above-described conventional servo motor driving device will be described. As described above, when the q-axis current command is generated so as to follow the position command from the NC device 10 and exceeds the allowable current value of the semiconductor switching circuit 4, the current limit is set by the limiter 21. Is performed.

Further, when the current command value or the ratio of the phase current value detected by the current detection unit 5 to the allowable current value exceeds a certain value, and when it exceeds a certain time, a predetermined alarm process is performed as an overload alarm. . Further, when the deviation between the position command value and the position feedback value given to the position control unit 11 is a value that is more than a certain ratio apart from the deviation calculated theoretically, a predetermined alarm process is determined as an excessive deviation difference. Done.

In addition, when a current flowing through each transistor of the semiconductor switching circuit 4 is detected and recognized as an overcurrent, or when a gate cutoff request is generated from a multi-axis driving device, a converter unit, or an NC device, The gate of each transistor of the semiconductor switching circuit is cut off by hardware.

In a fully closed loop having the machine-side detector 19, the machine-side and motor-side coincide with zero in the normal state based on the resolution and number of pulses of the machine-side detector 19 and the resolution and number of pulses of the motor-side detector 18. If the difference in the number of pulses that should have been calculated to exceed a certain allowable range, a predetermined alarm process is performed as a feedback abnormality.

Since the conventional servo motor driving device does not have a function of monitoring the current waveform pattern of the current of each phase flowing to the motor output terminal, it is not possible to detect a wrong connection of the motor output terminal, and it is simply an excessive deviation or excess. There is a problem that the operation can only be stopped as a load alarm.

Further, since there is no function of detecting the voltage of each phase applied to the motor output terminal, there is a problem that it is not possible to detect the non-connection of the motor output terminal or the non-connection of the converter bus.

In addition, since there is no function to monitor the gate cutoff signal to the transistor and the type of the gate cutoff request signal in the inverter section that controls the current of the servomotor, the cause of the alarm such as excessive deviation and feedback abnormality can be determined in more detail. There is a problem that cannot be done.

In addition, in the case of an alarm such as an excessive deviation, an overload alarm, or a feedback abnormality in a fully closed loop having a load-side detector, the operation has to be stopped because it does not have a function of discriminating those factors in more detail. There is a problem that it does not obtain, or spends a lot of time to find out the cause.

In addition, when an excessive deviation or overload alarm occurs during acceleration / deceleration, etc., there is no means to distinguish whether the alarm occurred due to insufficient acceleration / deceleration time constant or an abnormal load. However, if the parameters are automatically readjusted, the operation must be stopped even when the operation can be continued without stopping the operation.

In addition, since the type of the detector is not determined, if the detector setting using parameters differs from the communication specification of the actually connected detector, a no-signal alarm is generated and the detector and the connection cable are disconnected. In addition to misjudgment as a failure, there were problems such as prolonged recovery and unavailability of simple parameter setting errors.

The present invention has been made in order to solve the above-described problems, and has a function to determine a cause of an alarm such as a wrong connection of a motor output terminal, a disconnection of a motor output terminal or a converter bus, an excessive deviation or a feedback error, and the like. Accurately detects incorrect wiring of feedback cables, incorrect setting of various parameters, incorrect connection of detectors, lack of acceleration / deceleration time constants, occurrence of abnormal loads, etc. It is another object of the present invention to provide a servo control system abnormality detection / diagnosis method and apparatus for automatically changing various servo control conditions so that servo control is performed in an optimum state.

Further, the abnormality detection / diagnosis method of the servo control system according to the present invention detects a current flowing in at least two phases of the U-phase, V-phase, and W-phase of the servo motor output terminal at the first acceleration after power-on, By monitoring the current waveform pattern, it is possible to detect erroneous connection of the motor output terminal, and to cause alarms such as erroneous connection of the motor output terminal, disconnection of the motor output terminal or converter bus, excessive deviation, or feedback error. Judgment, erroneous wiring of feedback cable, erroneous setting of various parameters, erroneous connection of detector, shortage of acceleration / deceleration time constant, occurrence of abnormal load, etc. Is a servo control system that automatically changes various servo control conditions so that servo control is performed in an optimal state. The methods and automated optimization methods, as well as the purpose of obtaining an abnormality detecting and diagnosing apparatus and automatic optimization apparatus of a servo control system.

In order to achieve the above-mentioned object, a servo control system abnormality / diagnosis method and apparatus according to the present invention detects a transmission-side connection state of a plurality of detector reception circuits at the time of power-on, and detects an actual connection. The device type name is automatically determined, and when the detector type specified by the parameter is different from the actually connected detector, a parameter abnormality alarm is generated.

The automatic optimization method and apparatus of the servo control system according to the next invention detects the transmitter connection state of the plurality of detector receiving circuits at power-on, and automatically determines the actually connected detector model name, When the detector type specified by the parameter is different from the actually connected detector, a switch is made to the receiving circuit corresponding to the connected detector.

An abnormality detection / diagnosis method and apparatus of a servo control system according to the next invention detects U-phase, V-phase, and W-phase currents and phase voltages flowing to output terminals of a servomotor, and detects a phase voltage exceeding a predetermined value. When there is a phase in which no current flows despite the existence, it is determined that the motor output terminal is not connected.

A servo control system abnormality detection / diagnosis method and apparatus according to the next invention detects all the voltages of each phase acting on a motor output terminal during acceleration or deceleration, and detects all phase voltages when they become zero. Is characterized in that it is determined that the converter bus is not connected.

An abnormality detection / diagnosis method and apparatus for a servo control system according to the next invention detects a voltage between each phase of an output terminal of a servo motor, calculates a switching voltage of each phase, and a filter having the calculated switching voltage as an input. Is used to continuously detect smooth phase voltages.

The method and apparatus for detecting and diagnosing abnormality of a servo control system according to the next invention are characterized in that when a gate cutoff signal to a transistor in an inverter unit for controlling current of a servomotor is generated when an alarm is not in operation, the gate cutoff is performed. A location where a request signal is generated is detected, and the number of times the signal is generated is stored in a memory for a predetermined time in the past for each detected location, and a cause of an alarm of a control system abnormality such as an excessive error or a feedback abnormality is determined. It is characterized by the following.

A servo control system abnormality detection / diagnosis method and apparatus according to the next invention is characterized in that, in a fully closed loop type position control having a load-side detector, a polarity of a position command, a position feedback, a speed feedback, a current command, and a current feedback is determined. It is characterized by monitoring from power-on and determining that the feedback cable is incorrectly wired if only the position feedback has the opposite polarity when all of the signals have a certain magnitude or more.

An abnormality detection / diagnosis method and apparatus for a servo control system according to the next invention moves a certain amount corresponding to one rotation of a motor or the like at the time of power-on in a full closed loop type position control having a load-side detector. The number of pulses detected by the motor-side detector and the number of pulses detected at the machine end are compared, and based on the result of the comparison, erroneous settings of machine parameters such as the machine gear ratio, ball screw pitch, and machine-side detector resolution are detected. It is characterized by doing.

An abnormality detection / diagnosis method and apparatus for a servo control system according to the next invention is characterized in that software for controlling the current of a servomotor creates a servomotor model with d-axis and q-axis current commands as input, and positions the model. If the difference between the feedback value and the actual motor end position feedback value is too large even after the current limit, despite being within a predetermined allowable range, it is determined that the acceleration / deceleration time constant is insufficient. And

An abnormality detection / diagnosis method and apparatus for a servo control system according to the next invention is characterized in that software for controlling the current of a servomotor creates a servomotor model with d-axis and q-axis current commands as input, and positions the model. If the difference between the feedback value and the actual motor end position feedback value exceeds a predetermined allowable range, the inertia is within the allowable range, and if no erroneous gate cutoff has occurred, an abnormal load exists. Is determined to be present.

A method and apparatus for automatically adjusting a servo control system according to the next invention perform a position control of a semi-closed loop system at power-on in a position control of a full closed loop system having a load-side detector. The polarity of the position feedback signal from the load-side detector is determined in the next step.If the polarity does not match the direction of the commanded position, the polarity of the position feedback amount of the load-side detector is inverted, and then the fully closed loop method This is characterized by shifting to the position control.

A method and an apparatus for automatically optimizing a servo control system according to the next invention provide a position feedback amount and a machine end detection by a motor end detector from a power-on time in a fully closed loop position control having a machine end position detector. The difference from the position feedback amount by the detector is monitored, and when the difference becomes a predetermined value or more, the polarity of the position feedback amount by the machine-side detector is inverted.

A method and apparatus for automatically optimizing a servo control system according to the next invention performs dual feedback control in a position control of a full closed loop system having a machine end position detector, and performs position control by a motor end detector from a power-on time. The difference between the feedback amount and the position feedback amount by the machine-side detector is monitored, and when the difference is equal to or larger than a predetermined value, the polarity of the position feedback amount by the machine-side detector is inverted.

When the polarity of the position feedback amount of the load-side detector is inverted, the information is stored in a non-volatile memory, and the next power-on is performed. Sometimes, the feedback polarity of the position feedback amount of the load-side detector is inverted based on this information.

An automatic optimization method and apparatus for a servo control system according to the next invention calculates an optimal acceleration / deceleration time constant from an output torque of a servo amplifier required at the time of rapid traverse acceleration / deceleration. It is characterized in that a command is created with a constant.

The automatic optimization method and apparatus for a servo control system according to the next invention individually calculates an optimal acceleration / deceleration time constant possible for each movement direction from an output torque of a servo amplifier required at the time of rapid traverse acceleration / deceleration. During deceleration, a command is created with an optimal acceleration / deceleration time constant in the corresponding motion direction.

An automatic optimization method and apparatus for a servo control system according to the next invention separately calculates an optimal acceleration / deceleration time constant that can be obtained during acceleration and deceleration from an output torque of a servo amplifier required during rapid traverse acceleration / deceleration. At the next acceleration / deceleration, a command is created with an optimum acceleration / deceleration time constant corresponding to acceleration and deceleration.

An automatic optimization method and apparatus for a servo control system according to the next invention provides an optimum acceleration / deceleration time constant that can be obtained from an output torque of a servo amplifier required during rapid traverse acceleration / deceleration during acceleration, deceleration, and for each direction of motion. Calculate individually and always calculate possible time constants from the output torque of servo amplifier required for acceleration and deceleration during acceleration and deceleration in each feed direction. It is characterized in that a command is created with a corresponding optimum acceleration / deceleration time constant.

(5) The automatic optimization method and apparatus for a servo control system according to the next invention is characterized in that the excessive error alarm determination position deviation amount is set to a value larger than usual only during rapid traverse acceleration / deceleration.

(4) The automatic optimization method and apparatus for a servo control system according to the next invention is characterized in that the overspeed alarm determination motor rotation speed is set to a value larger than usual only during rapid traverse acceleration / deceleration.

The method and apparatus for automatically adjusting the servo control system according to the next invention is characterized in that the maximum speed of the speed command is clamped at a constant value.

The method and apparatus for automatically adjusting the servo control system according to the next invention are characterized in that the maximum speed of the speed command is clamped at a constant value only during acceleration / deceleration.

The method and apparatus for automatically adjusting the servo control system according to the next invention is characterized in that the maximum speed of the speed command is clamped at a constant value only during the maximum current limitation of the servo amplifier.

As described above, in the method and apparatus for automatically optimizing the servo control system according to the present invention, when the power supply is turned on, the detection side connection state of the plurality of detector-like reception circuits is detected, and the detector type actually connected is detected. Automatically distinguishes the name, and if the detector type specified by the parameter is different from the actually connected detector, a parameter error alarm will be generated. A servo control system is obtained.

