08 · General Motion Control

SIEMENS
Global network of innovation
Table of Contents

Introduction ............................................................................. 2
Totally Integrated Automation .................................................. 4
Motion Control ........................................................................ 5
Mechanical Basics ................................................................ 13
Servomotor Construction ...................................................... 25
Servomotor Ratings............................................................... 33
Speed-Torque Characteristics ................................................ 39
Siemens Servomotors ........................................................... 44
Servomotor Accessories ....................................................... 46
Encoders and Resolvers ........................................................ 49
Pulse Width Modulation ........................................................ 55
Siemens MASTERDRIVE MC Family .................................... 63
MASTERDRIVE MC Compact PLUS ..................................... 64
MASTERDRIVE MC Compact and Chassis ........................... 73
Technology Options ............................................................... 78
Cables ................................................................................... 87
Applications .......................................................................... 88
Selection ............................................................................... 95
SIMODRIVE .......................................................................... 97
Review Answers ................................................................... 99
Final Exam ........................................................................... 100

1
 Introduction

Welcome to another course in the STEP 2000 series, Siemens

Technical Education Program, designed to prepare our sales
personnel and distributors to sell Siemens Energy &
Automation products more effectively. This course covers
Basics of General Motion Control and related products.

Upon completion of Basics of General Motion Control you

should be able to:

• Explain the concepts of force, inertia, speed, and torque

• Explain the difference between work and power

• Describe the construction of a servomotor

• Identify the nameplate information of a servomotor

necessary for application to a MASTERDRIVE MC

• Describe the operation of a three-phase rotating magnetic

field

• Describe the relationship between V/Hz, torque, and

current

• Describe the operation of an encoder

• Describe the basic construction and operation of a PWM

type MASTERDRIVE MC

• Describe features and operation of the Siemens

MASTERDRIVE MC

• Describe basic motion control applications

2
This knowledge will help you better understand customer
applications. In addition, you will be able to describe products to
customers and determine important differences between
products. You should complete Basics of Electricity and Basics
of AC Drives before attempting Basics of General Motion
Control. An understanding of many of the concepts covered in
Basics of Electricity and Basics of AC Drives is required for
Basics of General Motion Control.

If you are an employee of a Siemens Energy & Automation

authorized distributor, fill out the final exam tear-out card and
mail in the card. We will mail you a certificate of completion if
you score a passing grade. Good luck with your efforts.

SIMOVERT is a registered trademark of Siemens AG.

MASTERDRIVES is a trademark of Siemens AG.

Other trademarks are the property of their respective owners.

National Electrical Manufacturers Association is located at 2101

L. Street, N.W., Washington, D.C. 20037. The abbreviation
“NEMA” is understood to mean National Electrical
Manufacturers Association.

3
 Totally Integrated Automation

Totally Integrated Automation (TIA) is more than a concept. TIA

is a strategy developed by Siemens that emphasizes the
seamless integration of automation products.

The TIA strategy incorporates a wide variety of automation

products such as programmable controllers, computer
numerical controls, Human Machine Interfaces (HMI), and
drives which are easily connected via open protocol networks.

This course focuses on the MASTERDRIVES™ MC which are

an important element of the TIA strategy. MASTERDRIVE MC
drives are designed for motion control applications that require
precise control. In addition, MASTERDRIVE MC drives can
easily communicate with other control devices such as
programmable logic controllers (PLCs) and personal computers
(PCs) through the PROFIBUS-DP communication system and
other various protocols.

4
 Motion Control

Motion control is an industry term used to describe a range of

applications that involve movement with varying degrees of
precision. Many motion control applications require only that an
object be moved from one place to another with limited concern
for acceleration, deceleration, or speed of motion. On the
opposite extreme are machine tool applications which require
the precise coordination of all aspects of motion, including a
high degree of coordination for multiple simultaneous
movements.

Axis Single-axis motion involves controlling one rotational axis. This

is typically a motor shaft that can be driven forward or reverse.
Mechanisms are often used to translate the rotational motion
into linear motion. Multi-axis control involves control of multiple
rotational axes, each of which could be converted into linear
motion. Some applications require the control of multiple axes,
with each axis operating independently. Other applications
require varying degrees of coordination for multiple axes ranging
from synchronizing the start of motion control for multiple axes
to the highly coordinated multiple-axis control required for
machine tool applications.

5
Motion Control Examples The following illustration is an example of basic single-axis
motion. This illustration shows an object moving on a conveyor.
The conveyor is driven by a Siemens AC motor which turns in
one direction at a relatively constant speed. The sensing and
control circuit for this application consists of a Siemens limit
switch or sensor, a Siemens S7-200 PLC, and a Siemens Sirius
Type 3R full-voltage starter. Additional control and safety
circuits would be required, but are not important for this
explanation.

In this example, the motor will move the object along the
conveyor until the sensor is reached. At that point the sensor
will change the state of a PLC input. The PLC will respond to
this change of the input state by de-energizing the motor
starter, thereby stopping the motor.

This application did not require that the acceleration and

deceleration of the motor or the speed of the motor be
controlled. In addition, the control over the final position of the
object is not precise, but these conditions are often acceptable
in many applications.

6
Another application might involve the use of an AC drive, such
as a Siemens MICROMASTER, MIDIMASTER, or
MASTERDRIVE. In this example a PLC is used to control a
trimming cycle for a continuous roll. A sensor, connected to a
PLC input, is used to detect a reference mark on the roll. An AC
drive, controlled by the PLC, is used to control the acceleration,
deceleration, and speed of an AC motor.

In this application the motor drives a belt which feeds the roll
through a cutter. When the sensor detects the mark it changes
the state of a PLC input. The PLC signals the drive to stop the
motor long enough for the cut to be made. The motor is then
restarted. This application involves control over motor
acceleration, deceleration, and speed, but only moderate
position control.

7
 Motion control applications are often more complex than those
described in the previous examples, involving precise
positioning and synchronized control of one or more axes. For
example, a four-color printing process is used when printing
color material such as brochures or magazine covers. In a four-
color process, a separate printing stage is used for each color. In
this example a continuous roll of paper is fed through a four-
color printing press. Four servomotors are connected to four MC
drives. The drives control the speed and position of each motor.
Each drive knows the exact speed and position of its associated
motor. Fine adjustments are made to ensure the images line up
exactly at each printing stage.

8
Machine Tool Applications Before continuing with our discussion of motion control as it
relates to the MASTERDRIVE MC, it is worthwhile to briefly
describe machine tool motion control applications. This is
essential to highlight the differences with MASTERDRIVE MC
motion control.

Machine tools are designed to perform a series of specific tasks

such as milling, drilling, grinding, or turning that require a high
degree of coordination over multiple axes. For example, the in
and out movement of a cutting tool on a lathe must be
simultaneously coordinated with the side-to-side movement of
that tool. This is necessary to precisely machine the part being
turned. In more complex machine tool applications, many more
axes of motion may need to be controlled in a coordinated
fashion to machine a part quickly and precisely.

Essentially, it is this precise coordination of mulitple axes by a

control system, called a Computer Numerical Control (CNC),
that characterizes machine tool control applications. This course
does not focus on machine tool motion control applications, but
instead covers the single-axis or multiple axes applications
appropriate for MASTERDRIVE MC drives.

9
Linear and Rotational Axes Motion control can operate on a linear or rotational axis. A
linear axis application, such as a traversing car, has a defined
traversing range with end stops. An item may simply be
moved from one station to the next, or it may make several
stops where different manufacturing process are performed.

A rotational axis application has an endless traversing range.

A rotary table, for example, travels along the shortest path
from one point to the next. A rotary table may also have
selectable or predefined directions of rotation to move from
one point to the next.

10
Siemens MC Drives The range of applications in motion control is more specialized
than many other manufacturing applications. Motion control
drives, and their associated motors must be capable of:

• Zero-speed holding torque

• Quick start/stop cycles
• High accelerating torque
• Repeatable velocity and torque profiles
• Synchronization
• Positioning capabilities
• Precise speed control

Controlling the starting, stopping, and speed of an AC motor in

a motion control system is the job of a variable speed drive, like
the Siemens SIMOVERT® MASTERDRIVE MC. SIMOVERT is
a Siemens trade name which refers to SIemens AC MOtor
inVERTers. Although an inverter is only one part of an AC drive,
it is common practice to refer to an AC drive as an inverter. The
Siemens MASTERDRIVE MC (motion control) drive belongs to
the SIMOVERT MASTERDRIVES product family. Siemens also
manufactures a complete line of servomotors to compliment
the drive family.

11
Review 1
1. The Siemens ____________ MC is specifically designed
for general motion control applications.

2. Motion control can operate on ____________ or

____________ axis.

3. Which of the following characteristics are required of a

motion control drive?

a. Zero-speed holding torque

b. Quick start/stop cycles
c. High accelerating torque
d. Repeatable velocity and torque profiles
e. Synchronization with other drives
f. Positioning capabilities
g. Precise speed control
h. All of the above

12
 Mechanical Basics

Before discussing Siemens MASTERDRIVE MC drives and

motors, it is necessary to understand some of the basic
terminology associated with the mechanics of motion control
and drive operation. Many of these terms are familiar to us in
some other context. Later in the course we will see how these
terms apply to motion control.

Units of Measurement There are two units of measurement commonly used. The
International System of Units, known as SI (Système
Internationale d’Unités), is used throughout the world. The SI
system is more recently used in the United States. The English
system, which most of us are more familiar with is used
primarily in the United States. Both systems of measurement
will be referenced throughout this course. To avoid confusion,
the SI system will be given first followed by the English system
in parenthesis. In some tables and charts both systems will be
shown side-by-side.

Force In simple terms, a force is a push or a pull. Force may be caused

by electromagnetism, gravity, or a combination of physical
means. The SI unit of measurement for force is Newtons (N).
The English unit of measurement for force is pounds (lb).

Net Force Net force is the vector sum of all forces that act on an object,
including friction and gravity. When forces are applied in the
same direction they are added. For example, if two 10 lb
44.482 N (10 lb) forces were applied in the same direction the
net force would be 88.964 N (20 lb).

13
 If 44.482 N (10 lb) of force were applied in one direction and
22.41 N (5 lb) of force applied in the opposite direction, the net
force would be 22.41 N (5 lb) and the object would move in the
direction of the greater force.

44.482 N (10 lb) of force were applied equally in both directions,

the net force would be zero and the object would not move.

Torque Torque is a twisting or turning force that tends to cause an

object to rotate. A force applied to the end of a lever, for
example, causes a turning effect or torque at the pivot point.

Torque (τ) is the product of force and radius (lever distance).

Torque (τ) = Force x Radius

The SI unit of measurement is Newton-meters (Nm). In the

English system torque is measured in pound-feet (lb-ft) or
pound-inches (lb-in).If 44.482 N (10 lbs) of force were applied to
a lever 0.3048 meters long (1 foot), for example, there would be
13.56 Nm (10 lb-ft) of torque.

