Kollmorgen AKD2G Manual
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Kollmorgen AKD2G Manual

System configuration with linear motors
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AKD2G SYSTEM CONFIGURATION WITH KOLLMORGEN DDL LINEAR MOTORS
Rev B 5-16-2024
This document shows the wiring requirements for connecting the DDL linear motors to
the AKD2G servo drive. It also describes the setup procedure for configuring the
AKD2G drive in the Workbench software.

Table of Contents

5. AKD2G Primary Feedback X41
7. DDL Motor Power Connections
8. Motor Power Cable
1.
2.
3.
4.
Select Motor from Pull Down List
5.
6.
7.
8.
9.
10. Check Motor Phasing of Any Motor
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Summary of Contents for Kollmorgen AKD2G

  • Page 1: Table Of Contents

    AKD2G SYSTEM CONFIGURATION WITH KOLLMORGEN DDL LINEAR MOTORS Rev B 5-16-2024 This document shows the wiring requirements for connecting the DDL linear motors to the AKD2G servo drive. It also describes the setup procedure for configuring the AKD2G drive in the Workbench software. Table of Contents...
  • Page 2 AKD2G System Configuration with Kollmorgen DDL linear motors with standard convention Overview This procedure covers the case where the feedback AXIS#.PL.FB counts up or positive when moving the coil in the same direction as the motor lead exit. In the case the...

  • Page 3: System Wiring Configuration

    System Wiring Configuration 1. AKD2G System Cable Diagram...

  • Page 4: Aci-Akd-A ( Heidenhain Sin/Cos )

    2. ACI-AKD-A (Heidenhain Sin/Cos) Cable Adapter Note this is compatible with either X23 (F3-Option) or X41 (SFA)

  • Page 5: Aci-Akd-A ( Renishaw Sin/Cos )

    3. ACI-AKD-A (Renishaw Sin/Cos) Cable Adapter Note this is compatible with either X23 (F3-Option) or X41 (SFA)

  • Page 6: Akd2G Primary Feedback X23

    4. AKD2G F EEDBACK...
  • Page 8 5. X41 Feedback Connector...

  • Page 10: Ddl Motor Hall Sensor Connections

    6. DDL Motor Hall Sensor Connections DDL Motor Hall Sensor Connections Motor Connector Motor Hall AKD2G Drive Pin Numbers Effect Colors Connection Connector X23 or X41 Pin No. Yellow Green Black...
  • Page 11 7. DDL Motor Coil Connections Motor Connector Motor Coil Wire AKD2G Drive Pin Numbers Color Connection Connector X1 or X2 White Black Connector Shell Grn/Yel PE GND Connector Shell Violet Shield...
  • Page 12 8. X1 and X2 Motor, Brake, Feedback Connection Pinout...

  • Page 13: Minimum Wiring Requirement For The Akd2G

    9. Minimum Wiring Requirement for the AKD2G Drive Note: This wiring demonstrates the bench test conducted to test this procedure. Please reference all wiring and safety requirements as detailed in the AKD2G installation manual.

  • Page 15: Configure The Akd2G Drive Using The Workbench Software

    10. Configure the AKD2G Drive Using the Workbench Software Install AKD2G Workbench. The software program can be found on the website (http://www.kollmorgen.com/en-us/products/drives/servo/AKD2G/), (http://kdn.kollmorgen.com/) and the Product Support Package (PSP) CD-ROM packaged with the drive. Follow the installation instructions. (If in doubt, install “Kollmorgen WorkBench GUI Full Version.”)

  • Page 16: Connect To The Akd Drive

    2. Connect to the AKD2G Drive Follow the instruction from the WorkBench help file. Help pulldown menuDocumentation->AKD2G Navigate to “Connecting to a Device” in the Table of Contents.