In the method and apparatus for automatically optimizing a servo control system according to the next invention, when a power supply is turned on, a connection state on a transmitting side of a plurality of detector-like receiving circuits is detected to automatically determine a detector type actually connected. However, if the detector type specified by the parameter is different from the actually connected detector, it automatically switches to the receiving circuit corresponding to the connected detector. Thus, an intelligent and highly reliable servo control system that can start operating normally can be obtained.

In the servo control system abnormality detection / diagnosis method and apparatus according to the next invention, all the U-phase, V-phase, and W-phase currents and phase voltages flowing to the output terminal of the servomotor are detected, and the voltage is set to a certain value. Despite the above, if there is a phase in which no current flows, it is determined that the motor output terminal is not connected, so that it is accurately known that the motor output terminal is not connected.

In the method and apparatus for detecting and diagnosing abnormality of the servo control system according to the next invention, when all the voltages of each phase acting on the motor output terminal at the time of acceleration or deceleration are detected, and all the phase voltages become 0, Since it is determined that the converter bus is not connected, it is understood that the converter bus is not connected.

In the servo control system abnormality detection / diagnosis method and apparatus according to the next invention, a voltage between each phase of a servo motor output terminal is detected to calculate a switching voltage of each phase, and the calculated switching voltage is input. Since the phase voltage is detected by using the filter, a phase voltage whose magnitude can be easily evaluated is obtained, and abnormality detection and diagnosis using the phase voltage can be performed reliably.

In the abnormality detection / diagnosis method and apparatus of the servo control system according to the next invention, since the gate cutoff signal of the transistor in the inverter unit for controlling the current of the servomotor is monitored to determine the location where the signal is generated, an excessive error, The cause of the alarm of the control system abnormality such as the feedback abnormality can be understood, and the subsequent response can be smoothly performed.

In the servo control system abnormality detection / diagnosis method and apparatus according to the next invention, in a closed loop having a load-side position detector, the polarity of a position command, a position feedback, a speed feedback, a current command, and a current feedback is changed at power-on. If only the position feedback is the reverse polarity when all the signals have a certain magnitude or more, it is determined that the feedback cable is erroneously wired, so that the erroneous wiring of the feedback cable can be accurately understood.

In the method and apparatus for detecting and diagnosing abnormality of the servo control system according to the next invention, in a closed loop having a machine end position detector, when a certain amount corresponding to one rotation of the motor or the like is moved at the time of power-on. By comparing the number of pulses detected at the motor end with the number of pulses detected at the machine end, erroneous settings of machine parameters such as machine gear ratio, ball screw pitch, and machine end detector resolution are detected. Is correctly set, and the timing of machine start-up adjustment can be streamlined.

In the method and apparatus for detecting and diagnosing abnormality of a servo control system according to the next invention, in a software for controlling current of a servo motor, a servo motor model having d-axis and q-axis current commands as inputs is created, and If the difference between the position feedback value and the actual motor end position feedback value is within a certain allowable range even after the current limit and the error is excessively large, it is determined that the acceleration / deceleration time constant is insufficient. It can be clearly understood that the acceleration / deceleration time constant is insufficient.

In the method and apparatus for detecting and diagnosing abnormality of a servo control system according to the next invention, in a software for controlling current of a servo motor, a servo motor model having d-axis and q-axis current commands as inputs is created, and If the difference between the position feedback value and the actual motor end position feedback value exceeds a predetermined allowable range, if the rotor inertia and load inertia are within the allowable range, and if no erroneous gate interruption has occurred, an abnormal load Is determined to be present, it is accurately known that an abnormal load exists.

In the method and apparatus for automatically adjusting the servo control system according to the next invention, even if the feedback polarity of the position control machine-end position detector based on the semi-closed loop method is initially reversed, it is automatically adjusted. Since the position control by the fully closed loop method is started, the system can be operated without generating an alarm such as an excessive deviation and a feedback abnormality and without causing a system down. This makes it possible to realize a very reliable servo control system that is not affected by user parameter settings, erroneous connections, and the like.

In the method and apparatus for automatically adjusting the servo control system according to the next invention, even if the feedback polarity of the load-side position detector is reversed, the feedback polarity is automatically adjusted. The operation of the system can be continued without generating an alarm and without causing the system to go down. This makes it possible to realize a very reliable servo control system that is not affected by user parameter settings, erroneous connections, and the like.

In the automatic optimization method and apparatus of the servo control system according to the next invention, the feedback polarity of the load-side position detector is determined by performing dual feedback control, and the feedback polarity of the load-side position detector is reversed. In addition, since it is automatically optimized, the operation of the system can be continued without generating an alarm such as an excessive deviation and a feedback abnormality, and without causing a system down. This makes it possible to realize a very reliable servo control system that is not affected by user parameter settings, erroneous connections, and the like.

In the automatic optimization method and apparatus of the servo control system according to the next invention, when detecting the state where the feedback polarity of the load-side position detector is reversed, the information is stored in the nonvolatile memory, The next time the power is turned on, the feedback polarity is inverted based on this information for control, so that even if there is a mistake in setting or connection, a highly reliable intelligent intelligent control system can be realized.

In the automatic optimizing method and apparatus of the servo control system according to the next invention, the optimal time constant is calculated from the output torque of the servo amplifier required at the time of rapid traverse acceleration / deceleration, and the optimal time constant is calculated at the next acceleration / deceleration. Therefore, even if there is a change in the mechanical load, an optimum time constant suitable for the change is always obtained.

In the automatic optimization method and apparatus for a servo control system according to the next invention, the optimum time constant possible is calculated for each movement direction (feed direction) from the output torque of the servo amplifier required at the time of rapid traverse acceleration / deceleration to calculate the next time. At the time of acceleration / deceleration, since the command is created with the optimal time constant of the corresponding motion direction, an optimal acceleration / deceleration time constant is always obtained according to the moving direction even on a load imbalance axis such as a vertical movement axis.

In the automatic optimization method and apparatus for a servo control system according to the next invention, the optimum time constant that can be calculated from the output torque of the servo amplifier required for acceleration and deceleration during rapid traverse acceleration / deceleration is calculated, and the next time Since the command is created with the optimum time constant in the corresponding direction during deceleration, the acceleration / deceleration time can be shortened, for example, the time constant during deceleration that can assist the torque by friction or the like can be reduced.

In the automatic optimizing method and apparatus of the servo control system according to the next invention, acceleration during acceleration / deceleration for each feed direction, the optimum time constant possible from the output torque of the servo amplifier required for each of the deceleration is always determined. At the next acceleration / deceleration, the command is created with the corresponding optimal time constant at the next acceleration / deceleration, so that the optimal acceleration / deceleration time constant can be obtained corresponding to all of the load imbalance (gravity, etc.), friction, and those changes over time. .

In the automatic optimization method and apparatus of the servo control system according to the next invention, it is assumed that the time constant at the time of rapid traverse acceleration / deceleration is set small or the maximum output torque of the servo amplifier is reached due to an abnormal load. Therefore, the excessive error alarm determination position deviation is set to a value larger than usual only during the rapid traverse acceleration / deceleration, so that an excessive error alarm is less likely to occur and a highly reliable servo control system can be realized.

In the method and apparatus for automatically adjusting the servo control system according to the next invention, it is assumed that the time constant at the time of rapid traverse acceleration / deceleration is set small or the maximum output torque of the servo amplifier is reached due to an abnormal load. In addition, the determination of the overspeed alarm is performed only during the rapid traverse acceleration / deceleration. Since the motor speed is set to a value larger than the normal value, the occurrence of the overspeed alarm is unlikely to occur, and a more reliable servo control system than before can be provided.

In the automatic optimization method and apparatus of the servo control system according to the next invention, it is assumed that the time constant at the time of rapid traverse acceleration / deceleration is set small or the maximum output torque of the servo amplifier is reached due to an abnormal load. Since the overshoot is suppressed by previously clamping the maximum speed of the speed command at a constant value, an excessive error or an overspeed alarm is hardly generated, and a stable and reliable servo control system can be obtained.

In the method and apparatus for automatically optimizing the servo control system according to the present invention, since the maximum speed of the speed command is clamped at a constant value only during acceleration / deceleration, the setting of the time constant during rapid traverse acceleration / deceleration is small, , Overshoot hardly occurs even when the maximum output torque of the servo amplifier is reached, and a stable and highly reliable servo control system can be obtained.

In the automatic optimization method and apparatus of the servo control system according to the next invention, the maximum speed of the speed command is clamped at a constant value only during the maximum current limitation of the servo amplifier. Also, even when the maximum output torque of the servo amplifier is reached due to the influence of an abnormal load, overshoot hardly occurs, and a stable and highly reliable servo control system can be obtained.

Embodiments of the present invention will be described below in detail with reference to the drawings. The present invention is not limited by the embodiment.

Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In the embodiments of the present invention, the same components as those of the above-described conventional example are denoted by the same reference numerals as those of the above-described conventional example, and the description thereof is omitted.

Embodiment 1 FIG.
FIG. 1 shows an embodiment of a servo motor driving device used for carrying out a method for detecting and diagnosing abnormality of a servo control system according to the present invention. In this servo motor driving device, the current detector 5 for detecting the phase current flowing to the motor output terminal detects the W-phase current in addition to the U-phase and V-phase currents.

This servo motor driving device has voltage detecting circuits 9a, 9b, 9c. The voltage detection circuits 9a, 9b, and 9c divide the voltage between the U, V, and W phases and output a voltage proportional to the voltage between the phases to the A / D converter 6. The A / D converter 6 converts the voltage detected by the voltage detection circuits 9a, 9b, 9c into a digital value and outputs the digital signal to the CPU 7.

FIG. 2 shows a motor output terminal connection diagnosis routine in the abnormality detection / diagnosis method of the servo control system according to the present invention. In this connection diagnosis routine, first, in step S101 after the power is turned on, the q-axis current command Iqa is detected for each sampling cycle, and the process proceeds to the next step S102.

In step S102, it is determined whether or not the absolute value is the certain magnitude I _R or the detected q-axis current command IQA, if the absolute value is the certain magnitude I _R or the q-axis current command IQA, acceleration Recognizing that the request is being made, the process proceeds to step S104. On the other hand, if it is not recognized that acceleration is being requested, the process proceeds to step S103.

In step S103, it is determined whether or not the acceleration command result flag has already been turned on. If the acceleration command result flag has already been turned on, it is recognized that the first acceleration request has been completed. If there is a wrong connection in the motor output terminal connection, the first acceleration request continues until an excessive error or overload alarm occurs, so the acceleration command actual flag is turned on and the first acceleration request has already been completed. When it is recognized that the normal connection is performed, the connection diagnosis routine is terminated. On the other hand, if the acceleration command result flag has not been turned on yet, it is recognized that no acceleration command request has occurred once after power-on, and the process returns to step S101.

In step S104, in order to recognize in step S103 that the acceleration command request has occurred after the power is turned on, the acceleration command actual flag is turned on, and the process proceeds to the next step S105. In step S105, U-phase, V-phase, and W-phase currents are detected at each sampling cycle. It is not always necessary to detect the current of the W phase, and it is sufficient to detect the current of two phases among the three phases. Here, the current of all three phases is detected.

In the next step S106, the absolute value of the detected current of each phase is separately compared with the previous peak value on each of the positive and negative sides of the current polarity. If the present value is updated from the comparison result to the previous peak value or if it is determined to be the same level, the process proceeds to the next step S107, and if not, the process proceeds to step S109.

In step S107, the peak value is updated on the positive side and the negative side of the current polarity, respectively, or a value marked with the same level value is rewritten as a new peak value used for comparison in step S106, and the process proceeds to next step S108. And proceed. In step S108, the peak value is updated on the positive side and the negative side of the current polarity, respectively, or the recognition data of the phase marked with the same level value is sequentially stored in the memory separately prepared on the positive side and the negative side. And the process proceeds to the next step S109.