14
 An increase in force or radius would result in a corresponding
increase in torque. Increasing the radius to 0.6096 meters
(2 feet), for example, results in 27.12 Nm (20 lb-ft) of torque.

Speed An object in motion travels a given distance in a given time.

Speed is the ratio of the distance traveled to the time it takes to
travel the distance.

Linear Motion The linear speed of an object is a measure of how long it takes
the object to get from point A to point B. Linear speed is usually
given in a form such as meters per second (m/s). For example,
if the distance between point A and point B were 10 meters,
and it took 2 seconds to travel the distance, the speed would be
5 m/s.

Rotational Motion The angular speed of a rotating object is a measurement of how

long it takes a given point on the object to make one complete
revolution from its starting point. Angular speed is of a rotating
object is an example where it is more common to use the
English system of revolutions per minute (RPM) versus the SI
unit of revolutions per second (RPS). An object that makes ten
complete revolutions in one minute, for example, has a speed
of 10 RPM.

15
Acceleration An object can change speed. An increase in speed is called
acceleration. Acceleration only occurs only when there is a
change in the force acting upon the object. An object can also
change from a higher to a lower speed. This is known as
deceleration (negative acceleration). A rotating object, for
example, can accelerate from 10 RPM to 20 RPM, or decelerate
from 20 RPM to 10 RPM.

Law of Inertia Mechanical systems are subject to the law of inertia. The law of
inertia states that an object will tend to remain in its current
state of rest or motion unless acted upon by an external force.
This property of resistance to acceleration/deceleration is
referred to as the moment of inertia.

The SI unit for inertia is kilogram-meter squared (kgm2). The

English system of measurement is pound-feet squared (lb-ft2).

If we look at a continuous roll of paper, as it unwinds, we know

that when the roll is stopped, it would take a certain amount of
force to overcome the inertia of the roll to get it rolling. The force
required to overcome this inertia can come from a source of
energy such as a motor. Once rolling, the paper will continue
unwinding until another force acts on it to bring it to a stop.

16
Friction Because friction removes energy from a mechanical system,
a continual force must be applied to keep an object in motion.
The law of inertia is still valid, however, since the force applied
is needed only to compensate for the energy lost. In the
following illustration a motor runs a conveyor. A large amount of
force is applied to overcome the inertia of the system at rest to
start it moving.

Once the system is in motion, only the energy required to

compensate for various losses need be applied to keep it in
motion.

These losses include:

• Friction within motor and driven equipment bearings

• Windage losses in the motor and driven equipment
• Friction between conveyor belt and rollers

17
Inertia Ratios One aspect of motion control systems which must be
considered is that the driven machine and the servo motor
driving the machine are physically interdependent. It is
important to ensure that the inertia of the servo motor is
matched to the inertia of the driven machine. Ideally it is
desirable to have a 1:1 inertia ratio between the load and the
motor. However, inertia ratios of 1:10 or greater are not
uncommon.

Typically, it is desirable to reach a new speed quickly when

changing speeds in a motion control system. When changing
from a lower speed to a higher speed, for example, the motor
accelerates the connected load quickly, resulting in a slight
overshoot before settling into the new speed. If there is too
great a mismatch between the motor and the load the system
can become unstable. Oscillations can occur which contribute
to system instability.

When the inertia of a system is properly matched the system

will settle into a new speed quickly. This provides a stable
system with quick response.

18
Work Whenever a force of any kind causes motion, work is
accomplished. For example, work is accomplished when an
object on a conveyor is moved from one point to another.

Work is defined by the product of the net force (F) applied and
the distance (d) moved. If twice the force is applied, twice the
work is done. If an object moves twice the distance, twice the
work is done.

W=Fxd

Power Power is the rate of doing work, or work divided by time.

In other words, power is the amount of work it takes to move

the package from one point to another point, divided by the
time.

19
Power Power in an electrical circuit is measured in watts (W) or
kilowatts (kW). AC drives and motors manufactured in the
United States are generally rated in horsepower (HP), however,
it is becoming common practice to rate equipment using the SI
units of watts and kilowatts.

Torque vs Power When considering motors and drives for a given application we
typically think in terms of power. We have learned that power is
a function of speed. No work is accomplished unless there is
motion. Therefore, power is zero when the system and its
associated motor is at rest (zero speed).

On the other hand, a characteristic of motion control systems is

the ability to deliver full torque at zero speed. For this reason it
is more common to base motion control systems on torque
rather than power.

Acceleration Torque The torque required to accelerate a machine should be

determined first. The following information is needed:

• Inertia of the machine in kgm2 (SI) or lb ft2 (English) (J)

• Amount of change of speed in RPM (∆n)
• Time taken to change speed in seconds (∆t)

A simple formula can be used to determine the required

acceleration torque (τa).

The torque required to accelerate a system with a total inertia of

0.005 kgm2 (0.1187 lb ft2) from rest to 3000 RPM in 0.2 seconds
would be 7.85 Nm(5.78 lb ft).

20
Effective (RMS) Torque Accelerating torque is usually required on an intermittent basis
only. Due to the cyclic nature of motion control applications,
servomotors have both continuous and intermittent ratings. To
select the correct continuous rating it is also necessary to know
the effective torque, also referred to as RMS (root-mean square)
torque.

The value of effective torque is actually a means of expressing

the equivalent of varying values of torque required during a
cycle of operation. Effective torque is determined by looking at
all the operating points of a torque-time curve during a
complete cycle.

Three operating points are used during a cycle in the following

example. The load requires 7.85 Nm (5.78 lb ft) of torque to
accelerate the load (T1) in 0.2 seconds. During constant state
run the load requires 1 Nm (.737 lb ft) of torque to overcome
losses due to friction and maintain speed (T2) for 1 second. To
decelerate the load and stop requires 2 Nm (1.474 lb ft) of torque
(T3) for 0.2 seconds. The system will remain stopped for 1
second before repeating the cycle. The total cycle time is
2.4 seconds (Tt).

21
Calculating Effective Torque The following formula can be used to calculate effective torque
using either SI or English units. Effective torque (τeff) is the
square root of the summation (Σ) of the square of torque
required (τ2) by the motor at each increment (Mot i) and time
period (∆ti) divided by the total cycle time (Tt).

Using the values for the three time periods in the previous
example, effective torque can be calculated.

Cycle Torque Torque Time

Increment (Nm) (lb ft) (seconds)
1 7.85 5.78 0.2
2 1 0.737 1
3 2 1.474 0.2
Time Between Cycles 1
Total Time 2.4

22
SimoSize Calculating the correct torque for a motion control system is
complex, requiring a thorough understanding of the system
involved. SimoSize is a PC tool which allows the user to
accelerate the design process by providing the necessary tools
in a Windows 95/98/NT format. SimoSize is available through
your sales representative at no charge and may be freely copied
and distributed.

SimoSize allows the user to select components such as gear

boxes, rotary tables, and belt-pulleys. The user can also specify
the profile needs such as acceleration, run speed, and run time.
A report generator in SimoSize performs calculations for speed,
torque, and inertia to properly select a servomotor.

23
Review 2
1. A ____________ is a push or a pull.

2. An object has 10 N of force applied in one direction and

5 N of force applied in the opposite direction. The net
force is ____________ .

3. A twisting or turning force that causes an object to

rotate is known as ____________ .

4. If 20 N of force were applied to a lever 0.3 meters long,

the torque would be ____________ Nm.

5. The law of ____________ states that an object will tend

to remain in its current state of rest or motion unless
acted upon by an external force.

6. Ideally it is desirable to have a ____________ inertia ratio

between the load and the motor.

7. ____________ is accomplished when force causes

motion.

8. A characteristic of motion control systems is the ability

to deliver full torque at zero speed. For this reason it is
more common to base motion control systems on
____________ rather than ____________ .

9. ____________ is a Siemens software program designed

to help calculate the speed, torque, and inertia of a
motion control system.

24
 Servomotor Construction

There are two types of AC servomotors used with motion

control drives: synchronous and induction. Induction motors are
also referred to as asynchronous motors. The two basic
elements of all AC motors are the stator and rotor. The principle
of operation of a stator is the same in asynchronous and
synchronous motors. There are, however, differences in rotor
construction.

Stator and a Rotating A rotating magnetic field must be developed in the stator of an
Magnetic Field AC motor in order to produce mechanical rotation of the rotor.
Wire is coiled into loops and placed in slots in the motor
housing. These loops of wire are referred to as the stator
windings. The following drawing illustrates a three-phase stator.
Phase windings (A, B, and C) are placed 120° apart. In this
example, a second set of three-phase windings is installed. The
number of poles is determined by how many times a phase
winding appears. In this example, each phase winding appears
two times. This is a two-pole stator. If each phase winding
appeared four times it would be a four-pole stator.

25
Magnetic Field When AC voltage is applied to the stator, current flows through
the windings. The magnetic field developed in a phase winding
depends on the direction of current flow through that winding.
The following chart is used here for explanation only. It assumes
that a positive current flow in the A1, B1 and C1 windings result
in a north pole.

Winding Current Flow Direction

Positive Negative
A1 North South
A2 South North
B1 North South
B2 South North
C1 North South
C2 South North

It is easier to visualize a magnetic field if a time is picked when

no current is flowing through one phase. In the following
illustration, for example, a time has been selected during which
phase A has no current flow, phase B has current flow in a
negative direction, and phase C has current flow in a positive
direction. Based on the above chart, B1 and C2 are south poles
and B2 and C1 are north poles. Magnetic lines of flux leave the
B2 north pole and enter the nearest south pole, C2. Magnetic
lines of flux also leave the C1 north pole and enter the nearest
south pole, B1. A magnetic field results as indicated by the
arrow.

26
 The amount of flux lines (Φ) the magnetic field produces is
approximately equal to the voltage (E) divided by the frequency
(F). Increasing the supply voltage increases the flux of the
magnetic field. Decreasing the frequency increases the flux.

If the field is evaluated at 60° intervals from the starting point, at

point 1 it can be seen that the field will rotate 60°. At point 1
phase C has no current flow, phase A has current flow in a
positive direction and phase B has current flow in a negative
direction. Following the same logic as used for the starting
point, windings A1 and B2 are north poles and windings A2 and
B1 are south poles. At the end of six such intervals the
magnetic field will have rotated one full revolution or 360°.

Synchronous Speed The speed of the rotating magnetic field is referred to as

synchronous speed (NS). Synchronous speed is equal to 120
times the frequency (F), divided by the number of poles (P). If
the applied frequency of the two-pole stator used in the
previous example is 60 hertz, synchronous speed is 3600 RPM.