  • Page 17: Expand "Settings" And Select The Motor Setup Screen

    3. Expand “Settings” and Select The Motor Setup Screen...
  • Page 18 OTE FOR THIS EXAMPLE WILL BE SHOWN...
  • Page 19 Selecting the Motor. 1: S AUTOSET= “OFF”. OTOR STEP 2: Click on Select Motor...
  • Page 20 STEP 3: Change Motor Family to the correct motor type. In this example the blah blah is used. STEP 4: Select the Motor Part#.
  • Page 21 STEP 5: Select the Feedback # for the linear encoder used to commutate the motor. In this example the feedback is connected to X23 and Feedback 3 will be used. STEP 6: Click OK.
  • Page 22 The Motor screen attributes should look similar to the following:...
  • Page 23 Note the Pole Pitch is 32.000 mm for Kollmorgen DDL motors. It can be changed in a custom motor file for non-Kollmorgen linear servo motors. This value also is shown/used in AXIS#.MOTOR.PITCH. Note the default for AXIS#.MOTOR.PITCH is 32.000 mm...

  • Page 24: Select Motor Temperature Sensor

    5. Select Motor Temperature Sensor STEP 1: Expand Motor in the tree and click on “Motor Temperature”...
  • Page 25 Thermal Protection Option. 1. Thermostat Option type “TR”: PTC thermistor sensor Kollmorgen DDL linear motors use a PTC thermistor sensor if the Thermostat Option selected is TR “Thermistor” (MOTOR.RTYPE = 0, “Single PTC...
  • Page 26 2. Thermostat Option type “TS”: Thermal switch Kollmorgen DDL linear motors use a thermal switch if the Thermostat Option selected is TS Thermostat (MOTOR.RTYPE = 5, “Thermal Switch”)
  • Page 27 3. No Thermal Sensor In the case a thermal sensor is not used in the application, the thermal protection setting can be set to 127-No Thermal Sensor. Note our demo setup used option 127-No Thermal Sensor...

  • Page 28: Select The Feedback Type

    6. Select Feedback Type Notes on the resolution setting are explained below. Note from the Axis 1 Feedback screen the feedback source for commutation is Feedback 3 as well as the Velocity Loop and Position Loop feedback ( same as commutation ).
  • Page 29 Click in the tree under Feedback Devices the Feedback number used ( 3 in this example ). Use the Feedback Selection listbox to select the encoder used in your application.

  • Page 30: Configuring Encoder Feedback Resolution

    In this example our demo uses Incremental with Halls. 7. CONFIGURING ENCODER FEEDBACK RESOLUTION Next the Encoder pitch must be entered. The following details and chart will assist in calculating and entering the correct value depending on your linear encoder specifications.
  • Page 31 In this demo an incremental encoder was used. To determine the Encoder pitch in nanometer/line use the following diagram and chart. �������������� �������������������� ( �� ) = �� ���� �������������� �������������������� ������ ������������ ( �� ) ����/�������� = �������������� �������������������� ( �� )( ���� ) ∗ 4 ����...
  • Page 32 Example as in our case. 1 um readhead 1 count per 1 um �������������� �������������������� ( �� ) = 1 ���� ���� 1 ���������� ������ ���� �������������� �������������������� ������ ������������ ( �� ) = 1 ( ���� ) ∗ 4 = 4 ����/�������� ����...

  • Page 34: Test Encoder Direction And Resolution

    8. Test Encoder Direction and Resolution The direction of the encoder, the motor phase sequence, and hall sequence all need to match exactly. The hall phasing also needs to match the motor phasing exactly. This is very difficult to do by trial and error. Axis Direction has to be set to zero (“AXIS1.DIR=0”...
  • Page 35 From the commutation drawings in Figure 2 the motor “positive” direction is toward the end of the motor where the wires exit the motor. The Feedback test available is the movement of the indicator on the Feedback screen for the given Feedback# of the motor ( i.e. linear encoder ). If the encoder is counting in the wrong direction, swap the Sine+ and Sine- signal or the A and A\ signal.