In step S109, when the amount of the recognition data stored in the previous step S108 exceeds a certain amount, the process proceeds to the next step S110, and otherwise, returns to step S101. In step S110, a current waveform pattern is found from the recognition data stored in step S108, and it is determined whether there is an erroneous connection of the motor output terminal.

When the acceleration command is a request for forward rotation of the motor, as shown in FIG. 3A, the pattern stored in the order of U, V, and W phases with respect to the U phase on both the positive and negative sides of the current polarity, as shown in FIG. , It is determined that the connection of the normal UVW phase is made. If the pattern of the U, W, and V phases is present on both the positive and negative sides, an incorrect connection that becomes the VWU phase or the WUV phase is determined. It is determined that it has been performed.

When the acceleration command is a motor reverse rotation request, as shown in FIG. 3-2, the pattern stored in the order of U, W, and V phases with respect to the U phase on both the positive and negative sides of the current polarity is used. If so, it is determined that the connection of the normal UVW phase has been made. If both the positive and negative sides have the U, V, and W phase patterns, an erroneous connection of the VWU phase or the WUV phase is made. It is determined that there is.

In any case, if the patterns of the recognition data on the positive and negative sides of the current polarity do not match, it is determined that there is another erroneous connection. With these determinations, the connection diagnosis routine ends. As a result, an erroneous connection of the motor output terminal is automatically detected, and it is avoided that the motor is operated in an erroneous state. Further, as described above, after the erroneous connection of the UVW phase is determined, the operation can be continued by automatically switching the voltage command output phase by software.

In this case, the respective voltage command output phases are exchanged by software processing based on the determination result of the erroneous connection as shown in FIG. 3 so that the connection is virtually correct. This is one embodiment of the method for automatically adjusting the servo control system according to the present invention.

FIG. 4 shows a phase voltage detection routine used for connection diagnosis of a motor output terminal and a converter bus in the abnormality detection / diagnosis method of the servo control system according to the present invention. In step S201, the data of the UV-phase voltage Vuv, VW-phase voltage Vvw, and WU-phase voltage Vwu, which are detected by the voltage detectors 9a to 9c, converted into digital signals by the A / D converter 6, and captured by the CPU 7, are output. Sampling is performed at predetermined time intervals.

In the next step S202, the switching voltages Vua, Vva, Vwa of each phase are calculated based on the data.
Vua = (Vuv−Vwu) / 3
Vva = (Vvw-Vuv) / 3
Vwa = (Vwu−Vvw) / 3

Since the voltages Vua, Vva, and Vwa calculated in step S202 are switching voltages in the inverter unit and are discrete data, in order to make it easy to evaluate the magnitude of the phase voltage, in step S203, the motor A smooth phase voltage Vu, Vv, Vw is obtained continuously through a filter using the nominal values of the armature inductance L and the armature resistance R.
Vu = RVua / (Ls + R)
Vv = R · Vva / (Ls + R)
Vw = R · Vwa / (Ls + R)
s is Laplace operator

FIG. 5 shows a motor output terminal connection diagnosis routine in the servo control system abnormality detection / diagnosis method according to the present invention. This motor output terminal connection diagnosis routine, first in step S300, the a i = 1, phase voltage Vi (Vu or Vv, Vw) in step S301 it is determined whether or not a predetermined value or more V _R. If vi ≧ V _R, the process proceeds to step S302 follows.

In step S302, the phase current Ii (Iu or Iv, Iw) before and after the sampling is detected, and in step S303, it is determined whether or not the phase current Ii is substantially zero. If the phase current Ii is substantially zero, the process proceeds to step S304, where it is determined that the i-phase is not connected.

Since i = 1 is defined in advance as a U phase, i = 2 is defined as a V phase, and i = 3 is defined as a W phase, steps S301 to S303 determine i ≧ 3 in step S305 and determine in step S306 Updating of the detection target phase i by i = i + 1 is performed for each phase in the order of the U phase, the V phase, and the W phase. As a result, the disconnection of the motor output terminal is automatically and accurately detected for each of the U, V, and W phases.

6 shows a converter bus connection diagnosis routine in the servo control system abnormality detection / diagnosis method according to the present invention. In this converter bus connection diagnosis routine, first in step S401, it performs an absolute value is in whether a magnitude I _R or determination of q-axis current command IQA. If the absolute value is the certain magnitude I _R or the q-axis current command IQA, the process proceeds to step S402.

In step S402, it is determined whether all of the calculated phase voltages Vu, Vv, and Vw are substantially zero even when it is recognized that the amplifier is requesting acceleration in step S401. If all of the phase voltages Vu, Vv, Vw are substantially zero, the process proceeds to step S403, and it is determined that the converter bus is not connected. As a result, it is automatically and accurately detected that the converter bus is not connected.

Embodiment 2. FIG.
FIG. 7 shows a gate control circuit of a transistor in the semiconductor switching circuit 4 of the current control unit (inverter unit) used for implementing the abnormality detection / diagnosis method of the servo control system according to the present invention. This gate control circuit has an overcurrent detector 29 for detecting that an overcurrent has flowed through the semiconductor switching circuit 4.

The CPU 7 outputs a signal indicating that an overcurrent has flown by the overcurrent detector 29 from the latch circuit 30, and outputs a gate-off signal indicating that a gate cutoff request has been made by an amplifier or converter of another axis from the latch circuit 31 from the NC. The gate-off signals are individually fetched from the latch circuits 32, respectively, and a logical product signal of these three signals is input from the AND gate 33.

The AND gate 34 is connected to the gate of the transistor Tr of the semiconductor switching circuit 4. The AND gate 34 receives the output signal of the AND gate 33 and the gate ON / OFF signal output by the CPU 7.

In this gate control circuit, the CPU 7 determines whether an overcurrent flows through the inverter unit, a request to cut off the gate by an amplifier or converter of another axis occurs, or a gate-off (gate cut-off) signal is generated from the NC device. Regardless, if no gate alarm signal is output to the AND gate 34 assuming that it is operating normally without detecting any alarm, the outputs of the latch circuits 31 and 32 are checked, and a gate cutoff request is issued based on the output. A flag corresponding to the portion where the signal is generated is set, and the number of times the signal has been generated is stored in the memory for a predetermined period of time in the past. If this number exceeds a certain number, it is determined that the location of occurrence is abnormal. As a result, a factor (occurrence location) of the occurrence of an abnormality in the control system such as an excessive error or a feedback abnormality is determined.

FIG. 8 shows a routine for diagnosing the cause of gate interruption in the method for detecting and diagnosing abnormality in the servo control system according to the present invention. In this diagnostic routine, in step S451, the output state of the gate shutoff for the AND gate 34 is monitored at a predetermined cycle, and in step S452, it is determined whether the gate shutoff output is being performed, that is, whether the gate off signal is being output to the AND gate 34. Determine.

場合 If the gate cutoff output is not being performed, the process proceeds to step S453, and in step S453, the output states of the latch circuits 31, 32 of each factor signal are checked. Next, in step S454, the output states of the latch circuits 31 and 32 are reflected on the gate cutoff signal output flag of the CPU 7, and if the gate cutoff signal output flag is on, the process proceeds to step S445, where the gate of the generated factor is set. The number of cutoff outputs (the number of times the gate cutoff signal output flag is turned on for each latch circuit) is counted.

Next, in step S456, the gate cutoff signal output flag is cleared to off, and in the next step S457, it is determined whether or not the count value of the gate cutoff output has reached a predetermined value or more. If the count value of the gate cutoff output has reached a predetermined value or more, the process proceeds to step S458, and an abnormal location (for example, a converter or an NC device of another axis) due to a factor exceeding the allowable number is determined.

If it is determined in step S452 that the gate shutoff output is being performed, the flow advances to step S459 to determine whether a predetermined time has elapsed. If the predetermined time has elapsed, the flow advances to step S460 to count the gate shutoff output. Clear the value to 0. As a result, a location where a control system abnormality such as an excessive error or a feedback abnormality has occurred can be immediately identified.

Embodiment 3 FIG.
FIG. 9 shows a wiring diagnosis routine of the feedback cable in the abnormality detection / diagnosis method of the servo control system according to the present invention. This feedback cable wiring diagnosis is applied to the servo control system based on the fully closed loop shown in FIG. 44. First, in step S501, the position command value output from the NC device 10 and the output from the machine end detector 19 are output. The position feedback value to be output, the speed feedback value output by the motor end detector 18, the current command value output by the speed control unit 12, the current feedback value, and their respective polarities are always detected and monitored from the power-on.

Next, in step S502, it is determined whether or not all of these signal values are equal to or more than a predetermined value. If all of these signal values are equal to or more than the predetermined value, the process proceeds to step S503. In step S503, it is determined whether or not only the position feedback signal has the opposite polarity. If only the position feedback signal has the opposite polarity, the process proceeds to step S504, and it is determined that the feedback cable is incorrectly wired. As a result, incorrect wiring of the feedback cable is automatically and accurately detected.

Embodiment 4. FIG.
FIG. 10 shows a parameter setting diagnosis routine in the abnormality detection / diagnosis method of the servo control system according to the present invention. In the parameter setting diagnosis routine, first, in step S701, it is determined whether or not the polarity of the position feedback signal and the polarity of the position command are the same. If these polarities are equal, the process proceeds to step S702, where these polarities are determined. If not equal, the process proceeds to step S706.

In step S702, the number of pulses from the Z-phase to the Z-phase of the motor end detector 18 is counted, and it is confirmed whether or not this is equal to the set motor end detector resolution. If it is determined that this is correct, the process proceeds to the next step S703, and if not, the process proceeds to step S705.

In step S703, when a certain feed amount is positioned, the number of rotations of the servo motor 8 is calculated from the resolution of the machine end position detector 19 and the number of pulses at that time, and the number of rotations of the motor end detector 18 per rotation is calculated. Calculate the number of pulses. Next, in step S704, when the result is X times the actual motor end detector resolution, a setting error of (X = gear ratio / machine end detector resolution / pitch) times the true setting results. Check if it is. In step S705, it is determined that the resolution setting of the motor end detector 18 is abnormal.

In step S706, it is determined that the feedback cable is incorrectly wired. Thereby, when a feedback abnormality occurs at the time of starting up the machine, it is distinguished whether this is a machine abnormality (scale abnormality) or a difference in parameter settings of a gear ratio, a machine end detector resolution, and a pitch.

Embodiment 5 FIG.
FIG. 11 shows the internal configuration of a current control unit used for carrying out the method for detecting and diagnosing abnormality of a servo control system according to the present invention. This current control unit corresponds to the current control unit 13 in the general servo control system shown in FIG. 44, and is different from the conventional current control unit shown in FIG. And a torque calculation unit 27 and a motor position calculation unit 28.

The three-phase converter 26 performs three-phase conversion of the d- and q-axis current command values at the beginning of the acceleration / deceleration command using a magnetic pole position actually detected from the motor end as an initial value, and outputs a three-phase current Ium of the motor model. , Ivm, Iwm. The torque calculator 27 calculates the model output torque Tem from the model three-phase current values Ium, Ivm, Iwm output from the three-phase converter 26 and the torque constant KT.

The motor position calculator 28 calculates the magnetic pole position θrm of the motor model using the model output torque Tem output from the torque calculator 27, the nominal value of the inertia, and the number of magnetic poles. Using the three-phase current values Ium, Ivm, Iwm and the magnetic pole position θrm, the motor model output torque Tem is calculated by the following equation.

Tem = √2 / 3 · KT · ｛−Ium · sin θrm−Ivm · sin (θrm-2π / 3)
−Iwm · sin (θrm-2π / 3)｝

(4) The position feedback value θm of the motor model is obtained from the motor model output torque Tem calculated in this manner. Then, the difference between the position feedback value θm of the motor model obtained as described above and the actual motor end position feedback value θ is monitored, and this difference is maintained until immediately before an excessive error or an overload alarm occurs. If it is within the allowable range even after the current limitation, it is determined that the acceleration / deceleration time constant is insufficient. Thereby, the shortage of the acceleration / deceleration time constant is recognized.