27
Synchronous Rotor Synchronous motors are not induction motors. They are called
“synchronous” because the rotor operates at the same speed
as the rotating magnetic field. There are different methods to
achieve synchronization between the rotor and the rotating
manetic field. The most common method in servomotor
applications is the use of a permanent magnet rotor. Permanent
rare-earth magnets are glued onto the rotor. This type of rotor is
found on smaller synchronous motors. A synchronous motor of
this design is relatively small with low rotor inertia. The smaller,
low inertia rotor provides fast acceleration and high overload
torque ratings.

When the stator windings are energized, a rotating magnetic

field is established. The permanent magnet rotor has its own
magnetic field that interacts with the rotating magnetic field of
the stator. The north pole of the rotating magnetic field attracts
the south pole of the permanent magnet rotor. As the rotating
magnetic field rotates, it pulls the permanent magnet rotor,
causing it to rotate.

DC Motor Comparison A permanent magnet synchronous motor can be compared to a

standard DC motor. A DC motor consists of a stator and rotor.
The rotor windings are made up conductors that terminate at a
commutator. DC voltage is applied to the rotor thru carbon
brushes which ride on the commutator.

28
A permanent electromagnet with north and south poles is
established when DC voltage is applied to the stator. The
resultant magnetic field is static (non-rotational).

The DC voltage applied to the rotor conductors causes current

to flow. This current reverses direction twice per revolution.
Voltage polarity is such that during one half of a revolution
current flows through half the conductors in one direction and
half of the conductors in the opposite direction.

Current flow momentarily decreases to zero in a conductor

when a brush is in direct contact with it. Polarity of the applied
voltage is reversed. This is known as commutation. Current flow
through the conductor increases in the opposite direction. The
resultant magnetic field reverse polarity for the second half of a
revolution.

The resultant magnetic armature fields are of opposite polarity

to the main stator field. The north pole of the rotor is attracted to
the south pole of the stator and rotation results.

conductor.

There are weak points with this design. The commutator adds
significant weight to the rotor, increasing inertia and reducing
acceleration capability. The design of the commutator also limits
the maximum speed of the motor. Current flow through rotor
windings generates heat in the center of the motor that requires
some method of cooling, such as intenal ventilation. In addition,
there are added maintanance cost, such as brushes, which
must be checked and replaced regularly.

29
Synchronous Servomotor Permanent magnet synchronous servomotors offer many
advantages over DC motors. The permanent magnetic field is
generated by the rotor instead of the stator. There is no current
flow to generate heat in the rotor. Instead, heat is generated in
the stator windings which are close to the surface of the motor.
In many applications natural convection cooling is all that is
required. In some more demanding applications an external
blower provides sufficient cooling. Since no internal ventilation
is required, servomotors can be built to higher degrees of
protection. Servomotors have a higher efficiency since there are
no losses in a rotor/armature winding.

In addition, there is no commutator to limit speed or

acceleration. Instead of switching rotor current mechanically to
establish the correct polarity of the rotor’s magnetic field, the
MASTERDRIVE MC commutates the magnetic field of the
stator electronically. In order to accomplish this the drive must
monitor the position of the permanent magnet rotor with
respect to the rotating magnetic field of the stator. This
information is provided to the drive by a feedback device known
as an enccoder. On permanent magnet type synchronous
motors, the encoder must give the absolute position of the rotor
within one revolution.

30
Asynchronous Rotor Siemens also offers asynchronous (induction) servomotors. The
most common type of rotor used with asynchronous motors is
the “squirrel cage” rotor. The construction of the squirrel cage
rotor is reminiscent of the rotating exercise wheels found in
cages of pet rodents. The rotor consists of a stack of steel
laminations with evenly spaced conductor bars around the
circumference. The conductor bars are mechanically and
electrically connected with end rings. A slight skewing of the
bars helps to reduce audible hum. The shaft is an integral part of
the rotor construction.

There is no direct electrical connection between the stator and

the rotor or between the power supply and the rotor of an
asynchronous motor. When a conductor, such as a conductor
bar of the rotor, passes through a magnetic field, a voltage (emf)
is induced in it. The induced voltage causes current flow in the
conductor.

31
 Current flow in the conductor bars produces magnetic fields
around each rotor bar. The rotor becomes an electromagnet with
alternating north and south poles. It must be remembered that
current and magnetic fields of the stator and rotor are constantly
changing. The following drawing illustrates one instant in time
during which current flow through winding A1 produces a north
pole. The expanding field cuts across an adjacent rotor bar,
inducing a voltage. The resultant magnetic field in the rotor
tooth produces a south pole, which is attracted to the stator’s
north pole. As the stator magnetic field rotates the rotor follows.

Asynchronous Slip There must be a difference in speed between the rotor of an

asynchronous motor and the rotating magnetic field. This is
known as slip. If the rotor and the rotating magnetic field were
turning at the same speed, no relative motion would exist
between the two and no lines of flux would be cut. With no flux
lines cut no voltage would be induced in the rotor. The
difference in speed is called slip. Slip is necessary to produce
torque.

Slip is dependent on load. An increase in load will cause the

rotor to slow down, that is to increase the slip. A decrease in
load will cause the rotor to speed up or decrease slip. The
following formula is used to calculate slip. For example, a four-
pole motor operated at 60 Hz has a synchronous speed of 1800
RPM. If rotor speed at full load were 1765 RPM, slip is 1.9%.

32
 Servomotor Ratings

Siemens Servomotors Servomotors, like the Siemens servomotor shown below, are
high-performance motors specifically designed for use with the
high demand of variable speed drives and motion control
applications.

Nameplate The nameplate of a motor provides important information

necessary when applying a motor to an AC drive and motion
control application.

33
Catalog and Serial Number The catalog number gives important information about the
motor. The first four digits of the catalog number are the model
number. In this case it is a 1FT6 synchronous servomotor. In
addition to the 1FT6 Siemens also manufactures a 1FK6
synchronous servomotor. There is also the 1PH7, 1PL6, and
1PH4 asynchronous servomotors.

1FT6082-8AF71-1AG1

The serial number (Nr) is used to identify the motor.

E J899 1745 01 001 EN 60034

Voltage The example motor, like all 1FK6 and 1FT6 motors, is rated for
380 to 460 VAC, which correlates to an effective voltage in the
stator windings of 240 VAC. Induction motors are designed to
operate on a voltage source that supplies a smooth sinusoidal
sine wave, such as the one shown below.

AC variable speed drives, unfortunately, do not produce a

smooth sinusoidal waveform. Modern drives produce a PWM
(pulse width modulation) waveform. This technology produces
very rapid changes in voltage, resulting in high voltage spikes
that can shorten the life of a motor. In addition, motion control
applications typically incorporate quick starts and stops which
add further stress to a standard motor. Siemens servomotors
are specifically designed to operate with the PWM waveform
produced by modern AC variable-speed motion control drives.

34
Speed and Torque Rated speed is the nameplate speed, given in RPM, where the
motor develops rated torque (τn) at rated voltage. This motor, for
example, is rated to develop 10.3 Nm of torque at 3000 RPM
with a supply voltage range of 380 to 460 VAC, which correlates
to an effective voltage in the stator windings of 240 VAC. The
nameplate of the 1F.6 motors also shows ratings when the
supply voltage is reduced 50%. At 50% supply voltage rated
speed is 1500 RPM, rated torque is 11.7 Nm, and the effective
stator winding voltage is 120 VAC. This information is put in
parenthesis because this supply voltage is outside the rated
voltage of the MASTERDRIVE MC drive.

The nameplate on this motor also gives a maximum speed of

4160 RPM. Maximum speed is the fastest speed the motor can
operate at and still develop enough torque to maintain that
speed with some amount of load. Variable speed drives are
capable of running a motor at various speeds. When a variable
speed drive is set to turn a motor faster than rated speed, the
motor’s ability to develop continuous and overload torque is
diminished. A variable speed drive should not be set to operate
a servomotor above its maximum speed.

Current Stall (Stand still) current is 8.2 amps at zero speed and stall
torque (τo) with 60 K rise. The Current at stall is 10.7 amps with
a 100 K rise.

Stall Torque and Current Stall describes a condition where power is supplied to the
motor but the rotor is at zero speed. This condition occurs when
an AC drive is causing the motor to act as an electrical brake to
hold the connected load at a specific position.

Stall Current (Io) is the current drawn by the motor that is

required to produce the given stall torque (τ0).

Stall torque is also a thermal limiting torque when the motor is

at standstill, corresponding to 60 K or 100 K temperature rise.
Stall torque is available at zero speed for an unlimited time.

35
Insulation Class In an electrical circuit, current causes heat. A certain amount of
current will flow in the windings of a motor as soon as it is
started. This will cause motor temperature to rise. DIN
(Deutsche Industrie Normenausschuss) is a set of German
standards now used in other countries. DIN VDE 0530 classifies
the accepted amount of temperature rise. The three most
commonly used classes are B, F, and H.

Before a motor is started its windings are at the temperature of

the surrounding air. This is known as ambient temperature. The
standard ambient temperature for electrical equipment is 40° C.
Each insulation class has a specific allowable temperature rise.
Ambient temperature and allowable temperature rise equals the
maximum winding temperature in a motor. In addition, a margin
is allowed to provide for a point at the center of the motor’s
windings where the temperature is higher. This is referred to as
the motor’s hot spot.

Temperature rise is always given in absolute values. The

absolute value of Celsius is the Kelvin (K). Kelvin is the SI unit of
temperature. The degree sign (°) is not used with Kelvin.

The insulation or thermal class (Th. CL. F.) of the example motor
is Class F. Class F insulation has a maximum temperature rise of
105 K. The maximum winding temperature is 145° C (40° C
ambient plus 105 K rise). The maximum steady-state
temperature of a motor with Class F insulation is 155° C.

The operating temperature of a motor is an important factor in

efficient operation and long life. Operating a motor above the
limits of the insulation class reduces the motor’s life
expectancy. A 10 K increase in the operating temperature can
decrease the life expectancy of a motor as much as 50%.

36
Stall Torque, Current, There are two ratings for stall torque (τo), stall current (Io), and
and Temperature Rise temperature rise given for this motor. These ratings are related.

τo = 10.4/13.0 Nm
Io = 8.20/10.7 A
Temperature Rise = 60/100 K

The motor begins developing torque to turn the connected load.

If the load is such that it only requires 10.4 Nm of torque at stall,
current will be 8.20 A and the temperature rise will be 60 K. If
the load requires 13.0 Nm at stall, current will be 10.7 A and
temperature rise will be 100 K. This is well within Class F
temperature limitations.

IP Protection The International Electrotechnical Commission (IEC) is an

organization that, among other things, defines the degree of
protection provided by enclosures. IEC is associated with
electrical equipment sold in many countries, including the
United States.

The IEC system of classification consists of the letters IP

followed by two numbers. The first number indicates the
degree of protection provided by the enclosure with respect
to persons and solid objects entering the enclosure. The
second number indicates the degree of protection against the
ingress of water. The motor indicated by the sample nameplate
is dust tight and protected against splashing water (IP 64).