  • Page 36: Check Motor Feedback Resolution

    9. Checking Motor Feedback Resolution The feedback resolution can be tested by marking two lines on the magnet way 32mm apart. You can use whatever length you want, but longer is more accurate. STEP 1: Click on Units for the given Axis used. STEP 2: Change the User Units to “mm”, “mm/s”, and “mm/s^2”...
  • Page 37 This part of the setup will require a two channel oscilloscope with isolated channels. Move the motor in the positive direction based on the motor manufactures specification. The AKD2G commutates a motor in the phase sequence of U V W in the positive direction.
  • Page 38 While moving the motor in a positive direction the motor V phase (V phase with reference to W phase) will lead the back emf voltage waveform by 120° of W phase (W phase with reference to U phase). Use Figure 2 to determine the Hall Sensor alignment of the motor. Make sure the feedback position value (PL.FB) is counting in the positive direction.

  • Page 39: Test Hall Sequence When Moving Motor In The Positive Direction

    11. Test Hall Sequence When Moving Motor in the Positive Direction The hall phasing can be check with the parameter FB#..HALLSTATE in terminal. This is a binary value, where “001” is Hall U, “010” is Hall V, and “100” is Hall W.
  • Page 40 Hall Sensor Sequence when FeedBack (PL.FB) Is Counting Positive Using the Scope is easier to capture and analyze.
  • Page 41 Hall Sensor Sequence when FeedBack (PL.FB) Is Counting Positive Note with the AKD2G the FB#.HALLSTATE only reports the decimal value. I checked this with Terminal and the sequence reported was 1, 5, 4, 6, 2, 3, 1. Step(CW) FB#.HALLSTATE...

  • Page 42: Motor Back Emf And Hall Sensor Signal Alignment

    12. Motor Back emf And Hall Sensor Signal Alignment Figure 2 When using a Kollmorgen DDL motor, MOTOR.PHASE = 120 when the feedback direction is positive toward the “Lead Exit End” of motor (that is, the end of the motor where the leads come out), and when the hall alignmet and motor phasing match exactly as shown in Figure 2.

  • Page 43: How To Verify The Motor's Commutation Alignment Angle: Motor.phase

    13. How to Verify the Motor’s Commutation Alignment Angle (MOTOR.PHASE) STEP 1: Set the Wake & Shake Current for the axis used ( b7axis 1 or axis 2) equal to continuous of your linear motor in the Terminal Screen. The keyword is AXIS#.WS.IMAX where # is 1 or 2 for the axis number. The continuous current rating of the motor can be seen from the Motor screen.
  • Page 44 Returning to the Terminal set the AXIS#.WS.IMAX to the continuous current rating from the Motor screen. STEP 2:Setup the Wake and Shake Routine. Navigate to the Wake and Shake screen under the Axis#->Settings->Motor->Wake and Shake.
  • Page 45 Change the Wake and Shake mode to 2-Auto Wake and Shake and click on the “Arm” button to arm the Wake and Shake routine. The status to the right of the Arm button should change from Idle to Armed. Note you cannot arm the W&S if the axis is already enabled ( disable prior to arming ).
  • Page 46 The status to the right of the Arm button should change to “Running” while the W&S is executing. Monitor the Motor Phase read-only on the W&S screen while the W&S runs.This indicates the W&S algorithm is searching for the correct commutation angle in deg.
  • Page 47 The W&S will either finish and indicate “Successful” if it was able to determine the Motor Phase or “Error” if the W&S algorithm failed. Note for the standard convention the Motor Phase should be approximately 120 degrees. When commissioning the linear motor system, the Wake and shake routine should be performed in several different positions of the motor’s travel.

  • Page 48: Verify The Motor Is Setup Correctly By Jogging It In Both Directions

    14. Verify the Motor is Setup Correctly by Jogging it in Both Directions Make sure the AKD2G drive’s peak current is limited before doing this exercise. A linear motor runaway can result in damage to the system equipment or possible bodily injury.
  • Page 49 STEP 4: Select the Service Motion Mode. In this example we’ll start by using Pulse STEP 5: Input a slow jog velocity. In this example we’ve entered 10 mm/s.
  • Page 50 STEP 6: Input the time ( duration ) of the pulse. Make sure the move time does not allow the motor to hit the hard stops ( end of travels ) with the given target velocity inputted in STEP 6. It is recommended to start this test at the mid-stroke of travel. STEP 9: Adjust the Accel/Decel for Service Motion as desired.
  • Page 51 STEP 10: Enable the Axis. Axis 1 is shown in the status bar. STEP 9: Click the Service Motion Start Button to pulse (move) the axis in the forward (positive) direction.
  • Page 52 STEP 10: Set the slow jog velocity to a negative value. We used -10 mm/s in this example. Press the Start button in the Service Motion screen to pulse(move) the axis in the negative (reverse) direction. STEP 11: Set the Service Motion Mode to Continuous and Start/Stop using the Service Motion Control first with a positive Velocity setpoint and then a negative Velocity setpoint to jog the axis continuously in both directions.