Also, when the difference between the position feedback value θm of the motor model and the actual motor end position feedback value θ exceeds a certain allowable range, the error between the actual value of the rotor inertia and the load inertia and the set value is within the allowable range, If no erroneous gate interruption or the like has occurred, it is determined that this is an overload. Thus, it is recognized that an overload, that is, an abnormal load exists.

FIG. 12 shows a diagnosis routine for pursuing a cause at the time of current limitation in the abnormality detection / diagnosis method of the servo control system according to the present invention. In this diagnostic routine, first, in step S801, the position feedback value θm of the motor model is calculated.

Next, in step S802, it is determined whether an excessive error or overload alarm has been output. If an excessive error or overload alarm has been output, the process proceeds to step S803, and the current is measured until immediately before these alarms occur. It is determined whether the restriction has been performed. If the current limitation has been performed, the process proceeds to step S804, and it is determined whether or not the difference between the position feedback value θm of the motor model and the actual motor end position feedback θ is within an allowable value. If the difference between the motor model position feedback value θm and the actual motor end position feedback θ is within the allowable value, the process proceeds to step S805, and it is determined that the acceleration / deceleration time constant is insufficient.

On the other hand, when the difference between the position feedback value θm of the motor model and the actual motor end position feedback θ is not within the allowable value, the process proceeds to step S806, and it is determined whether an erroneous gate cutoff or the like has occurred. I do. If an erroneous gate cutoff or the like has not occurred, the process proceeds to step S807, and it is determined that an overload has occurred.

If it is determined in step S803 that the current limitation is not performed, the process proceeds to step S809 to check the set value of the load inertia of the motor model. With this diagnosis routine, diagnosis of suitability of the acceleration / deceleration time constant and overload determination are performed.

Embodiment 6 FIG.
The automatic optimization method of the servo control system according to the present invention is carried out by a general servo control system as shown in FIG. 43. When the power of the amplifier is turned on, the semi-closed loop system and the fully closed loop system are used. Among the methods, the position control is always performed by a feedback signal from the motor end detector 18 in a semi-closed loop method. At this time, the feedback signal from the machine end detector 19 is also processed at the same time, and it is checked whether the accumulated moving distance by the motor end detector 18 and the polarity match. If the polarities match, the process shifts to the position control by the full closed loop method. On the other hand, if the polarities are opposite, the position information accumulated by the Automatically shift to full closed loop position control without stopping.

FIG. 13 shows a position control system automatic switching routine in the method for automatically adjusting the servo control system according to the present invention. In step S1001, the position control by the semi-closed loop method is executed immediately after the power is turned on.

In the next step S1002, it is determined whether or not the accumulated movement distance based on the position command from the NC device 10 has reached a predetermined value (for example, 1 mm), in other words, the designated movement distance has reached the polarity determination distance of the machine end detector 19. It is determined whether or not it has been performed. If the cumulative movement distance based on the position command from the NC device 10 has reached a predetermined value, the process proceeds to step S1002. In step S1003, the sign of the accumulated feedback position on the full closed loop side and the sign of the command accumulated position are compared, in other words, it is checked whether the position feedback amount of the machine end detector 19 and the polarity of the position designation match. I do. If the polarities match, the process proceeds to step S1005. If the polarities do not match, the process proceeds to step S1004.

In step S1004, the accumulated feedback amount generated by the load-side detector 19 is inverted. In step S1005, the feedback signal corresponding to the movement so far is switched to the fully closed loop side, and the position control by the semi-closed loop system is changed to the position control by the fully closed loop system.

As a result, even when the position feedback amount of the load-side detector 19 does not match the polarity of the position designation at the time of starting the system, the system state relating to the polarity is automatically optimized, and the operation continues without system down. be able to.

As described above, the feedback reverse polarity of the machine-end detector 19 automatically determined is stored in the non-volatile memory, and the next time the power is turned on, the position control can be performed with the correct feedback polarity from the first time. However, the semi-closed loop method may include some error due to mechanical elements such as backlash, so it is preferable to add a filter, for example, a first-order delay to switching.

Embodiment 7 FIG.
The automatic optimization method of the servo control system according to the present invention executes the position control by the fully closed loop method using the load-side detector 19 from the time of power-on, and has a certain error with the feedback amount by the motor-side detector 18. When the value is not less than the value, the system state can be automatically optimized by reversing the feedback amount of the load-side detector 19 up to the present.

FIG. 14 shows an automatic polarity reversing routine in the method for automatically adjusting the servo control system according to the present invention. In step S1101, immediately after the power is turned on, the position control mode by the closed loop method is formed as usual. In the next step S1102, the difference between the fully closed-loop feedback position PMA and the semi-closed-loop feedback position PMO reaches a preset full closed-loop feedback reverse polarity determination value CER, and the signs are different from each other. Check if there is. If the difference reaches the determination value CER and the signs are different from each other, the process proceeds to step S1103.

で は In step S1103, the accumulated feedback position on the fully closed loop side is inverted, and the subsequent moving distance is processed as the reverse polarity. Thereby, even in this case, even if the polarity of the position feedback amount of the load-side detector 19 is reversed at the time of starting the system, the system state relating to the polarity is automatically adjusted, and the operation can be continued without the system going down. Can be. In this case as well, by storing the automatically determined feedback reverse polarity of the machine-end detector 19 in the non-volatile memory, position control can be performed with the correct feedback polarity from the first time when the power is turned on next time.

Embodiment 8 FIG.
FIG. 15 shows a servo control system of a dual feedback control system used for implementing the method for automatically adjusting a servo control system according to the present invention. This servo control system has a control unit 35 that filters the error between the feedback position by the motor end detector 18 and the feedback position by the machine end detector 19 by a first-order lag. Used as a position feedback amount.

This dual feedback control is a statically full-closed loop system in which the error between the motor end detector 18 and the machine end detector 19 is tracked with a certain time constant, and is a control system applied to low-rigidity machines. It is.

FIG. 16 shows an automatic polarity reversal routine in the above-described dual feedback control type servo control system. In step S1201, the dual feedback control is formed immediately after the power is turned on. At this time, the time constant of the first-order lag filter is set to be larger than a normal parameter setting value.

In the next step S1202, the difference between the full closed loop side feedback position PMA and the semi closed loop side feedback position PMO reaches a preset full closed loop feedback reverse polarity determination value CER, and the signs are different from each other. Check if there is. If the difference reaches the determination value CER and the signs are different from each other, the process proceeds to step S1203. In step S1203, the accumulated feedback position on the fully closed loop side is inverted, and the subsequent moving distance is processed as the reverse polarity.

In the next step S1204, the first-order lag filter time constant of the dual feedback control is returned to the parameter set value, and the operation is continued. Thereby, even in this case, even if the polarity of the position feedback amount of the load-side detector 19 is reversed at the time of starting the system, the system state relating to the polarity is automatically adjusted, and the operation can be continued without the system going down. Can be. In this case as well, by storing the reverse polarity of the feedback of the machine end detector 19 automatically determined in the non-volatile memory, the position control can be performed with the correct feedback polarity from the first time when the power is turned on next time.

Embodiment 9 FIG.
FIG. 17 shows an embodiment of the servo control system used for implementing the method for automatically adjusting the servo control system according to the present invention. This servo control system includes a control unit 36 that clamps the maximum value of the current command calculated by the speed control unit 12.

FIG. 18 shows a routine for adjusting the time constant during acceleration / deceleration in the method for automatically adjusting the servo control system according to the present invention. First, in step S1501, it is determined whether fast forward is currently being performed. If fast-forwarding is being performed, the process advances to step S1502 to sample the current command value In. The sampling of the current command value In is performed at a constant period (every maximum several ms) during fast-forward.

Next, in step S1503, the absolute value | In | of the sampled current command value is compared with the maximum value Ip of the current command sampled up to the previous time during the current rapid traverse. If | In | is larger, the process advances to step S1504 to change the maximum value Ip to the current | In |.

Next, in step S1505, it is determined whether or not the current fast-forward has been completed. Here, the fast-forwarding is defined as the entire time of one movement. If fast-forwarding has been completed, the process proceeds to step S1506. If not completed, the process returns to step S1502 after the sampling cycle, and samples the next current command value In. In step S1506, the ratio β of the maximum value Ip of the current command in the current rapid traverse to the maximum current Imax that can be output by the motor drive device such as a servo amplifier is calculated by the following equation.

β = Ip / Imax
In order to make the ideal output ratio α and to make the output ratio in the next rapid traverse acceleration / deceleration close to the ideal output ratio α, the next rapid traverse based on the current rapid traverse time constant A and the ideal output ratio α and ratio β The calculation of the constant B is performed by the following equation.

B = A · β / α = A · (Ip / Imax · α)
The acceleration / deceleration time constant B obtained from the calculation result is substituted into A, and the next acceleration / deceleration is performed using this time constant. As a result, every time acceleration / deceleration is performed, the optimal acceleration / deceleration time constant is calculated in real time, the acceleration / deceleration time constant is automatically optimized, and acceleration / deceleration operation that is not affected by machine load fluctuations is realized. I do. When the load differs depending on the movement method such as an unbalance axis, it is necessary to determine the time constant based on the larger current command value depending on the movement direction.

Normally, the change in mechanical load does not show a large change, so the acceleration / deceleration time constant is determined based on the average value of the acceleration / deceleration maximum values of several to several tens of times or the peak value. Is also good. In addition, since the lubrication of the machine is poor at the first power-on in the morning and the load is often the largest, the time constant at the time of power-on is set to a large value, for example, about 50% of Imax, and the time constant is automatically set. It is also conceivable to pack up.

Embodiment 10 FIG.
FIGS. 19 and 20 show a time constant optimization routine suitable for a case where the required torque varies depending on the direction of motion, such as an unbalanced shaft. First, in step S1601, it is determined whether fast forward is currently being performed. If fast-forwarding is being performed, the process advances to step S1602 to determine the direction of fast-forwarding. If fast forward is being performed in the + direction, the process advances to step S1603. On the other hand, if the fast-forward is not being performed in the + direction, the process proceeds to step S1611 because the fast-forward is in the negative direction. In step S1603, the current command value In is sampled. The sampling of the current command value In is performed at a constant period (every maximum several ms) during fast-forward.

Next, in step S1604, the absolute value | In | of the sampled current command value is compared with the maximum value Ip + of the current command sampled up to the previous time during the current rapid traverse. If | In | is larger, the process proceeds to step S1605, and the maximum value Ip + is changed to the current | In |.

Next, in step S1606, it is determined whether or not the current fast-forward has ended. Here, the entire time of one movement is also set during the fast-forward. If fast-forwarding has been completed, the process proceeds to step S1607. If not completed, the process returns to step S1603 after the sampling cycle, and samples the next current command value In. In step S1607, the ratio β of the maximum value Ip + of the current command in the current rapid traverse to the maximum current Imax that can be output by the motor drive device such as a servo amplifier is calculated by the following equation.

β = (Ip +) / Imax
In order to make the ideal output ratio α and to make the output ratio in the next rapid traverse acceleration / deceleration close to the ideal output ratio α, the next rapid traverse based on the current rapid traverse time constant A + and the ideal output ratio α and ratio β The calculation of the constant B + is performed by the following equation.

(B +) = (A +) · β / α = (A +) {(Ip +) / Imax · α)}
The acceleration / deceleration time constant B + obtained from the calculation result is substituted into A +, and the next acceleration / deceleration in the + direction is performed with this time constant. In step S1609, the current command value In is sampled. The sampling of the current command value In is also performed at a constant cycle (every maximum number of ms) during fast-forward.