1st Number Description

0 Not Protected
1 Protected Against Objects Greater than 50 mm
2 Protected Against Objects Greater than 12 mm
3 Protected Against Objects Greater than 2.5 mm
4 Protected Against Objects Greater than 1.0 mm
5 Protected Against Dust
6 Dust Tight
2nd Number
0 Not Protected
1 Protected Against Dripping Water
2 Protected Against Dripping Water when Tilted up to 15°
3 Protected Against Spraying Water
4 Protected Against Splashing Water
5 Protected Against Water Jets
6 Protected Against Heavy Seas
Protected Against the Effects of Immersion for Specific
7
Time and Pressure
Protected Against Continuous Submersion Under
8
Conditions Specified by the Manufacturer

37
Review 3
1. Two types of servomotors used in motion control drives
are ____________ and ____________ .

2. Phase windings in a 3-phase motor are located

____________ degrees apart.

3. The speed of the rotating magnetic field is known as

____________ speed.

4. The difference between rotor speed and synchronous

speed of an asynchronous motor is known as
____________ .

5. The output of a PWM type drive is ____________ .

a. sinusoidal
b. pulse width modulated

6. The temperature rise of insulation class F is

____________ K.

7. A motor that is dust tight and protected against

splashing water would have an IP rating of
____________ .

38
 Speed-Torque Characteristics

Duty Cycle All motors are limited by the amount of heat that can develop in
the motor windings. Speed-torque curves are based on
standardized duty cycles which lead to the same temperature
rise. The number of possible duty cycle types is almost infinite.
To help promote a better understanding, duty cycles have been
divided into nine standardized categories, which cover most of
the applications encountered.

S1 Continuous Running Duty

S2 Short-Time Duty
S3 Intermittent Periodic Duty Without Starting
S4 Intermittent Periodic Duty With Starting
S5 Intermittent Periodic Duty with Starting and
Electric Braking
S6 Continuous Operation Periodic Duty
S7 Continuous Operation Periodic Duty with Starting
and Electric Braking
S8 Continuous Operation Periodic Duty with Related
Load/Speed Changes
S9 Continuous Operation Duty with Non-Periodic Load
and Speed Variations

Duty cycle profiles can become complex. S1, S3, and S6,
however, are three common duty cycles. Part 2 of the General
Motion Control Catalog provides speed/torque curves for S1
and intermittent/periodic duty cycles where applicable.

S1 Duty Each duty cycle is characterized by cycle times, cycle durations,

and load. S1 duty cycle, for example, characterizes a condition
where the motor operates under constant load of sufficient
duration for thermal equilibrium to be established. All motors
listed in the Siemens catalog are designed for continuous duty
type S1, unless otherwise indicated.

39
S3 Duty S3 duty operation is comprised of a sequence of identical duty
cycles, each of which consists of a period of constant load
followed by an interval of no load. Starting current has no
marked effect on the temperature rise of the motor. Operating
time is given in minutes, such as 10 minutes, 30 minutes, or 60
minutes. If no time is given a 10 minute cycle time is assumed.
Cycle duty is given in a percent such as 15%, 20%, 25%, 30%,
or 40%. An S3 duty cycle of 40% for 10 minutes, for example,
would indicate a motor load would be constant for 40% of the
time (4 minutes). A no load condition would occur for 60% of
the time (6 minutes).

S6 Duty S6 duty operation is similar to S3 duty operation. The main

difference is that there aren’t any de-energized intervals. The
motor remains energized during the no load interval. Operating
time and cycle duration are given in the same manner as for S3
duty operation.

40
Speed-Torque Curve A motor can be identified by its frame size, which is associated
of Synchronous with useful mounting information. The speed and torque
Servomotor characteristics for a given frame size depend upon the motor
windings available. A common approach for representing the
range of speed and torque characteristics available for a given
motor frame size is the speed-torque curve.

A speed-torque curve, like the one shown in the following

illustration, shows a motor frame which can be wound for
various speeds and duty cycles. A letter in the catalog number
is used to designate the speed of the motor. A speed-torque
curve will show the expected torque performance of a motor for
a specific duty cycle at a given speed. The motor frame for a
permanent magnet synchronous motor illustrated by the
following speed-torque curve is used on four different motor
windings: 2000, 3000, 4500, and 6000 RPM. Torque ratings in
this example are shown for S1 and S3 duty cycles.

41
 The speed-torque curve can be made less confusing by filtering
out information so that only the applicable winding and duty
cycles are shown. In the following illustration a motor with an F
winding (3000 RPM) is used. The rated stall torque (zero speed
torque) when operating the motor in S1 duty is about 1.1 Nm
(0.81 lb ft). As the motor accelerates to rated speed, torque
decreases to approximately 0.9 Nm (0.66 lb ft) due to friction
(bearings) and stator losses (mainly eddy currents). The
maximum torque that the motor can supply for a short period of
time at rated speed is called τlimit.

If the motor speed is increased beyond rated speed (3000 RPM)

continuously available torque, indicated by the S1 line,
continues to decrease. The maximum speed is defined by the
intersection of the S1 line with the voltage limiting curve. The
voltage limiting curve must be followed from that point on.
Higher speeds result in reduced available torque.

The maximum torque or current limiting curve indicates the

maximum available short-time torque of the motor. Exceeding
the limit results in a sudden demagnetizing of the permanent
magnets, destroying the synchronous motor.

The rated stall torque when operating the motor in S3 duty is

approximately 1.5 Nm (1.1 lb ft). Torque will remain constant until
about 2000 RPM. Torque will then decrease slightly to
approximately 1.4 Nm (1.0) at 3000 RPM. Torque will continue to
decrease as motor speed is increased above the rated speed of
3000 RPM.

42
Speed-Torque Curve for Speed-torque curves can also be supplied for a specific motor.
Specific Motors Larger motors are rated in Newton meters (Nm) and pound-feet
(lb-ft). Smaller motors are rated in Newton meters (Nm) and
pound-inches (lb-in). The following speed-torque curve, for
example, shows the operating capabilities of a 1FT6082 motor.
The motor associated with this curve can deliver 13 Nm (115 lb-
in) at stall and 10.3 Nm (91.2 lb-in) at rated speed (3000 RPM)
continuously. The region in the light grey area of the graph
represents a continuous operating range (S1 duty cycle). The
area represented by the dark grey region of the graph
represents the intermittent operating region.

43
 Siemens Servomotors

Siemens manufactures asynchronous and synchronous

servomotors for virtually every motion control application.
Selection and ordering information, as well as configuration aids
such as speed-torque curves for specific motors, can be found
in Part 2 of the General Motion Control Catalog. This is available
from your local Siemens sales representative.

44
Synchronous Servomotors Siemens manufactures two models of permanent-magnet
synchronous servomotors. The 1FK6 is a standard servomotor.
The 1FT6 is a performance servomotor.

Motor Protection Cooling Power Range Rated Torque

kW (HP) Nm (lb-in)
1FK6 IP64 (IP65)* Natural 0.5 - 5.2 0.8 - 16.5
(0.7 -7.0) (7 - 148)
1FT6 IP64 (IP65, IP67)* Natural 0.5 - 15.5 0.8 - 88
(0.7 - 20.7) (7 - 779)
Blower Vent 6.9 - 34.6 17 - 160
(9.2 - 46.4) (150 - 1416)
Water 11 - 27.6 34 - 78
(14.7 - 37) (300 - 690)
* Optional

Asynchronous Siemens manufactures three models of squirrel-cage

Servomotors asynchronous servomotors: 1PH7, 1PL6, and 1PH4.

Motor Protection Cooling Power Range Rated Torque

kW (HP) Nm (lb-ft)
1PH7 IP 55 Blower Vent 3.7 - 215 22 - 1145
Surface (5 - 288) (16 - 844)
1PL6 IP23 Blower Vent 24.5 - 300 370 - 1720
(32.8 - 400) (273 - 1268)
1PH4 IP65 Water 7.5 - 61 48 - 330
(10 - 81) (35 - 243)

45
 Servomotor Accessories

Holding brakes, built-on gears, and encoders are typical

accessories for use with servomotors and motion control
systems. Holding brakes and built-on gears will be covered in
this section. Encoders will be covered in a separate section.

Holding Brakes Many systems need a holding brake as part of an emergency-

stop function, or for other reasons related to safety. These
brakes are electromagnetic brakes. When voltage is applied to
the brake, the brake is released and the motor is free to be
turned by the AC drive. In the event of a power loss, such as a
power interruption caused by initiating an emergency stop, the
brake is engaged. This will bring the motor to a standstill.

Holding brakes are available for the 1FK6, 1FT6, and 1PH7
motors.

46
Gear Reducer In drive systems servomotors are frequently combined with
planetary gear reducers. Planetary gears designed for use with
Siemens servomotors provide a compact unit with low torsional
play, high torsional rigidity, and low running noise.

Earlier in the course we discussed some basic mechanical

concepts which include power, torque, and speed. One way to
see the relationship of these concepts is through a gear
reducer. Power is a function of speed, and directly proportional
to both speed and torque. If torque and speed are increased,
power would also increase. However, if torque is increased and
speed is decreased by a proportionate amount, power remains
constant. This is exactly what happens in a gear reducer. The
following drawing illustrates a 30:1 gear reducer. The input is
driven by a servomotor with 4.068 Nm (3 lb-ft) of torque at 1750
RPM. Output speed is reduced by the gear reducer to 58.3
RPM. Output torque, however, increases to 103.73 Nm
(76.5 lb-ft) for use by the connected system.

47
SPG, LP, and PG Series Siemens uses SPG and LP series planetary gears made by
Alpha Geardrives, Elk Grove Village, IL, for 1FK6, 1FT6, and
some 1PH7 motors. Siemens uses PG series planetary gears
manufactured by ZF Friedrichshafen, Florence, KY, for 1FK6 and
1FT6 motors.

SPG Gears LP Gears PG Gears

Transmission 4, 5, 7, 10 5, 10 4, 5, 7, 10
Ratios, single-stage
Transmission 16, 20, 28, 25, 50, 100 16, 20, 25, 35,
Ratios, 2-stage 40, 50, 70, 40, 49, 50, 70,
100 100
Efficiency up to 97% >95% >95% single-
stage, >97%, 2-
stage
Torsional Play up to under <10 arc min <6 arc min single-
2 arc min stage, <10 arc
min 2-stage

Review 4
1. ____________ is the duty cycle designation for
continuous running duty.

2. If no time is given for a duty cycle a ____________

minute time is assumed.

3. The speed-torque curve for specific servomotors show

speed-torque ratings for ____________ and
____________ operating regions.

4. The maximum rated torque of a 1PH4 asynchronous

servomotor is ____________ HP.

5. 1PH7, 1PL6, and 1PH4 are examples of ____________

servomotors.

48
Encoders and Resolvers

Siemens encoders and resolvers are designed for use with the
Siemens servomotors discussed in previous sections. Encoders
and resolvers allow the MASTERDRIVE MC to determine
speed, position, and direction of shaft rotation.