  • Page 53: Home Axis And Use Motion Tasking To Extend And Retract

    15. Home Axis and Use Motion Tasking to Extend and Retract STEP 1: Disable the axis. STEP 2: Safely move the motor to the desired home position. STEP 3: Change the Axis’ operation mode to Position. STEP 4. Home the axis using Current Position and 0 for Dist. After homing and Position.
  • Page 54 Enable the axis and press the Start button on the Home screen. Note the Position Feedback read-only on the Home screen should read 0.000 mm after homing.
  • Page 55 STEP 5. Setup two motion task one to extend the motor/axis out to X mm and one for a return to home ( both absolute motion tasks ). Execute the extend ( i.e. out to 100mm ). Measure the physical location of your motor ( i.e. carriage ) and compare the position feedback shown in Workbench vs.
  • Page 56 Appendix A Configuring a DDL Liner Motor with Feedback Counting in the Opposite Direction 1. DDL Motor Coil Connections Motor Connector Motor Coil Wire AKD2G Drive Pin Numbers Color Connection Connector X2 White Black Connector Shell Grn/Yel PE GND Connector Shell...
  • Page 57 2. DDL Motor Hall Sensor Connections Motor Connector Motor Hall AKD2G Drive Pin Numbers Effect Colors Connection Connector X10 Pin No. Yellow Green Black...
  • Page 58 3. Checking Motor Feedback Resolution The feedback resolution can be tested by marking two lines on the magnet way 32mm apart. You can use whatever length you want, but longer is more accurate. Change the User Units to “mm”. If the position display does not match the distance the motor is moved, you may need to revisit the encoder scaling section of this manual or confirm the feedback device scale.
  • Page 59 This part of the setup will require a two channel oscilloscope with isolated channels. Move the motor in the positive direction based on the motor manufactures specification. The AKD2G commutates a motor in the phase sequence of U V W in the positive direction.
  • Page 60 While moving the motor in a positive direction the motor V phase (V phase with reference to W phase) will lead the back emf voltage waveform by 120° of W phase (W phase with reference to U phase). Use Figure 3 to determine the Hall Sensor alignment of the motor. Make sure the feedback position value (PL.FB) is counting in the positive direction.
  • Page 61 5. Test Hall Sequence When Moving Motor in the Positive Direction The hall phasing can be check with the parameter FB#..HALLSTATE in terminal. This is a binary value, where “001” is Hall U, “010” is Hall V, and “100” is Hall W.
  • Page 62 Using the Scope is easier to capture and analyze. Hall Sensor Sequence when FeedBack (PL.FB) Is Counting Positive Note with the AKD2G the FB#.HALLSTATE only reports the decimal value. I checked this with Terminal and the sequence reported was 1, 5, 4, 6, 2, 3, 1.
  • Page 63 The hall phasing can be check with the parameter FB1.HALLSTATE. This is a binary value, where “001” is Hall U, “010” is Hall V, and “100” is Hall W.
  • Page 64 LIGNMENT Figure 3 When using a Kollmorgen DDL motor, MOTOR.PHASE = 120 when the feedback direction is positive toward the “Lead Exit End” of motor (that is, the end of the motor where the leads come out), and when the hall alignmet and motor phasing match exactly as shown in Figure 3.
  • Page 65 Appendix B 1. Hall Effect Cable P 1 - 9 p i n d s u b P 2 - 9 p i n d s u b H a l l C a b l e H a l l C a b l e + 5 V 1 1 G r a y H A L L U 2...

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