Next, in step S1610, the absolute value | In | of the sampled current command value is compared with the maximum value Ip− of the current command sampled up to the previous time during the current rapid traverse. If | In | is larger, the process advances to step S1611 to change the maximum value Ip- to the current | In |.

Next, in step S1612, it is determined whether or not the current fast-forward has ended. Here, the entire time of one movement is also set during the fast-forward. If fast-forwarding has been completed, the process proceeds to step S1613. If not completed, the process returns to step S1609 after the sampling period, and samples the next current command value In. In step S1613, the ratio β of the maximum value Ip− of the current command in the current rapid traverse to the maximum current Imax that can be output by the motor drive device such as a servo amplifier is calculated by the following equation.

β = (Ip −) / Imax
The ideal output ratio is α, and the next rapid traverse is performed based on the current rapid traverse time constant A− and the ideal output ratio α and ratio β in order to bring the output ratio in the next rapid traverse acceleration / deceleration closer to the ideal output ratio α. The calculation of the time constant B− is performed by the following equation.

(B −) = (A−) · β / α = (A −) {(Ip −) / Imax · α)}
The acceleration / deceleration time constant B− obtained from the calculation result is substituted into A−, and the next acceleration / deceleration in the − direction is performed with this time constant. Thus, every time the acceleration / deceleration is performed, the optimal acceleration / deceleration time constant for each motion direction is individually calculated in real time, the acceleration / deceleration time constant for each motion direction is automatically optimized individually, and the load on the machine is reduced. Realizes acceleration / deceleration operation in which the system stability is not affected by fluctuations. As a result, although the acceleration / deceleration time constant is determined by the torque required for raising the unbalance shaft, it can be made smaller at the time of lowering, and the machining time can be shortened.

Embodiment 11 FIG.
In mechanical drive, the output torque differs between acceleration and deceleration due to frictional force, and the optimal value of the time constant differs between acceleration and deceleration. Perform separately with deceleration.

FIGS. 21 and 22 show a time constant optimizing routine in a case where the automatic optimizing of the acceleration / deceleration time constant is performed separately for acceleration and deceleration. First, in step S1701, it is determined whether fast forward is currently being performed. If fast-forwarding is being performed, the process proceeds to step S1702, and in step S1702, it is determined whether or not acceleration is being performed based on a change in speed change. If the vehicle is accelerating, the process proceeds to step S1704; otherwise, the process proceeds to step S1703.

In step S1703, it is determined whether or not the vehicle is decelerating based on a change in speed. If the vehicle is decelerating, the process proceeds to step S1709; otherwise, the process returns to step S1701. In step S1704, the current command value In is sampled. The sampling of the current command value In is performed at a constant period during fast-forward.

Next, in step S1705, the absolute value | In | of the sampled current command value is compared with the maximum value Ipa of the current command sampled up to the previous time during the current rapid traverse. If | In | is larger, the process proceeds to step S1706, and the maximum value Ipa is changed to the current | In |.

Next, in step S1707, it is determined whether or not the current fast-forward acceleration has been completed. If the rapid traverse acceleration has been completed, the process proceeds to step S1708. If not completed, the process returns to step S1704 after the sampling period, and samples the next current command value In. In step S1708, the ratio β of the maximum value Ipa of the current command in the current rapid traverse to the maximum current Imax that can be output by the motor driving device such as a servo amplifier is calculated by the following equation.

β = (Ipa) / Imax
In order to make the ideal output ratio α and to make the output ratio in the next rapid traverse acceleration / deceleration close to the ideal output ratio α, the next rapid traverse is performed based on the current rapid traverse time constant Aa and the ideal output ratio α and ratio β. The calculation of the constant Ba is performed by the following equation.

(Ba) = (Aa) · β / α = (Aa) {(Ipa) / Imax · α)}
The acceleration time constant Ba obtained from the calculation result is substituted for Aa, and the next fast-forward acceleration is performed with this time constant. In step S1709, the current command value In is sampled. The sampling of the current command value In is also performed at a constant period during fast-forward.

Next, in step S1710, the absolute value | In | of the sampled current command value is compared with the maximum value Ip− of the current command sampled up to the previous time during the current rapid traverse. If | In | is larger, the process advances to step S1711 to change the maximum value Ipb to the current | In |.

Next, in step S1712, it is determined whether or not the current fast-forward has ended. If fast-forwarding has been completed, the process proceeds to step S1713. If not completed, the process returns to step S1709 after the sampling period, and samples the next current command value In. In step S1713, the ratio β of the maximum value Ipb of the current command in the current rapid traverse to the maximum current Imax that can be output by the motor driving device such as a servo amplifier is calculated by the following equation.

β = (Ipb) / Imax
In order to make the ideal output ratio α and to make the output ratio in the next rapid traverse acceleration / deceleration close to the ideal output ratio α, the next rapid traverse based on the current rapid traverse time constant Ab and the ideal output ratio α and ratio β The calculation of the constant Bb is performed by the following equation.

(Bb) = (Ab) · β / α = (Ab) {(Ipb) / Imax · α)}
The deceleration time constant Bb obtained from the calculation result is substituted for Ab, and the next fast-forward deceleration is performed with this time constant. As a result, each time acceleration / deceleration is performed, the optimal acceleration / deceleration time constants for acceleration and deceleration are individually calculated in real time, and the time constant for acceleration and the time constant for deceleration are automatically optimized individually. In addition, an acceleration / deceleration operation in which the stability of the system is not affected by the load fluctuation of the machine is realized.

Embodiment 12 FIG.
FIGS. 23 to 27 show a time constant optimizing routine for automatically optimizing the acceleration / deceleration time constant for the direction of motion and for acceleration and deceleration.

In step S1801, it is determined whether or not fast-forward is performed. If fast-forwarding is not being performed, the process returns to step S1801, and if fast-forwarding is being performed, the process proceeds to steps S1802a to 1802d. In steps S1802a to S1802d, one of the following four types of fast-forward is specified. That is, in step S1802a, it is determined whether or not the acceleration is in the + direction. If the acceleration is in the + direction, the process proceeds to step S1803.

In step S1802b, it is determined whether the acceleration is in the negative direction. If the acceleration is in the negative direction, the process proceeds to step S1813. In step S1802c, it is determined whether or not deceleration is in the + direction. In the case of deceleration in the + direction, the flow advances to step S1823. In the step S1802d, it is determined whether or not the deceleration is in the negative direction. If the deceleration is in the negative direction, the process proceeds to step S1833. In step S1803, the current command value In is sampled at a constant period during fast-forward.

Next, in step S1804, the absolute value | In | of the sampled current command value is compared with the maximum value Ip + a of the current command sampled up to the last time during the current rapid traverse. If | In | is larger, the process advances to step S1805 to change the Ip + a value to the current | In |.

Next, in step S1806, it is determined whether or not the current fast-forward has been completed. If fast-forwarding has been completed, the process proceeds to step S1807. If not completed, the process returns to step S1803 after the sampling period, and samples the next current command value In. In step S1807, the ratio β of the maximum value Ip + a of the current current command to the maximum current Imax that can be output by the motor drive device such as a servo amplifier is calculated by the following equation.

β = (Ip + a) / Imax
In order to set the ideal output ratio to α and make the output ratio in the next rapid traverse acceleration / deceleration close to α, the calculation of the next rapid traverse time constant B + a based on the current rapid traverse time constant A + a and the ideal output ratio α and ratio β is performed. Do.

(B + a) = (A + a) · β / α
= (A + a) · {(Ip + a) / Imax · α}
The acceleration / deceleration time constant (B + a) obtained from the calculation result is substituted for (A + a), and the next fast-forward + direction acceleration command is created with this time constant. In step S1813, the current command value In is sampled at a constant period during fast-forward.

Next, in step S1814, the absolute value | In | of the sampled current command value is compared with the maximum value Ip-a of the current command sampled up to the previous time during the current rapid traverse. If | In | is larger, the process advances to step S1815 to change the Ip-a value to the current | In |.

Next, in step S1816, it is determined whether or not the current fast-forward has ended. If fast-forwarding has been completed, the process proceeds to step S1817. If not completed, the process returns to step S1813 after the sampling period, and samples the next current command value In. In step S1817, the ratio β of the maximum value Ip-a of the current current command to the maximum current Imax that can be output by the motor drive device such as a servo amplifier is calculated by the following equation.

β = (Ip−a) / Imax
In order to make the ideal output ratio α and to make the output ratio in the next rapid traverse acceleration / deceleration close to α, the next rapid traverse time constant B−a based on the current rapid traverse time constant A−a and the ideal output ratio α and ratio β The calculation of a is performed.

(Ba) = (A-a) · β / α
= (A−a) · {(Ip−a) / Imax · α}
The acceleration / deceleration time constant (Ba) obtained as a result of this calculation is substituted into (A-a), and the next fast feed + direction deceleration command is created with this time constant. In step S1823, the current command value In is sampled at a constant period during fast-forward.

Next, in step S1824, the absolute value | In | of the sampled current command value is compared with the maximum value Ipa of the current command sampled up to the previous time during the current rapid traverse. If | In | is larger, the process proceeds to step S1825, and the value of Ip + d is changed to | In |

Next, in step S1826, it is determined whether or not the current fast-forward has ended. If fast-forwarding has been completed, the process proceeds to step S1827. If not completed, the process returns to step S1823 after the sampling period, and samples the next current command value In. In step S1827, the ratio β of the maximum value Ipd of the current current command to the maximum current Imax that can be output by the motor drive device such as a servo amplifier is calculated by the following equation.

β = (Ip + d) / Imax
In order to make the ideal output ratio α and make the output ratio in the next rapid traverse acceleration / deceleration close to α, the calculation of the next rapid traverse time constant B + d based on the present rapid traverse time constant A + d and the ideal output ratio α and the ratio β is performed. Do.

(B + d) = (A + d) · β / α
= (A + d) · {(Ip + d) / Imax · α}
The acceleration / deceleration time constant (B + d) obtained from this calculation result is substituted for (A + d), and the next fast-forward + direction deceleration command is created with this time constant. In step S1833, the current command value In is sampled at a constant period during fast-forward.

Next, in step S1834, the absolute value | In | of the sampled current command value is compared with the maximum value Ip-d of the current command sampled up to the previous time during the current rapid traverse. If | In | is larger, the process advances to step S1835 to change the Ip-d value to the current | In |.

Next, in a step S1836, it is determined whether or not the current fast-forward is completed. If fast-forwarding has been completed, the process proceeds to step S1837. If not completed, the process returns to step S1833 after the sampling period, and samples the next current command value In. In step S1837, the ratio β of the maximum value Ip-d of the current current command to the maximum current Imax that can be output by the motor drive device such as a servo amplifier is calculated by the following equation.

β = (Ip−d) / Imax
In order to make the ideal output ratio α and to make the output ratio in the next rapid traverse acceleration / deceleration close to α, the next rapid traverse time constant B− based on the current rapid traverse time constant Ad and the ideal output ratio α and the ratio β The calculation of d is performed.

(Bd) = (Ad) · β / α
= (Ad) ｄ {(Ip-d) / ImaxＩα}
The acceleration / deceleration time constant (Bd) obtained from the calculation result is substituted for (Ad), and the next fast-forward-direction deceleration command is created with this time constant. As a result, every time acceleration / deceleration is performed, the optimal acceleration / deceleration time constants for each direction of acceleration and deceleration are calculated in real time, and acceleration / deceleration operation that is not affected by mechanical load fluctuations including the amount of friction affects system stability. Realize.