One type of encoder available for use with Siemens

servomotors is an incremental encoder. An incremental encoder
consists of a transparent disk marked with lines around the
radius. A photoelectric scanning device is located near the disk.
The output of an incremental encoder is either a series of
pulses or a series of sinusoidal waveforms.

49
Closed-Loop Control In a motion control system, precise control must be maintained
over acceleration, deceleration, velocity, and position. This
requires that the drive or other controlling device be provided
with commands associated with these items. The drive
determines the signal to provide to the servomotor by
comparing the actual values with the command values. The
actual values are calculated based upon feedback received from
the encoder. This is an example of closed-loop control.

In the following illustration an input reference signal, indicating

the position the load is to be moved to, is applied to a counter in
the motion control drive. As the motor is accelerated pulses
from an encoder are returned to the counter at an increasing
rate. Once the motor has reached the desired running speed the
pulses are returned at a constant rate. The drive can keep track
of the rotor’s position and number of rotations by counting these
pulses. When the load approaches the desired location the
drive slows the motor to a stop. The load is now in the desired
location.

50
Rod 431 Rotary This encoder has two output channels (Ua1 and Ua2) which are
Pulse Encoder phase shifted by 90°. The encoder has 1024 increments per
revolution. Channel Ua0 is a reference pulse which occurs once
per revolution. When power is initially applied to the servomotor
the drive will not know the exact position of the rotor. Rotor
position can only be calculated within one revolution once the
zero reference mark has been crossed the first time. Because
synchronous servomotors must know rotor position within one
revolution this encoder can only be used with 1PH7, 1PL6, and
1PH4 asynchronous servomotors.

By comparing channel Ua1 and Ua2 the drive can determine

which direction the motor is running.

51
ERN 1387/1381 The ERN 1387 encoder has four tracks and a reference pulse.
Encoders A1 channel produces one sine signal per revolution and B1
channel produces one cosine signal. These signals are used to
determine exact rotor position from initial power up within one
revolution. After each revolution the calculated position is
adjusted to the position indicated by the reference pulse
position, if necessary. This encoder is suitable for use with all
Siemens synchronous and asynchronous motors.

The 1381 encoder is a two-channel device which does not

produce A1 and B1 signals. The 1381should be used only with
asynchronous servomotors.

Tracks A and B on both encoders produce a sinewave output of

2048 microperiods per revolution. Evaluation electronics within
the MASTERDRIVE MC can increase the resolution to 16.8 x
106 periods per revolution (ppr).

52
EQN 1325 Absolute- The EQN 1325 absolute value encoder is made up of two
Value Encoder sections. The outer ring is identical to the ERN 1387 and is used
to provide speed and direction information. Two output
channels, A and B, produce 2048 periods per revolution.
Channel B is offset from channel A by 180 degrees. The drive
can determine which direction the motor is running by
comparing channel A with channel B. A second feature of the
EQN 1325 is the coded inner rings. These provide a unique
code for 8192 positions. This unique code is sent to the drive via
an EnDat interface. The drive uses this unique code number to
determine rotor positon.

In addition, the encoder uses a mechanical gear sequence to

count up to 4096 revolutions and store them. As long as the
distance the application moves is less than 4096 revolutions
there is no need to “home” the application as the absolute
position is always known by the encoder count. As soon as it
counts 4096 revolutions the encoder starts counting again from
zero. These encoders are designed for use with synchronous
and asynchronous servomotors.

53
Two-Pole Resolver A resolver is similar to an encoder, but instead of using a
photoelectric sensor a rotating transformer is employed. The
primary is located on the rotor of the resolver. Two secondary
windings, arranged at right angles to each other, make up the
stator. The amplitude of the sinewave induced into each stator
winding depends on the angular position of the rotor winding.
Since the amplitude variations available at the stator windings
are 90° apart, one signal is called a sine signal and the other is
called a cosine signal.

The sine signal and the cosine signal are both applied to the
MASTERDRIVE MC. By comparing the two signals, the
MASTERDRIVE MC can determine the angular position of the
rotor and its direction of rotation. Each revolution of the rotor is
divided into 4096 increments. Once the initial position of an axis
is determined by finding a home position, exact position of an
axis will be tracked by the MASTERDRIVE MC over multiple
revolutions of the resolver. Two-pole resolvers are designed for
use with synchronous and asynchronous servomotors.

54
Pulse Width Modulation

Before discussing the MASTERDRIVE MC it is necessary to

know something about Pulse Width Modulation (PWM). Pulse
width modulation is one type of technology used by AC drives,
such as the MASTERDRIVE MC. PWM drives convert a fixed
voltage, fixed frequency into a variable voltage, variable
frequency output to control the speed of an AC motor. Pulse
width modulation provides a more nearly sinusoidal current
output to control frequency and voltage supplied to an AC
motor than other technologies. PWM drives are more efficient
and typically provide higher levels of performance than other
drives. A basic PWM drive consists of a converter, control logic,
and an inverter.

55
Converter The converter section consists of a either a fixed diode bridge
rectifier or a thyristor bridge rectifier which converts the three-
phase power supply to a DC voltage. The C1 capacitor(s)
smooths the converted DC voltage by limiting current peaks
and reducing harmonics. The rectified DC value is
approximately 1.35 times the line-to-line value of the supply
voltage. For example, the rectified DC value is approximately
650 VDC for a 480 VAC supply.

Control Logic Output voltage and frequency to the motor are controlled by the
and Converter control logic and inverter section. The inverter section consists
of six switching devices. Various devices can be used such as
thyristors, bipolar transistors, MOSFETS and IGBTs. The
following schematic shows an inverter that utilizes IGBTs. The
control logic uses a microprocessor to switch the IGBTs on and
off providing a variable voltage and frequency to the motor.

56
IGBTs IGBTs (insulated gate bipolar transistors) provide the high
switching speed necessary for PWM inverter operation. IGBTs
are capable of switching on and off several thousand times a
second. An IGBT can turn on in less than 400 nanoseconds and
off in approximately 500 nanoseconds. An IGBT consists of a
gate, collector and an emitter. When the control circuit applies a
positive voltage (typically +15 VDC) to the gate the IGBT will
turn on. This is similar to closing a switch. Current will flow
between the collector and emitter. An IGBT is turned off by
removing the positive voltage from the gate. During the off state
the IGBT gate voltage is normally held at a small negative
voltage (-15 VDC) to prevent the device from turning on.

Developing PWM There are several PWM techniques. It is beyond the scope of
Waveforms this book to describe them all in detail. The following text and
illustrations describe one method. An IGBT can be switched on,
connecting the motor to the positive value of DC voltage (650
VDC from the converter). Current flows in the motor. The IGBT
is switched on for a short period of time, allowing only a small
amount of current to build up in the motor, and then switched
off. The IGBT is switched on and left on for progressively longer
periods of time, allowing current to build up to higher levels
until current in the motor reaches a peak. The IGBT is then
switched on for progressively shorter periods of time,
decreasing current build up in the motor.

57
 The negative half of the sine wave is generated by switching an
IGBT connected to the negative value of the converted DC
voltage.

The voltage and frequency are controlled electronically by

circuitry within the AC drive. The fixed DC voltage (650 VDC) is
modulated, or clipped, with this method to provide a variable
voltage and frequency. At low output frequencies a low output
voltage is required. The switching devices are turned on for
shorter periods of time. Voltage and current build up in the
motor is low. At high output frequencies a high voltage is
required. The switching devices are turned on for longer periods
of time. Voltage and current build up in the motor increases.

58
Regeneration and Braking In the speed-torque chart there are four quadrants according to
direction of rotation and direction of torque. Quadrant I is
forward motoring or driving (CW). Quadrant III is reverse
motoring or driving (CCW). Reverse motoring is achieved by
reversing the direction of the rotating magnetic field.

The dynamics of certain loads, such as those associated with

many motion control applications, require four-quadrant
operation. Torque will always act to cause the rotor to run
towards synchronous speed. If the synchronous speed is
suddenly reduced, negative torque is developed in the motor.
This could occur, for example when a stop command is initiated
and the drive tries to slow down to bring the motor to a stop.
The motor acts like a generator by converting mechanical power
from the shaft into electrical power which is returned to the AC
Drive. This is known as regeneration, and helps slow the motor.
A similar process occurs when coasting downhill in a car. The
car’s engine will act as a brake. Braking occurs in quadrants II
and IV.

One method of dealing with negative torque and the current it

produces is controlled deceleration. Voltage and frequency is
reduced gradually until the motor is at stop. This would be
similar to slowly removing your foot from the accelerator of a
car. Many applications, however, require the motor to stop
quicker, and the drive must be capable of handling the excess
energy produced by motor when this is done.

59
Braking Resistors Electrical energy returned to the drive from the motor during
regeneration can cause the DC link voltage to become
excessively high. Braking resistors are one method used to
control regeneration during a rapid deceleration. A braking
resistor is placed across the DC link, through an IGBT. Energy
returned by the motor is seen on the DC link. When the DC link
reaches a predetermined limit the control logic switches on the
IGBT, completing the path from the negative to the positive DC
link through the IGBT and resistor. Excess energy is dissipated
by the resistor, reducing bus voltage. When DC link voltage is
reduced to a safe level the IGBT is switched off, removing the
resistor from the DC link. This process allows the motor to act
as a brake, slowing the connected load quickly.

60
Rectifier Regenerative Another method of dealing with excessive regeneration is with
Front End a rectifier regenerative front end. Diodes in the converter
section are replaced with SCRs and a second regen bridge is
added. An SCR functions similarily to a dode rectifier, except
that it has a gate lead, which is used to turn the SCR on. This
allows the control logic to control when the converter bridge
and regen bridge are turned on.

A simplified block diagram provides a clearer view of the regen

process. When the servomotor needs motoring energy to
accelerate or maintain speed against the inertia of a load, the
converter bridge is turned on. When the motor is in the
regenerative mode, it acts like a generator, supplying electrical
energy back to the DC link. When the DC link voltage reaches a
predetermined level the motoring SCRs are switched off and
the regen (generating) SCRs are switched on. This allows the
excess energy to be returned to the AC line in the form of AC
current.

61
ACTIVE FRONT END An ACTIVE FRONT END (AFE) is another option available to
control regenerative voltage. With this option the diodes in the
converter bridge are replaced with IGBT modules and a Clean
Power Filter. The IGBT, controlled by control logic, operates in
both motoring and regenerating modes. In addition, AFE
provides low stressing of the line supply. Harmonics are
extremely low and the power returned is in the form of
sinusoidal current.

Review 5
1. The Rod 431 rotary pulse encoder can only be used
with ____________ servomotors.

2. The EQN 1325 absolute-value encoder can count up to

____________ revolutions.

3. Braking occurs in quadrants ____________ and

____________ .

4. ____________ ____________ ____________ is one type

of regenerative braking that uses IGBTs in the converter
section.