Embodiment 13 FIG.
Even if the time constant during acceleration / deceleration is optimized, if the current command value reaches the limit value, the position tracking error due to servo control will be delayed from the ideal value, resulting in speed overshoot or excessive error alarm. May occur and the system may go down. As a countermeasure against this, an excessive error determination value during rapid traverse acceleration / deceleration is made variable to make it difficult to generate an excessive error alarm.

FIG. 28 shows an excessive error determination value changing routine. In step S1901, the excessive error determination value DOD is set to a standard value DB. That is, DOB = DB. The method of determining DB is usually set to about 50% of the ideal droop amount generated during the fast-forward maximum speed (steady state).

In step S1902, it is determined whether fast-forward acceleration / deceleration is being performed based on the amount of change in the position command value per unit time output by the device C. If fast-forward acceleration / deceleration is in progress, the process advances to step S1903; otherwise, the process returns to step S1901. In step S1903, the excess error determination width DOD = DB · a. a is an acceleration / deceleration error excessively large allowable coefficient, which is set to a> 1, usually about 2.

Next, in step S1904, an ideal droop amount (position deviation amount) Di for the current command input is calculated. Next, in step S1905, the actual droop amount D at the present time is detected. Next, in step S1906, a difference b between the ideal droop Di and the actual droop amount D is calculated.

Next, in step S1907, it is determined whether or not the absolute value of the actual droop error b exceeds DOD. If not exceeded, the process returns to step S1901 after a lapse of a predetermined time, and if exceeded, the process proceeds to step S1908. In step S1908, an excessive error alarm is generated, an emergency stop state is set, and an NC reset is waited. In step S1909, it is determined whether there is an alarm reset request from the NC device (actually, input from the worker). If there is an alarm reset request, the process proceeds to step S1910. In step S1910, the emergency stop state is released, and the flow returns to step S1901. As a result, the occurrence of an overspeed alarm is less likely to occur, and a highly reliable servo control system is provided.

Embodiment 14 FIG.
Despite the acceleration / deceleration time constant being optimized, the following error in the servo control position was delayed from the ideal value due to the current command reaching the limit value, which caused the speed overshoot. Occurs, or an excessive error alarm occurs and the system goes down, the output current (output torque) reaches the maximum value, and it is inevitable that the speed overshoot occurs.

Normally, when the motor rotates at a speed about 1.2 times the specified maximum rotation speed of the servo motor, an overspeed alarm is generated and the system is protected. When entering such a mode, an alarm is generated. In order to cope with such a case, the overspeed alarm determination value VOS is changed only during rapid traverse acceleration / deceleration so that this alarm does not occur.

FIG. 29 shows an overspeed alarm judgment value change routine. In step S2001, the overspeed alarm determination motor rotation speed VOS is set to the standard value VB. Normally, it is appropriate that VB is about 1.2 times the maximum rotation speed of the motor used.

Next, in step S2004, the actual motor speed V is detected. Next, in step S2005, it is determined whether or not the actual motor speed V exceeds the overspeed alarm determination value VOS. If not exceeded, the process returns to step S2001 after the elapse of a predetermined time, and if exceeded, the process proceeds to step S2006.

で は In step S2006, an overspeed alarm is generated, an emergency stop state is set, and an NC reset is waited. In step S2007, it is determined whether or not there is an alarm reset request from the NC device (actually, input from the operator). If there is an alarm reset request, the process proceeds to step S2008. In step S2008, the emergency stop state is released, and the process returns to step S2001. As a result, the occurrence of an overspeed alarm is less likely to occur, and a highly reliable servo control system is provided.

Embodiment 15 FIG.
FIG. 30 shows an embodiment of a servo control system used for implementing the method for automatically adjusting a servo control system according to the present invention. This servo control system includes a control unit 37 that clamps the maximum value of the speed command calculated by the position control unit 11. Thus, even when the current limit is reached, the overshoot amount can be suppressed by clamping the speed command at a constant value V _MAX (about 1.2 times the maximum motor speed).

Embodiment 16 FIG.
In this embodiment, the amount of overshoot is suppressed by clamping the speed command only during rapid traverse acceleration / deceleration, so that the ability to follow a command with a large acceleration is not sacrificed and high-speed cutting is not affected.

FIG. 31 shows a speed command clamping routine in this embodiment. First, in step S2201, the clamp of the speed command is released. Next, in step S2202, it is determined whether fast-forward acceleration / deceleration is being performed based on the amount of change in the position command per unit time output by the NC device. If the vehicle is accelerating or decelerating, the process proceeds to step S2203; otherwise, the process returns to step S2201.

In step S2203, the maximum clamping value of the speed command and V _MAX for fast forward acceleration or deceleration. In step S2204, the speed command calculated by the position control determines whether exceeds V _MAX. Proceeds to step S2205 if the speed command exceeds V _MAX, in step S2205, and outputs the absolute value of the speed command as V _MAX, the flow returns to step S2201.

As a result, the maximum speed of the speed command is clamped at a constant value only during acceleration / deceleration, so that the time constant setting during rapid traverse acceleration / deceleration is small or the maximum output torque of the servo amplifier is reached due to the effect of abnormal load. In such a case, overshoot hardly occurs.

Embodiment 17 FIG.
In this embodiment, the speed command is clamped only when the current command value reaches the current limit. FIG. 32 shows a speed command clamping routine in this embodiment. In step S2301, the clamp of the speed command is released, and then in step S2302, the current command value In is sampled.

Next, in step S2303, it is determined whether or not the current command value In has reached the current limit value. If the current command value In has reached the current limit value, the process proceeds to step S2304; otherwise, the process proceeds to step S2305. In step S2304, the maximum clamping value of the speed command to V _MAX.

In step S2305, the speed command calculated by the position control determines whether exceeds V _MAX. Proceeds to step S2306 if the speed command exceeds V _MAX, in step S2306, and outputs the absolute value of the speed command as V _MAX, the flow returns to step S2301.

As a result, even when the setting of the time constant during rapid traverse acceleration / deceleration is small or the maximum output torque of the servo amplifier is reached due to an abnormal load, overshoot is unlikely to occur, and a stable and reliable servo control system can be obtained. .

Embodiment 18 FIG.
In this embodiment, during the rapid traverse acceleration, the speed clamp function when the current command value reaches the current limit is further developed, the position droop amount for overshooting as the speed command is thinned out, and the deceleration time constant from the deceleration start point is reduced. Is distributed and added.

FIG. 33 shows the operation flow of this embodiment. In step S2401, it is determined whether fast forward is in progress. If fast-forwarding is being performed, the process proceeds to step S2402; otherwise, the process returns to step S2401. In step S2402, it is determined whether the current command value has reached the current limit. If the current command value has reached the current limit, the process proceeds to step S2403; otherwise, the process returns to step S2401.

In step S2403, clamping the speed command at the motor maximum speed V _MO. And it compares the maximum position droop amount D _MAX and the actual amount of droop D obtained by calculating the position loop gain from V _MO, a process for thinning out position droop D _ER portion of the portion beyond the position command performed during acceleration, Wait for deceleration. In step S2404, it is determined whether or not deceleration is performed. When deceleration is started, the process proceeds to step S2405. In step S2405, Komu plus position command component D _ER decimated from the moment the deceleration is started at the time of deceleration. FIG. 34 shows the relationship between the speed command and the current command controlled as described above.

As a result, even when the setting of the time constant during rapid traverse acceleration / deceleration is small or the maximum output torque of the servo amplifier is reached due to an abnormal load, overshoot is unlikely to occur, and a stable and reliable servo control system can be obtained. .

Embodiment 19 FIG.
In this embodiment, when the current command value reaches the current limit value during rapid traverse acceleration, the position command (command speed) per unit time is decelerated, so that overshoot does not easily occur and an excessive error alarm does not easily occur. To do. Note that this operation is performed so that the trajectory does not shift with respect to all the axes during the interpolation operation of a plurality of axes.

FIG. 35 shows an operation flow of this embodiment. In step S2501, it is determined whether fast-forwarding is in progress. If fast-forwarding is being performed, the process proceeds to step S2502; otherwise, the process returns to step S2501. In step S2502, it is determined whether the current command value has reached the current limit value. If the current command value has reached the current limit value, the process proceeds to step S2503.

In step S2503, the amount of change in the position command per unit time is limited so that the current command of the servo model set inside the NC device does not exceed the current control value level. That is, the position command is thinned out. When the current control is released, the position command for the shortage due to the thinning at that time is given with a certain time constant or by time distribution, and the absolute position is adjusted. As a result, overshoot is less likely to occur and an excessive error alarm is less likely to occur.

Embodiment 20 FIG.
In this embodiment, when the maximum output torque of the servo amplifier is reached during rapid traverse due to an abnormal load, the position loop gains of all the axes are reduced only during that time to prevent an excessive error from occurring.

FIG. 36 shows an operation flow of this embodiment. In general, the required torque is larger during acceleration than during deceleration. Therefore, the following description focuses on acceleration. In step S2601, it is determined whether fast forward is in progress. If fast-forwarding is being performed, the flow advances to step S2602. In step S2602, it is determined whether or not the current command value has reached the current limit value. If the current command value has reached the current limit value, the process proceeds to step S2603.

In step S2603, when the droop amount becomes larger than the ideal value and the NC device lowers the position loop gain of the axis that has reached the current limit of the servo amplifier control unit and the current limit is released, the position loop gain is increased. During the rapid traverse, if the fixed or constant speed operation is reached, the value is gradually returned to the original value. As a result, if the maximum output torque of the servo amplifier is reached during rapid traverse due to an abnormal load, the position loop gain of all axes is reduced only during that time, and the movement of the servo system becomes gradual. Operation can continue without happening.

Embodiment 21 FIG.
In this embodiment, when the maximum output torque of the servo amplifier is reached due to the effect of an abnormal load during rapid traverse, the position loop gains of all axes are reduced by a certain time constant, and the position loop gain at the time when the current limit is released is reduced. This change is completed, and control is performed with the same gain until the movement is completed. In the next operation, the fast-forward time constant is changed by the above-described acceleration / deceleration time constant optimization, so that the movement is started by the original set position loop gain.

FIG. 37 shows an operation flow of this embodiment. Generally, the required torque is larger during acceleration than during deceleration. In step S2701, it is determined whether fast-forwarding is in progress. If fast-forwarding is in progress, the flow advances to step S2702.

In step S2702, it is determined whether the current command value has reached the current limit value. If the current command value has reached the current limit value, the flow advances to step S2703. In step S2703, the droop amount becomes a value larger than the ideal value, and the NC 10 reduces the position loop gain of the axis that has reached the current limit of the servo amplifier control unit with a certain time constant. If the gain reaches a fixed or constant speed operation during the rapid traverse, the gain is gradually increased to the original value. As a result, the operation of the system can be continued without generating an excessive error alarm.

Embodiment 22 FIG.
In this embodiment, when the maximum output torque of the servo amplifier is reached due to an abnormal load during fast traverse, the speed command is V = corresponding to the rated motor speed + α (α is about 2% of the rated motor speed). Is calculated from the current droop amount so that the velocity command does not always exceed the value of V.

FIG. 38 shows an operation flow of this embodiment. Generally, the required torque is larger during acceleration than during deceleration. In step S2801, it is determined whether fast forward is in progress. If fast-forwarding is being performed, the flow advances to step S2802.

In step S2802, it is determined whether the current command value has reached the current limit value. If the current command value has reached the current limit value, the flow advances to step S2803. In step S2803, the droop amount becomes a value larger than the ideal value, and the NC device reduces the position loop gain Kp of the current-limited axis of the servo amplifier control unit to a value calculated by the following equation. When the position loop gain Kp reaches the fixed or constant speed operation during the rapid traverse at the time of release, the position loop gain Kp is gradually increased to the original value.

Kp = (Rated motor speed + α) / 60 · D
D is the droop amount.

Thus, in this embodiment, the operation of the system can be continued without generating an excessive error alarm.