62
Siemens MASTERDRIVE MC Family

Siemens offers a broad range of AC drives, including the

MICROMASTER, MIDIMASTER, and MASTERDRIVE families.
The MASTERDRIVE family is further divided into vector control
(VC) and motion control (MC). This section will focus on the
MASTERDRIVE MC. These drives are specially designed for
servo drive application. Drives are available from 0.55 kW to
200 kW (0.75 HP to 270 HP). Selection and ordering
information, as well as engineering information and dimension
drawings, can be found in Part 1 of the General Motion Control
Catalog, available from your local Siemens sales representative.

The MASTERDRIVE MC family consists of Compact PLUS,

Compact, and Chassis units.

MC Drive kW HP
Compact PLUS 0.55 - 18.5 0.75 - 25
Compact 2.2 - 37 3 - 50
Chassis 45 - 200 60 - 270

63
 MASTERDRIVE MC Compact PLUS

Power Connections The following drawing is a layout illustration of a 4 kW Compact

PLUS drive. X9, X100, X101, and X103 are control terminals for
user wiring. The main power supply (380 - 480 VAC) is
connected to X1. A feature of the drive is the X3 DC bus link
which allows for quick connection of one unit to another in
multi-drive configurations. Terminals are provided on X6 for
braking resistors and a precharge module. Programming is done
with the PMU keypad. The servomotor is connected to X2.
Three slots (slot A, B, and C) are provided for option boards.

Programming and Acces is gained to the MASTERDRIVE MC for programming

Operating Sources operating parameters and motion profiles from the following
sources:

Operator Control Panel (OP1S)

Parameterization Unit (PMU)
Various Serial Interfaces
PC Based Software (Simovis)

64
PMU and OP1S Parameters, such as ramp times, minimum and maximum
frequencies, and modes of operation are easily set. The
changeover key (“P”) toggles the display between a parameter
number and the value of the parameter. The up and down
pushbuttons scroll through parameters and are used to select a
parameter value, once the “P” key sets the parameter. The
OP1S has a numbered key pad for direct entry. In the event of a
failure the inverter switches off and a fault code appears in the
display. In addition the drive can be started, stopped, and
reversed. The OP1S stores up to eight parameter sets.

Control Terminals The following schematic illustrates the control wiring of one
control board available for the Compact PLUS. The control unit
(CU) is the “brains” of the drive. The control unit controls all
drive functions such as start, stop, acceleration, deceleration,
motor voltage and frequency, monitoring, and other functions.

65
24 Volt Power Supply When the DC link is charged control voltage is supplied by an
internal source. In addition, a 24 volt power supply can be
connected to the drive. This enables parameterization and
monitoring of the unit even when the DC link voltage has been
discharged. The 24 VDC can be cascaded on AC - AC units via
terminals 33 and 34 of X100. X100 also provides a connection
to cascade a serial USS interface (RS485). Switch S1 is used to
turn the USS interface on and off.

X101 Control Terminal There are four bidirectional digital inputs and outputs. These can
be programmed for various functions. Outputs, for example, can
be programmed to signal a run or stop condition. Inputs can be
programmed as start/stop commands. There are two additional
digital inputs, which can be used for high speed inputs with a
sampling time of 1 µs. There is one analog input and one analog
output.

X103 Terminal An OP1S, PC, or other device can be connected to X103 serial
port. An internal link to the USS RS485 interface makes it
possible to communicate with other devices which are
connected to the serial USS interface.

SAFE OFF SAFE OFF is a function that prevents unintended movement or

restarting of a drive after shutdown. This function is available as
an option in Compact PLUS drives.

66
Rectifier Unit The rectifier unit can be used with one or more inverters.
Rectifier units are available in 41, 120, and 230 amps. Main
power is connected to X1. Rectified DC voltage (510 - 650 VDC)
is supplied to connected inverters through X3. There are some
advantages to using one Compact PLUS rectifier unit to supply
multiple inverters:

• One drive in braking mode can regenerate energy via the

DC link (X3) to supply energy to drives in motoring mode.

• Built-in braking chopper requiring only a resistor for excess

regeneration.

• Less input line components. For example, main line to

rectifier as opposed to individual breakers and line
rectifiers to each unit

Option Boards Up to three option boards can be installed in the Compact PLUS
unit. The encoder board for the servomotor (closed-loop motion
control) must be plugged into slot C. An additional encoder
board for the controlled machine can be plugged into one of the
other slots.
Slot
Option Boards
A B C
Encoder Boards
SBP
SBR NP NP
SBM
Communication Boards
CBP
CBC
SIMOLINK Board
SLB
Expansion Boards
EB1
EB2
Pref erred Slot
Possible Slot
Not Possible NP

67
Encoder Boards The encoder board selected would depend on the encoder or
resolver used with the servomotor or controlled machine. A
maximum of two encoder boards can be used with the
Compact PLUS.

SBP The SBP is used to connect pulse encoders to the

drive. The SBP can also be used to monitor an external
encoder, such as might be connected to the driven
machine.

SBR1 All normally available 2, 4, and 6-pole resolvers can be

connected to this option board.

SBR2 This encoder board is also used to connect a resolver.

In addition, this board provides pulse-encoder
simulation. This simply means that the SBR2
generates 1024 pulses per resolver pole-pair.

SBM The SBM is used for sine/cosine encoders as well as

absolute value encoders.

Communication Boards There are a number of communication boards available for use
with the MASTERDRIVE MC. The CBP board is used to connect
the drive over the open field bus, PROFIBUS-DP. This protocol
gives the MASTERDRIVE MC connection to all of Siemens
automation products for a totally integrated solution. A
maximum of two communication boards can be used.

SIMOLINK Board The SLB board is used for peer-to-peer communication with
other drives via SIMOLINK. SIMOLINK is a high speed
(11 mbaud) fiber optic ring bus that allows various data to be
passed from one drive to the next. When used with
MASTERDRIVE MC, SIMOLINK provides the media for
synchronizing all MC drives on the ring. An application example
of synchronized MASTERDRIVE MC drives used to control
offset printing can be found in the Applications section of this
book.

68
Expansion Boards Expansion boards are used to expand the number of digital and
analog inputs and outputs. The EB1 board has three digital
inputs and four bidirectional digital I/O. Bidirectional I/O can be
configured as a digital input or output. One of the analog inputs
is used as a voltage or current reference input. Two of the analog
inputs can also be configured as digital inputs.

The EB2 board has two digital inputs, one analog input, and
one analog output. In addition, the EB2 has four relay contacts.
Three of the contacts are normally open (NO) and one of the
contacts can be configured as normally open (NO) or normally
closed (NC).

I/O EB1 EB2

Digital Inputs 3 2
Bidirectional 4 0
Digital I/O
Analog Inputs 3 1
Analog Outputs 2 1
Relay Outputs 0 4
Input for 24 V 1 1
Power Supply

AC - AC (Converter) The terms AC - AC and DC - AC refers to methods of

configuring drives. AC - AC in the MASTERDRIVE MC family
refers to a single drive, connected to an AC source, controlling
an AC servomotor with an encoder or resolver.

69
AC - AC Example The following example shows the concept of an AC - AC
configuration. Three-phase power is applied to the drive through
the main circuit breaker. A line contactor (Q1) connects/
disconnects the system to/from the power supply. The line
contactor is controlled by an on/off switch connected to a 230
VAC power supply. The 24 volt power supply, connected to X9,
is required for maintaining communication and diagnostics
when the supply voltage (380 - 480 VAC) is removed. An output
contactor can be used to connect/disconnect the servomotor
from the drive at U2, V2, and W2. Digital inputs/outputs are
configured on X101. An OP1S operator panel can be connected
to X103. As an option, a capacitor module or brake resistor can
be added to absorb short-time energy peaks. A line filter can be
included to further reduce RFI if local codes require.

70
DC - AC (Inverter) The MASTERDRIVE MC can also be configured so that one unit
acts as a common DC bus (rectifier) for two or more AC
inverters. In the following illustration, for example, one DC unit
(rectifier) supplies DC power to two DC - AC units (inverters)
through connector X3. The combined total output of the
inverters must not be greater than the DC power supplied by
the rectifier unit. This is referred to as a common bus
arrangement. Multi-axis control is one situation where a
common bus arrangement would be used. This configuration
allows for multiple axes to be connected to the same DC bus for
sharing energy.

71
Common Bus Example The following drawing illustrates a multi-axis, common bus
Using Compact PLUS setup. A single AC - AC can be used to further supply the DC
bus and 24 VDC control power of up to two additional DC - AC
(inverter) units. This is due to an oversized input rectifier bridge
and internal power supply in the AC - AC unit. Multi-axis
systems can be implemented in a compact and efficient
manner. If one axis is braked, the braking energy is fed back into
the DC link and made available to the other connected motors.
Excess energy can further be reduced by means of an external
braking resistor. In this example the “SAFE OFF” and capacitor
module options have been added.

72
 MASTERDRIVE MC Compact and Chassis

The MASTERDRIVE MC compact and chassis drives have the

same features as the Compact PLUS. Drives are available as
AC - AC and DC - AC. These drives can be configured for multi-
axis control. Compact and chassis drives can be programmed
and operated from the Operator Control Panel (OP1S),
Parameterization Unit (PMU), and various serial interfaces.

Compact Drive The compact drive is available in four frame or enclosure sizes.
The following drawing is a layout illustration of enclosure sizes
A, B, and C. A larger enclosure is available for size D. The main
power supply (380 - 480 VAC) is connected to X1. The DC link is
available at X3. The servomotor is connected to X2.

73
Chassis Drive The chassis drive uses an open architecture for cabinet
mounting. The following drawing illustrates enclosure sizes E
and F. A similar larger enclosure is available for size G.

Electronics Box The compact and chassis units have an electronics box for
control and option boards. There are up to six slots available for
mounting option boards in the electronics box. The slots are
designated with the letters A to G. Slot B does not exist in the
compact and chassis units. An LBA (Local Bus Adapter) is
required if mounting positions 2 or 3 are needed. In addition,
adapter boards (ADB) are necessary for Slots D and E, and F and
G when utilizing the half-size option boards.

74
CUMC Control Board The compact and chassis motion control drive uses the same
main control board (CUMC). The CUMC board is located in the
electronics box. Control wiring is the same for both drives.

X101 X101 is similar to the Compact PLUS. There are four

bidirectional digital inputs and outputs. These can be
programmed for various functions. Outputs, for example, can be
programmed to signal a run or stop condition. Inputs can be
programmed as start/stop commands. There are two additional
digital inputs, one analog input, and one analog output.

X103 X103 is two USS RS485 serial interfaces, which make it

possible to communicate with other connected serial devices.

X300 An OP1S or PC can be connected to X300 for programming.