Embodiment 23 FIG.
Along with the development of absolute position and high resolution detectors used for position feedback, the I / F method is also diversified, and it is necessary to use receiving lines as much as possible in order to support all these detectors. is there.

In this embodiment, the type of the detector installed by itself is automatically determined at the time of power-on without depending on the setting of the detector by the reception line and the servo parameter corresponding to the three different detector I / Fs, and specified by the parameter. If the detected detector type is different from the actually connected detector, a parameter abnormality alarm is generated.

左側 The left side of FIG. 39 shows an example of the feedback detection circuit. This feedback detection circuit transmits and receives (RQ and DT) the absolute position by serial communication with an incremental detector having the position of the pulse output, the speed control required ABZ phase and the UVW phase for the initial magnetic pole of the synchronous motor, and thereafter, This circuit shares three types of input / output circuits: an absolute position detector that performs communication in A, B, and Z phases, and a detector that always performs absolute position data by serial communication (only RQ and DT).

に お い て In FIG. 39, differential inputs of A phase, B phase, Z phase, U phase, V phase, and W phase from the upper left. In this example, the U phase and RQ (serial data request) are shared, and the V phase and DT (serial data line) are shared.

This feedback detection circuit includes differential receivers 171a to 171f, exclusive circuits 172a to 172f for detecting that differential inputs are connected, and an incremental counter (feedback amount creation counter) 173 counted by ABZ phase pulses. , A serial request I / F circuit 174 that supports a request portion of serial communication, a reception buffer (serial data reception I / F circuit) 175 that stores data from the detector, and a state of the initial magnetic pole UVW phase. It has a UVW phase read port 176 for observation and a phase no signal state read port 177 for observing the no signal state of each phase. Note that, as shown in FIG. 40, the termination circuit is connected to the exclusive circuit, so that the output of the exclusive circuit is always 1 in the open state.

右側 The right side of FIG. 39 shows the state of the read port 177 when three types of detectors are connected. If the driver enable line of the serial detector request line is disabled when the power is turned on, and if the detector is in a normal state for the six input states, information as shown on the right side of FIG. 39 is obtained. This information is compared with the detector model name parameter sent from the NC device, and if different, a parameter abnormality alarm is generated.

FIG. 41 shows this parameter abnormality diagnosis routine. First, in step S2901, all-phase input lines are set, and in the next step S2902, a no-signal state is checked.

Next, in step S2903, the connected detector is determined based on the no-signal state. In step S2904, the parameter indicating the detector model name is compared with the connected detector. In step S2905, it is determined whether or not the parameter indicating the detector model name matches the connected detector. If they do not match, the flow advances to step S2906 to generate a parameter abnormality alarm and bring down the system. As a result, when the detector type specified by the parameter is different from the actually connected detector, a parameter abnormality alarm is generated, and the cause of the failure can be easily sought.

Embodiment 24 FIG.
In this embodiment, when the detector is different from the detector specified by the parameter by the above-described automatic determination, the interface is switched to the I / F of the actually connected detector, and the connection state of the detector is automatically optimized.

FIG. 42 shows an operation flow of this embodiment. First, in step S3001, all-phase input lines are set, and in the next step S3002, a no-signal state is checked. Next, in step S3003, the connected detector is determined based on the no-signal state.

In step S3004, the parameter indicating the detector model name is compared with the connected detector. In step S3005, it is determined whether the parameter indicating the detector model name matches the connected detector. If they do not match, the process advances to step S3006 to match the setting of the transmission / reception unit to the I / F of the detector determined to be connected. Thus, even if there is an error in the parameter setting, a detection circuit adapted to the detector is formed without generating an alarm such as no signal, and the system operates normally.

As described above, the abnormality detection / diagnosis method and the automatic optimization method of the servo control system according to the present invention, and the abnormality detection / diagnosis device and the automatic optimization device of the servo control system are numerical values for controlling machine tools, robots, and the like. Useful for control devices and the like.

FIG. 2 is a block diagram showing an embodiment of a servomotor driving device used for performing a method for detecting and diagnosing abnormality of the servo control system according to the present invention. 5 is a flowchart showing a connection diagnosis routine of a motor output terminal in the abnormality detection / diagnosis method of the servo control system according to the present invention. FIG. 9 is an explanatory diagram illustrating a determination result of an incorrect connection. FIG. 9 is an explanatory diagram illustrating a determination result of an incorrect connection. 4 is a flowchart showing a phase voltage detection routine used for connection diagnosis of a motor output terminal and a converter bus in the abnormality detection / diagnosis method of the servo control system according to the present invention. 5 is a flowchart showing a motor output terminal connection diagnosis routine in the servo control system abnormality detection / diagnosis method according to the present invention. 4 is a flowchart showing a converter bus connection diagnosis routine in the servo control system abnormality detection / diagnosis method according to the present invention. FIG. 3 is a block diagram illustrating a gate control circuit of a current control unit used for performing a method of detecting and diagnosing abnormality of the servo control system according to the present invention. 4 is a flowchart showing a routine for diagnosing a cause of gate interruption occurrence in the abnormality detection / diagnosis method of the servo control system according to the present invention. 4 is a flowchart showing a wiring diagnosis routine of a feedback cable in the abnormality detection / diagnosis method of the servo control system according to the present invention. 5 is a flowchart showing a parameter setting diagnosis routine in the abnormality detection / diagnosis method of the servo control system according to the present invention. FIG. 2 is a block diagram showing an internal configuration of a current control unit used for performing a method for detecting and diagnosing abnormality of the servo control system according to the present invention. 6 is a flowchart showing a diagnosis routine for pursuing a cause during current control in the abnormality detection / diagnosis method of the servo control system according to the present invention. 4 is a flowchart showing a position control system automatic switching routine in the servo control system automatic optimization method according to the present invention. 5 is a flowchart showing a polarity automatic reversal routine in the servo control system automatic optimization method according to the present invention. FIG. 1 is a block diagram showing a servo control system of a dual feedback control system used for implementing a method for automatically adjusting a servo control system according to the present invention. 5 is a flowchart showing a polarity automatic reversal routine in a dual feedback control type servo control system. 1 is a block diagram showing an embodiment of a servo control system used for carrying out a method for automatically adjusting a servo control system according to the present invention. 5 is a flowchart showing one embodiment of a time constant optimizing routine in the automatic optimizing method of the servo control system according to the present invention. 9 is a flowchart showing another embodiment of the time constant adjusting routine in the automatic adjusting method of the servo control system according to the present invention. 9 is a flowchart showing another embodiment of the time constant adjusting routine in the automatic adjusting method of the servo control system according to the present invention. 9 is a flowchart showing another embodiment of the time constant adjusting routine in the automatic adjusting method of the servo control system according to the present invention. 9 is a flowchart showing another embodiment of the time constant adjusting routine in the automatic adjusting method of the servo control system according to the present invention. 9 is a flowchart showing another embodiment of the time constant adjusting routine in the automatic adjusting method of the servo control system according to the present invention. 9 is a flowchart showing another embodiment of the time constant adjusting routine in the automatic adjusting method of the servo control system according to the present invention. 9 is a flowchart showing another embodiment of the time constant adjusting routine in the automatic adjusting method of the servo control system according to the present invention. 9 is a flowchart showing another embodiment of the time constant adjusting routine in the automatic adjusting method of the servo control system according to the present invention. 9 is a flowchart showing another embodiment of the time constant adjusting routine in the automatic adjusting method of the servo control system according to the present invention. 4 is a flowchart showing an excessive error determination value change routine in the automatic optimization method for the servo control system according to the present invention. 4 is a flowchart showing an overspeed alarm determination value changing routine in the servo control system automatic optimization method according to the present invention. 1 is a block diagram showing one embodiment of a servo control system used for implementing a method for automatically adjusting a servo control system according to the present invention. 5 is a flowchart showing one embodiment of a speed command clamping routine in the method for automatically adjusting a servo control system according to the present invention. 9 is a flowchart showing another embodiment of the speed command clamping routine in the method for automatically adjusting the servo control system according to the present invention. 5 is a flowchart showing one embodiment of a speed / position control routine in the automatic optimization method for the servo control system according to the present invention. 4 is a graph showing a relationship between a speed command and a current command when the servo control system automatic optimization method according to the present invention is applied. 9 is a flowchart showing another embodiment of the speed / position control routine in the method for automatically adjusting the servo control system according to the present invention. 9 is a flowchart showing another embodiment of the speed / position control routine in the automatic optimization method for the servo control system according to the present invention. 9 is a flowchart showing another embodiment of the speed / position control routine in the method for automatically adjusting the servo control system according to the present invention. 9 is a flowchart showing another embodiment of the speed / position control routine in the method for automatically adjusting the servo control system according to the present invention. It is a figure which shows the example of a feedback detection circuit, and the state of a read port when three types of detectors are connected. FIG. 2 is a circuit diagram illustrating an example of an exclusive circuit. 4 is a flowchart showing a parameter abnormality diagnosis routine in the abnormality detection / diagnosis method of the servo control system according to the present invention. 5 is a flowchart showing a connection state automatic adjustment routine of the detector in the automatic adjustment method for the servo control system according to the present invention. FIG. 2 is a block diagram showing a general servo motor driving device used in a servo control system. FIG. 2 is a block diagram illustrating a general servo control system. FIG. 3 is a block diagram illustrating a current control unit of the AC servomotor.

Explanation of reference numerals

1 3-phase AC power supply, 2 rectifier circuit, 3 smoothing capacitor, 4 semiconductor switching circuit, 5 current detector, 6 A / D converter, 7 CPU, 8 AC servomotor, 9a, 9b, 9c voltage detection circuit, 10 NC Apparatus, 11 position control unit, 12 speed control unit, 13 current control unit, 15 reduction gear, 16 feed screw, 17 table, 18 motor end detector, 19 machine end detector, 20 speed control unit 21 limiter, 22 d- q coordinate converters {23a, 23b} current controllers, 24 3 phase converters, 25 PWM converters, 26 3 phase converters, 27 torque calculators, 28 motor position calculators, 29 overcurrent detectors, 30, 31, 32 Latch circuit, 33, 34 {and gate} 35, 36, 37 controller, 171a to 171f differential receiver, 17 a to 172f Exclusive circuit, 173 Incremental counter (feedback amount creation counter), 174 Serial request I / F circuit, 175 Receive buffer (serial data reception I / F circuit), 176 UVW phase read port, 177 No phase read of each phase port.

Claims (46)

When the power is turned on, the transmitter connection status of multiple detector receiver circuits is detected, the type of the detector actually connected is automatically determined, and the detector type specified by the parameter and the detector actually connected A parameter abnormality alarm if the values are different, a servo control system abnormality detection / diagnosis method. When the power is turned on, the transmitter connection status of multiple detector receiver circuits is detected, the type of the detector actually connected is automatically determined, and the detector type specified by the parameter and the detector actually connected If the values are different from each other, the method switches to a receiving circuit corresponding to the connected detector. Detects U-phase, V-phase, and W-phase currents and phase voltages flowing through the output terminals of the servomotor, and outputs a motor output when there is a phase in which no current flows despite the phase voltage being equal to or higher than a predetermined value. An abnormality detection / diagnosis method for a servo control system, characterized in that it is determined that a terminal is not connected. Servo control system abnormality characterized by detecting all voltages of each phase acting on the motor output terminal at the time of acceleration or deceleration, and determining that converter bus is not connected when all phase voltages become 0. Detection and diagnosis method. It is characterized in that a voltage between each phase of an output terminal of a servomotor is detected, a switching voltage of each phase is calculated, and a smooth phase voltage is continuously detected using a filter having the calculated switching voltage as an input. The method for detecting and diagnosing abnormality of a servo control system according to claim 3. If the gate cutoff signal to the transistor in the inverter that controls the current of the servomotor is generated when the alarm is not activated, the location where the gate cutoff request signal is generated is detected, and the number of times the signal is generated is detected. An abnormality detection / diagnosis method for a servo control system, characterized in that a predetermined amount of time is stored in a memory in the past for each location, and a cause of an alarm of a control system abnormality such as an excessive error or a feedback abnormality is determined. In the position control of the fully closed loop system with the load-side detector, the polarity of the position command, position feedback, speed feedback, current command, and current feedback is monitored from the time of power-on, and all the signals become larger than a certain magnitude. An error detection / diagnosis method for a servo control system, characterized in that when only the position feedback has the opposite polarity when the feedback is performed, it is determined that the feedback cable is incorrectly wired. In the position control of the fully closed loop system with the load-side detector, the number of pulses detected by the motor-side detector and the number of pulses detected by the load-side when the motor is moved by a certain amount equivalent to one rotation of the motor when the power is turned on. And detecting an erroneous setting of a machine parameter such as a gear ratio of a machine, a ball screw pitch, and a resolution of a machine end detector from the comparison result. In the software that controls the current of the servo motor, a servo motor model is created with d-axis and q-axis current commands as inputs, and the difference between the position feedback value of the model and the actual motor end position feedback value is However, if the deviation is too large despite being within a predetermined allowable range, it is determined that the acceleration / deceleration time constant is insufficient. In the software that controls the current of the servo motor, a servo motor model is created with d-axis and q-axis current commands as inputs, and the difference between the position feedback value of the model and the actual motor end position feedback value is within a predetermined allowable range. A servo control system abnormality detection / diagnosis method characterized by determining that an abnormal load is present when the inertia is within an allowable range and an erroneous gate cutoff or the like does not occur when the value exceeds . In the position control of the full closed loop system having the machine-side detector, the position control of the semi-closed loop system is performed when the power is turned on, and during this position control period, the polarity of the position feedback signal by the machine-side detector is determined, and the polarity is determined. If the position does not coincide with the direction of the command position, the polarity of the position feedback amount of the load-side detector is inverted, and thereafter, the system shifts to the full closed-loop position control. Method. In the position control of the fully closed loop system having the load-side position detector, the difference between the position feedback amount by the motor-side detector and the position feedback amount by the load-side detector from when the power is turned on is monitored. According to the present invention, there is provided an automatic optimization method for a servo control system, comprising inverting the polarity of a position feedback amount by a load-side detector. Dual-feedback control is performed in the position control of the fully closed loop system having the load-side position detector, and the difference between the position feedback amount by the motor-side detector and the position feedback amount by the load-side detector from power-on is monitored. And if the difference is equal to or greater than a predetermined value, the polarity of the position feedback amount by the machine-side detector is inverted. If the polarity of the position feedback amount of the load-side detector is reversed, this information is stored in the non-volatile memory, and the next time the power is turned on, the feedback polarity of the position feedback amount of the load-side detector is based on this information. 13. The method according to claim 11, wherein: An automatic servo control system characterized by calculating the optimal acceleration / deceleration time constant from the output torque of the servo amplifier required during rapid traverse acceleration / deceleration, and creating a command with the optimal acceleration / deceleration time constant at the next acceleration / deceleration. Optimization method. The optimum acceleration / deceleration time constant that can be calculated from the servo amplifier output torque required during rapid traverse acceleration / deceleration is calculated individually for each motion direction, and the next time the acceleration / deceleration is performed, a command is created using the optimum acceleration / deceleration time constant for the motion direction. An automatic optimization method for a servo control system. The optimum acceleration / deceleration time constant that can be calculated from the output torque of the servo amplifier required during rapid traverse acceleration / deceleration is calculated separately for acceleration and deceleration. An automatic optimization method for a servo control system, characterized in that a command is created with a constant. The optimum acceleration / deceleration time constant that can be obtained from the servo amplifier output torque required during rapid traverse acceleration / deceleration is calculated individually for acceleration, deceleration, and each motion direction, and acceleration / deceleration during acceleration / deceleration for each feed direction is performed. Calculates possible time constants from the output torque of the servo amplifier required for each of the above, and creates a command at the next optimal acceleration / deceleration time constant for acceleration, deceleration, and motion direction at the next acceleration / deceleration. Automatic optimization method of servo control system. 。A method for automatically optimizing a servo control system, wherein the excessive error alarm judgment position deviation amount is set to a value larger than usual only during rapid traverse acceleration / deceleration. (4) An overspeed alarm judgment method only during rapid traverse acceleration / deceleration A method for automatically optimizing a servo control system, wherein the motor speed is set to a value larger than usual. 自動 Automatic optimization method of servo control system characterized by clamping the maximum speed of the speed command at a constant value. 自動 A method for automatically optimizing a servo control system, wherein the maximum speed of a speed command is clamped at a constant value only during acceleration / deceleration. (4) An automatic optimization method for a servo control system, characterized in that the maximum speed of the speed command is clamped at a constant value only during the maximum current limitation of the servo amplifier. When the power is turned on, the transmitter connection status of multiple detector receiver circuits is detected, the type of the detector actually connected is automatically determined, and the detector type specified by the parameter and the detector actually connected An abnormality detection / diagnosis device for a servo control system, comprising a control means for generating a parameter abnormality alarm when the values are different. When the power is turned on, the transmitter connection status of multiple detector receiver circuits is detected, the type of the detector actually connected is automatically determined, and the detector type specified by the parameter and the detector actually connected A control circuit for switching to a receiving circuit corresponding to the connected detector when the values are different from each other. Detecting means for detecting U-phase, V-phase, and W-phase currents and phase voltages flowing to the output terminal of the servomotor;
Determining means for determining that the motor output terminal is not connected when there is a phase in which no current flows despite the phase voltage being equal to or higher than a predetermined value;
An abnormality detection / diagnosis device for a servo control system, comprising: Detecting means for detecting all voltages of each phase acting on the motor output terminal during acceleration or deceleration;
Determining means for determining that the converter bus is not connected when all the phase voltages become 0;
An abnormality detection / diagnosis device for a servo control system, comprising: Calculating means for detecting the voltage between each phase of the output terminal of the servomotor and calculating the switching voltage of each phase;
Detecting means for continuously detecting a smooth phase voltage using a filter having the calculated switching voltage as an input;
The abnormality detection / diagnosis device for a servo control system according to claim 26 or 27, further comprising: Detecting means for detecting a place where the gate cutoff request signal is generated, when a gate cutoff signal to the transistor in the inverter unit for controlling the current of the servomotor is not in operation;
Determining means for storing the number of times the signal has been generated in a memory for a predetermined time in the past for each detection location, and determining the cause of an alarm of a control system abnormality such as excessive error, feedback abnormality, and the like;
An abnormality detection / diagnosis device for a servo control system, comprising: In the position control of the fully closed loop system having a load-side detector, position command, position feedback, speed feedback, current command, monitoring means for monitoring the polarity of the current feedback from the time of power-on,
Determining means for determining that the feedback cable is incorrectly wired if only the position feedback has the opposite polarity when all the signals have a certain magnitude or more,
An abnormality detection / diagnosis device for a servo control system, comprising: In the position control of the fully closed loop system with the load-side detector, the number of pulses detected by the motor-side detector and the number of pulses detected by the load-side when the motor is moved by a certain amount equivalent to one rotation of the motor when the power is turned on. Means for comparing
A detecting means for detecting a parameter setting of a mechanical parameter such as a gear ratio of a machine, a ball screw pitch, and a resolution of a machine end detector from the comparison result;
An abnormality detection / diagnosis device for a servo control system, comprising: Creating means for creating a servomotor model with d-axis and q-axis current commands as input in software for controlling current of the servomotor;
If the difference between the position feedback value of the model and the actual motor end position feedback value is within the predetermined allowable range even after the current limit and the deviation is excessive, it is determined that the acceleration / deceleration time constant is insufficient. Determining means for performing
An abnormality detection / diagnosis device for a servo control system, comprising: a servo motor model that receives d-axis and q-axis current commands,
If the difference between the position feedback value of the model and the actual motor end position feedback value exceeds a predetermined allowable range, the inertia is within the allowable range, and if no erroneous gate interruption has occurred, an abnormal load Determining means for determining that a is present;
An abnormality detection / diagnosis device for a servo control system, comprising: In the position control of the full closed loop system having the machine-side detector, the position control of the semi-closed loop system is performed when the power is turned on, and during this position control period, the polarity of the position feedback signal by the machine-side detector is determined, and the polarity is determined. A servo control means for inverting the polarity of the position feedback amount of the load-side detector when the direction does not match the direction of the command position, and thereafter shifting to a full closed-loop position control. Automatic adjustment system for control system. In the position control of the fully closed loop system having the load-side position detector, the difference between the position feedback amount by the motor-side detector and the position feedback amount by the load-side detector from when the power is turned on is monitored, and the difference is a predetermined value. According to the present invention, there is provided an automatic optimization device for a servo control system, comprising: a control unit for inverting the polarity of a position feedback amount by a load-side detector. Dual-feedback control is performed in the position control of the fully closed loop system having the load-side position detector, and the difference between the position feedback amount by the motor-side detector and the position feedback amount by the load-side detector from power-on is monitored. An automatic optimizing device for a servo control system, comprising: control means for inverting the polarity of the position feedback amount by the machine-side detector when the difference becomes a predetermined value or more. If the polarity of the position feedback amount of the load-side detector is reversed, that information is stored in the non-volatile memory, and the next time the power is turned on, the feedback polarity of the position feedback amount of the load-side detector is based on this information. 37. The automatic optimization device for a servo control system according to claim 35, further comprising control means for reversing the angle. A control means for calculating a possible optimal acceleration / deceleration time constant from the output torque of the servo amplifier required at the time of rapid traverse acceleration / deceleration, and generating a command with the optimal acceleration / deceleration time constant at the next acceleration / deceleration. Automatic adjustment device for servo control system. The optimum acceleration / deceleration time constant that can be calculated from the servo amplifier output torque required during rapid traverse acceleration / deceleration is individually calculated for each movement direction, and the next time acceleration / deceleration is used, a command is created using the optimum acceleration / deceleration time constant for the movement direction. An automatic optimization device for a servo control system, comprising a control means. The optimum acceleration / deceleration time constant that can be calculated from the output torque of the servo amplifier required during rapid traverse acceleration / deceleration is calculated separately for acceleration and deceleration. An automatic optimizing device for a servo control system, comprising a control means for generating a command with a constant. The optimum acceleration / deceleration time constant that can be obtained from the servo amplifier output torque required during rapid traverse acceleration / deceleration is calculated individually for acceleration, deceleration, and each motion direction, and acceleration / deceleration during acceleration / deceleration for each feed direction is performed. A control means that always calculates the possible time constant from the output torque of the servo amplifier required for each of the above, and creates a command at the next optimal acceleration / deceleration time constant corresponding to the acceleration, deceleration and movement direction at the next acceleration / deceleration An automatic optimization device for a servo control system, comprising: (4) An automatic optimizing device for a servo control system, comprising setting means for setting an excessive error alarm determination position deviation amount to a value larger than usual only during rapid traverse acceleration / deceleration. (4) An automatic optimizing device for a servo control system, comprising: setting means for setting a motor rotation speed to a value larger than a normal value only during determination of an overspeed alarm during rapid traverse acceleration / deceleration. (4) An automatic optimizing device for a servo control system, comprising a clamping means for clamping a maximum speed of a speed command at a constant value. (4) An automatic optimizing device for a servo control system, comprising a clamp means for clamping a maximum speed of a speed command at a constant value only during acceleration / deceleration. (4) An automatic optimization device for a servo control system, comprising a clamp means for clamping the maximum speed of a speed command at a constant value only during the maximum current limitation of the servo amplifier.

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