75
Option Boards Up to six boards can be installed in the electronics box of the
compact and chassis units. The encoder board for closed-loop
control must be plugged into slot C. An additional encoder
board for the machine encoder can be plugged into one of the
other slots. A maximum of two expansion boards, two
communication boards, and two encoder boards can be used.

Mounting Position
1 Maximum No. of
CUMC 3 2 Components in
Option Boards
CUR Electronics Box
Slots
A C F G D E
Encoder Boards
SBP
SBR NP NP NP NP NP
SBM
Communication Boards*
CBP NP NP
SIMOLINK Board
SLB
Expansion Boards**
EB1
EB2

Pref erred Slot * Use Slot G w ith T100/T300

Possible Slot **Use Slot A or C w ith T100/T300
Not Possible NP

76
Review 6
1. The maximum kW available in a Compact unit is
____________ kW.

2. The main power supply of a Compact PLUS is

connected to ____________ .

3. A 24 volt power supply can be cascaded on Compact

PLUS AC - AC units from one drive to the next utilizing
connector X ____________ .

4. The preferred slot for the SBP encoder board is

____________ .

5. The ____________ board is used to communicate with

PROFIBUS-DP.

6. A single drive, that includes a rectifier and inverter in

one unit, is referred to as a ____________ .

7. An ____________ is required if mounting positions 2 or

3 are needed in the electronics box of a Compact or
Chassis unit.

77
 Technology Options

Technology software is an option available with the

MASTERDRIVE MC. Technology software can be divided into
three main categories:

• General Technology Functions

General technology functions include linear axis, rotary

axis, and roll feeding.

• Positioning

Positioning includes point-to-point positioning or automatic

positioning which combines muliple point-to-point moves.

• Synchronous Operation

Synchronous operation involves the synchronizing of two

or more axes via electronics. Synchronous operation
includes electronic gears, cams, clutches, and so on.

78
Basic Function Software Some technology functions are readily available and can be
implemented at any time. These include cam control and brake
control.

Cam Controller A cam controller switches digital outputs on and off. With this
function external switching elements, such as pneumatic
valves, may be operated at defined points. Two cam controllers
are available with the basic technology software. Each controller
has two positioning cams, making a total of four cams whose
switch-on and switch-off positions can be set independently of
each other. Digital outputs from the MASTERDRIVE MC signal
the on/off position to the controlled equipment.

Brake Control Applying and releasing a brake can be effected by means of

external commands. However, with the brake control function
built into the MASTERDRIVE MC braking can be fully
automated without intervention by an external machine control
unit.

There are three ways to operate a brake:

• Relay Output on the EB1 Expansion Board

• Digital Output from the MASTERDRIVE MC to an External

Relay

• The Relay for Operating the Main Contactor in the Chassis

and Compact Unit, when the Main Contactor is not used

79
Technology Software F01 The following position and synchronizing functions are software
options that can be purchased with the MASTERDRIVE MC, or
ordered and enabled at a later date. They are part of the
technology option software (F01) package.

Linear Axis Function The linear axis function is designed to traverse an object along a
specified range with fixed stops. A traversing car is an example
of a linear axis.

Rotary Axis Function A turntable is an example of a rotary axis. The rotary axis
function is designed to move an object the shortest distance
around a 360° path. Depending on where an object is, and
where it must be moved to, the servomotor will turn the table
either clockwise or counter clockwise.

Roll Feed This function works with a permanently rotating rotary axis and
incorporates a cut-to-length function. A roll feeding into a cutting
machine is one example.

80
Positioning The MASTERDRIVE MC drive has a positioning control system
capable of executing a variety of positioning tasks such as:

• Setup - Manually jogging an axis into position with

acceleration and speed determined by preset parameters

• Homing - Moving the axis to a predefined zero position

with acceleration and speed determined by preset
parameters

• Point-to-Point Positioning using Manula Data Input (MDI) -

Moving the axis to either an absolute or relative position at
a given speed and acceleration

• Roll Feed - Automatic cut-to-length feature useful for

presses, punching machines, and cross-cutters

• Automatic Mode - Automatic execution of complete

positioning programs

Although the MASTERDRIVE MC may be operated in multiple

modes in a given application, understanding a basic application
that involves automatic mode and homing would be beneficial
at this point. Since velocity versus time profiles are commonly
used to describe positioning applications, a simple example is
provided along with the explanation.

A velocity versus time profile provides a graphical

representation of the velocity of an axis at any point in time.
Velocity includes speed and direction. Speed in one direction is
considered to be positive velocity and speed in the opposite
direction is considered to be negative velocity. Positive velocity
is graphed above the time axis and negative velocity is graphed
below the time axis.

81
 In the following example the MASTERDRIVE MC controls the
vertical movement of a drill. The drill will penetrate a composite
material that has been moved into position.

The drilling sequence is:

Point A to B - From the home position, the drive is started and

accelerated to full speed. As the drill approached the workpiece
it decelerates to 190 millimeters per second (mm/s).

Point B to C - The drill penetrates the hard top layer.

Point C to D - The drill is accelerated to 1000 mm/s to drill

through the soft middle layer.

Point D to E - The drill is decelerated to drill through the hard

bottom layer, then slows to zero at point E.

Point E to F - The drill is accelerated to -1500 mm/s (negative

velocity) while it is raised out of the workpiece and returned to
the home position at point F.

82
Electronic Cam The following illustration is representative of two sample
electronic cam profiles available in the MASTERDRIVE MC.
Electronic cam profiles are used to replace mechanical cams,
and follow a specific cam pattern. The examples illustrate a
linear axis coordinated with a rotary axis. Both axes are
positioned at a known reference position to run the cam profile.
In this example the rotary axis is designated the master and the
linear axis is the slave. The slave axis (linear slider) will track the
master (black line on rotating cam). With the MASTERDRIVE
MC, unlike a mechanical cam, the profile can be changed easily,
almost “on the fly”. For example, sample profile 2 can replace
sample profile 1.

Each angular position on the cam is assigned a position on the

slider, creating a cam table like the following example.
Mathematical interpolation is used to control the move
between the points on the table. In sample profile 1, for
example, when the marker on the cam is 340° from the known
cam reference position, the slider marker is 20 mm from the
known slider reference position.

Master Slave
360°/0° 0 mm
10° 20 mm
20° 40 mm
30° 50 mm
40° 60 mm
50° 70 mm
60° 80 mm
70° 90 mm
80° 105 mm
--- ---
--- ---
340° 20 mm
350° 10 mm

83
Electronic Gear Box The electronic gear box function can be used to replace a
mechanical gear box on a machine. In the following illustration
two axes are used to control the speed of two carousels. One
carousel is the master and one is the slave. In this example
empty paint cans are loaded onto the master carousel where a
filling process is carried out. The cans are then transferred to the
slave carousel where lids are applied.

In many applications such as this there must be a difference in

speed between the two processes. It may take longer, for
example, to fill the can than to apply the lid. With the electronic
gear box function an electronic speed ratio exits between the
two carousels. Increasing the speed of the slave carousel, for
example, will decrease the ratio. The ratio can be set anywhere
from ±32,767:32,767, allowing for precise gear ratio
adjustments. It should also be noted that the speed of the entire
process can be changed while maintaining a desired ratio. For
example, once the process is running it may be desirable to
increase the process speed which will increase the production.

84
Electronic Clutch The electronic clutch function allows an axis to be engaged or
Engage/Disengage disengaged without losing position synchronization. This is
particularly important when several parts of a complex machine
are dependent on each other. In the following illustration, for
example, one axis controls an ejector. If a defective product is
detected the ejector is engaged for one cycle while the ejector
removes the defective product. A second axis disengages
(stops) the carousel for one cycle. At the end of the cycle the
ejector is disengaged and the carousel engaged.

If a missing object is detected on the infeed the electronic

clutch disengages the slave axis for one cycle to allow the next
object in line to be loaded into the slave axis. The clutch is then
engaged and the process is switched back to synchronous
mode operation.

85
Print Mark Registration Print mark registration is used to compensate for creep, stretch,
and thermal expansion of a printing operation. Registration
marks are sensed within 1 µs, allowing for appropriate
compensation at each print roll and at the cutter. The slave’s
position is evaluated relative to the registration mark. The
motion control drives correct for any deviation. Without this
correction creep, accumulates with every revolution. This creep
would cause printing and cutting to be unsynchronized.

86
 Cables

Power and encoder/resolver cables can be ordered by the meter

or are available prefabricated with appropriate plugs and
connectors.

Power and encoder (feedback) cables have a maximum

allowable length. Typically feedback cable length can be greater
than power cable length (approximately 492 ft or 150 m). The
following tables show the maximum power cable lengths.

Compact PLUS Output Unscreened Screened

0.55 kW
Converters 328 ft (100 m) 229 ft (70 m)
0.75 kW Inverters
1.1 kW - 18.5 kW 426 ft (130 m) 328 ft (100 m)

Compact and Chassis Output Unscreened Screened

up to 4 kW 164 ft (50 m) 114 ft (35 m)
5.5 kW 229 ft (70 m) 164 ft (50 m)
7.5 kW 328 ft (100 m) 219 ft (67 m)
11 kW 360 ft (110 m) 246 ft (75 m)
15 kW 410 ft (125 m) 278 ft (85 m)
18.5 kW 442 ft (135 m) 295 ft (90 m)
22 kW - 200 kW 492 ft (150 m) 328 ft (100 m)

87
 Applications

There are any number of applications where motion control can

be utilized. The features and functions of the MASTERDRIVE
MC product line provides appropriate solutions for these
application requirements. Choosing the right components can
be confusing and takes careful thought and planning. As you
have seen throughout this book there are a number of
servomotors, encoders, drives, and technology options to chose
from. The following application examples, along with the
selection flow chart in the next section, will help you in the
planning process. There are, of course, many applications other
than the ones illustrated in this section appropriate for the
MASTERDRIVE MC.

88
Offset Printing Offset printing traditionally uses a mechanical line shaft to
synchronize the different color print stations. The mechanical
devices involved require high maintenace, and the system is
limited in speed.

The mechanical line shaft system can be replaced with

individual servomotors which are precisely synchronized
through the MASTERDRIVE MC and SIMOLINK.
Communication to higher level controls, such as a SIMATIC S7
PLC, for evaluation of system status and drive setpoint signals,
is accomplished with PROFIBUS-DP.

Application Web Handling with Synchronization

Requirement
MASTERDRIVE MC Synchronization: Virtual Master, Real Master,
Feature Gear Box (Electronic Line Shaft)
MASTERDRIVE MC Increased Accuracy and Production Print Speed.
Solution/Benefit Flexibility to Add and Remove Print Stations
with Minimum Downtime.

89
Bottle Filling Some bottle filling applications, such as cosmetics, require the
distance between the filling pipe and the liquid level in the
bottle to be kept constant. In addition, the filling pump must
maintain a constant flow. These two axes can be precisely
synchronized with the MASTERDRIVE MC.

In this application, the pump drive acts as the master and the
filling gantry acts as the slave. As the pump provides a constant
flow of product, the filling gantry movement is synchronized,
through a cam profile that corresponds to the bottle contour.
This maintains a constant filling pipe to liquid distance.

Application 2-Axis Synchronized Control

Requirement
MASTERDRIVE MC Synchronization with Cam Profiling
Feature
MASTERDRIVE MC Quick Cam Profile Change to Accommodate
Solution/Benefit Bottle Contour Change. Increased Production for
Multi-Product Line Runs.

90
Horizontal Bagging This application involves a continuous roll of foil for horizontal
bagging. The sealing station handles the foil transport.
Electronic line shaft and print mark registration ensure the foil is
synchronized with the products being packaged. Electronic line
shafting also ensures the product feeder belt and the foil are in
continuous position synchronization. Print mark registration will
accelerate or decelerate the foil to make up for possible stretch.
This ensures that printed labels on the foil will be correctly
positioned on the package.

The transverse sealing station must travel with the line in order
to achieve continuous packaging. This is accomplished with the
MASTERDRIVE MC’s electronic line shaft and electronic cam
functions. The sealing station is accelerted with the electronic
line shaft function to the speed of the product (x-axis). The
electronic cam function closes the sealing jaws (y-axis) while
the sealer moves across and simultaneously seals the package.

Application Continous Positioning and Synchronization.

Requirement Continuous Packaging
MASTERDRIVE MC Print Mark Registration
Feature Synchronization: Electronic Line Shaft Control
Including Cam Profile

MASTERDRIVE MC Continous Adjustment to Compensate for Foil

Solution/Benefit Stretch. Multi-Axis Coordination for Sealing and
Bagging Sections.

91
Composite Drilling Positioning the x- and y-axis to locate the drilling tool can be
accomplished with the manual data input (MDI) mode. Once the
drilling tool has reached the desired location, the automatic
function takes over and controls the movement of the z-axis.
The following instruction set is an example of a drilling profile.

• Moving from A to B the drilling gantry rapidly traverses to

just in front of the board and starts to reduce the feed
velocity.
• At point B the drill reaches the reduced feed velocity to
drill through a plastic laminate.
• Moving from B to C the drill slows to drill through the
laminate.
• Moving from C to D the drill increases to normal velocity to
drill through core.
• Moving from D to E the drill reduces velocity to drill
through bottom laminate.
• Moving from E to F the drill returns with increased velocity.

Application Requirement 3-Axis Positioning (Composite Drilling).

MASTERDRIVE MC MDI Point-to-Point Positioning. Automatic Mode
Feature Positioning.
MASTERDRIVE MC High Accuracy Drill Bit Placement and Optimized
Solution/Benefit Drilling Speed to Improve Quality of Cut and Tool
Life.

92
Cut to Length In Cut to Length applications, the purpose is to cut material to a
Rotary Knife/Sheater precise length. For a fixed cut length, and a knife circumference
of the same length, it is simply a matter of maintaining a
constant speed between the web and the knife. However, for
products that require various cut lengths, the knife’s
circumference would have to vary to match these new cut
lengths. Since this would not be practical, the knife speed is
often profiled. By varying the knife speed various cut lengths
can be obtained. Furthermore, the rotary knife is accelerated so
that as the cutting edge comes into contact with the material it
is traveling at the same velocity. This is done to avoid “ripping”
the material.

To accomplish this task a Cam profile is often employed.

Using the technology features of the MASTERDRIVES MC, a
number of cam profiles can be created to perform the needed
contoured movement that is synchronized with the material to
perform the cut.

Application Variable Speed and Product Cut Lengths.

Requirement
MASTERDRIVE MC Synchronization with Cam Profiling
Feature
MASTERDRIVE MC Short Current Rise Time allows for High
Solution/Benefit Dynamic Response. Multiple Cam Profiles
Allow for Quick Changeover to Various Product
Lengths.

93
Pick and Place Pick and Place applications involve the precise movement of
product from one location to another. Using the Point-to-Point
positioning features (MDI mode) of the MASTERDRIVES MC,
this precise movement can be realized. Typically the gripper
claw is “homed” to the starting location during initialization of
the system. From that point, as product is sensed, the gripper
closes on it and the Point-to-Point move is made. Once the final
destination point is reached the gripper releases the product
and the return move to home position is carried out. SIMOLINK
is the perfect choice to coordinate these actions. It allows for
easily sending all of the appropriate status and control signals
from one axis drive to the next.

Application Pick and Place Positioning

Requirement
MASTERDRIVE MC MDI Point-to-Point Positioning
Feature
MASTERDRIVE MC High Accuracy Organization and Location of
Solution/Benefit Product Packaging

94
Selection

The following flow diagram, along with Part 1 and Part 2 of the
General Motion Control Catalog, will help you select the right
equipment for your motion control system.

95
96
 SIMODRIVE

In addition to the MASTERDRIVE MC, Siemens offers additional

general motion control products. Two examples from the
SIMODRIVE family of servodrives are described in the following
paragraphs.

POSMO A The SIMODRIVE POSMO A is an integrated motion control

system. POSMO consists of a motion control drive, servomotor,
gearbox, and incremental position transducer in one unit.
POSMO can be integrated into any PROFIBUS-DP environment.
Its only requirement is 24 VDC and PROFIBUS for programming
and control. The unit can even act as a stand alone unit by
programming it over PROFIBUS and utilizing two digital inputs
to perform various position moves.

POSMO Data Degree of Protection IP54

Voltage 24 VDC ±20%
Power 62 W
Gear Drive 4.5:1 to 162:1

97
SIMODRIVE 611 Universal The SIMODRIVE 611 Universal is a closed-loop control plug-in
unit. The 611 Universal is made up of an infeed module and
a power module. The infeed module contains a complete
electronics power supply and is used to convert the incoming
AC line (400 to 480 VAC) to DC. The power module houses the
611 Universal and provides the output to the servomotor. The
611 Universal will support 1 or 2 axis. Like the POSMO,
the SIMODRIVE 611 Universal can be integrated into
any PROFIBUS -DP environment. This drive is rated from 3 - 250
amps. It is designed for positioning tasks and can operate both
sinewave servomotors and linear motors.

Review 7
1. Which of the following is not part of the basic function
software?

a. Cam controller
b. Brake control
c. Electronic Clutch

2. The gear ratio of the electronic gear box function can be

set anywhere from ± ____________ .

3. Registration marks are sensed within ____________ µs

with the print mark registration function.

4. The maximum screened cable length of a 5.5 kW

Compact unit is ____________ ft.

5. When selecting a motion control system the speed and

____________ load cycles must be known.

98
 Review Answers

Review 1 1) MASTERDRIVE; 2) linear, rotational; 3) h.

Review 2 1) force; 2) 5 N; 3) torque; 4) 6; 5) inertia; 6) 1:1; 7) Work;

8) torque, power; 9) SimoSize.

Review 3 1) synchronous, asynchronous; 2) 120; 3) synchronous; 4) slip;

5) b; 6) 105; 7) 64.

Review 4 1) S1; 2) 10; 3) continuous, intermittent; 4) 81; 5) asynchronous.

Review 5 1) asynchronous; 2) 4096; 3) II, IV; 4) ACTIVE FRONT END

Review 6 1) 37; 2) X1; 3) 100; 4) C; 5) CBP; 6) converter; 7) LBA.

Review 7 1) C; 2) 32,767:32,767; 3) 1; 4) 164; 5) torque

99
 Final Exam

The final exam is intended to be a learning tool. The book may

be used during the exam. A tear-out answer sheet is provided.
After completing the test, mail the answer sheet in for grading.
A grade of 70% or better is passing. Upon successful
completion of the test a certificate will be issued.

Questions 1. ____________ is a twisting or turning force that causes

an object to rotate.

a. Torque c. Inertia
b. Friction d. Acceleration

2. Ideally it is desirable to have a ____________ ratio

between the load and the motor.

a. 1:2 c. 2:1
b. 1:1 d. 2:2

3. The torque required to accelerate a system with a total

inertia of 0.010 kgm2 from rest to 2500 RPM in 0.1
seconds is ____________ Nm.

a. 7.85 c. 26.17
b. 13.08 d. 32.56

4. ____________ is a Siemens PC program designed to

accelerate the process of calculating speed, torque,
and inertia of a motion control system.

a. SIMOLINK c. SimoSize
b. PROFIBUS-DP d. POSMO

5. The maximum temperature rise of a motor with Class

F insulation, not including the margin for a hot spot,
is ____________ K.

a. 80 c. 130
b. 125 d. 105

100
6. A motor with an enclosure that protects against dust
and water jets would be classified as
IP ____________ .

a. 23 c. 68
b. 55 d. 65

7. ____________ is a duty cycle which operates for an

intermittent period without starting between cycles.

a. S1 c. S2
b. S3 d. S4

8. Winding version ____________ is rated for 6000 RPM.

a. A c. F
b. G d. K

9. The range of rated torque of a 1PH7 motor is

____________ Nm.

a. 22 - 1145 c. 370 - 1720

b. 0.8 - 16.5 d. 34 - 78

10. The ____________ encoder has 8192 coded positions

and uses a mechanical gear sequence to count up to
4096 revolutions.

a. Rod 431
b. ERN 1381
c. ERN 1387
d. EQN 1325

11. ____________ is a method of braking which uses

IGBTs in the converter section and provides sinusoidal
regen current back to the incoming power supply.

a. ACTIVE FRONT END

b. Rectifier Regenerative Front End
c. Pulsed Resistor Braking
d. Pulse Width Modulation

12. The maximum kW rating of a Compact PLUS dirve

is ____________ kW.

a. 15 c. 18.5
b. 22 d. 37

101
 13. The Compact PLUS has ____________ programmable
bi-directional inputs and outputs.

a. two c. four
b. three d. six

14. Up to ____________ option boards can be installed in

the Compact PLUS.

a. two c. four
b. three d. six

15. ____________ is an encoder board used for sine/

cosine encoders as well as absolute value encoders.

a. SPB c. SBR1
d. SBR2 d. SBM

16. ____________ refers to a system in which one rectifier

supplys DC power to multiple AC inverters.

a. Multi-Axis c. PROFIBUS-DP
b. SIMOLINK d. Common Bus

17. ____________ is the preferred slot for an encoder board

in the Compact PLUS, Compact, and Chassis drives.

a. A c. C
b. B d. D

18. The Cam controller is part of the ____________ .

a. basic function software

b. rotary axis function
c. linear axis function
d. Roll feed function

19. The maximum length of a screened cable used on a

0.55 kW converter is ____________ meters.

a. 35 c. 65
b. 50 d. 70

102
20. ____________ is a type of motion control drive that has
an integrated motion control drive, servomotor, gear
box, and incremental position transducer is one unit.

a. SIMODRIVE 611 Universal

b. POSMO
c. Compact PLUS
d. PROFIBUS-DP

103
 Notes

104