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I have a Siemens SIMODrive 611 controlling the axis and spindle in my Bridgeport VMC-800. The drive controller sets a spindle fault any time a target speed increase of about 200 rpm is requested above 1000 rpm. I have tracked it down to the 600V DC Link supply being hammered by the spindle controller.
See the picture below. The machine is being powered by a phase converter with a 20hp idler.
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I have not been able to look at the incoming power at the HV power supply while triggering on the DC Link dropout. I believe I will need a true differential scope probe to effectively do that.Questions:1) Is there a parameter that can be changed that would reduce the required instantaneous current for the spindle drive? Possibly slow down the acceleration rate? After reading the manual for the drive there appears to be hundreds of parameters but I have no idea which one would help.2) If the parameters will not help, would one of the capacitor modules be enough to eliminate the error?Thanks!
A few things.1. Yes, all drives will have settings for accel/decel rates. Not sure of the exact parameters for your drive but the book will tell you easily.2. What is the HP of the drive and driven motor?3. Can you be certain you do not have other power issues? Ie, incoming power is well balanced? Stays decent during load?
Typically an RPC looks nice and balanced right until you load it, then things go whacky and one leg might be dropping way down.4. Are you sure all caps and diode packs are ok in the drive? Most are smart about this and will detect it but remember all legs just feed the common DC buss and charge a big pack of caps.
Obviously you may have ripple and/or diode faults if this an issue though.Need to find the accel settings and see what the value is. If it is trying to ramp too hot, that can be an issue but usually the slip just increases, not a big drop in DC buss V. Is that 108V of delta on the buss? You may not need a scope to check incoming power, just a good/fast meter and watch. Typically the OEM likes power at +/- 10% and you are seeing nearly 20% on the DC buss so you might have one leg dropping WAY down during accel which will fault every time as a leg loss. This is to prevent the other diodes from blowing from too much comp current.
I had this issue with my VMC 760 - there are parameters in the spindle drive you can adjust to increase the spindle acceleration time and this will likely fix your issue. Mine runs off a 15 HP RPC without problems. Mine ramps in about 7 seconds to max speed (6000 rpm) and I do wish it was faster but realistically, it's not a big deal.If you PM me your email I can send you a PDF which explains the process in (slightly) more detail, but basically on the spindle drive change parameter 51 to 4H to enable editing of parameters; the PDF says parameter 16 is ramp up time in seconds, so adjust this. Test the settings and when you have it working, write the settings to EEPROM by changing parameter 52 to 1H, it'll change back to 0H in 5 seconds after writing is complete.I think the root cause is probably bad RPC balancing but this is a decent remedy.Hope this helps! Thanks for the reply huleo!1) The problem is that the manual is like 1000 pages with hundreds of parameters.
Just a bit nervous to change anything without some level of confidence.2) The spindle is rated at 12hp constant and 15hp burst.3) No, at this point I am not sure that I do not have an input power issue. In fact, that is my best guess as to the root of the issue.
Unfortunately I have already done everything I know of to minimize that issue. The shop has 200 amp 'single' phase power with everything updated within the last two months. The RPC is new and dedicated to this machine with all phases balanced about as good as they get. BUT, I have not been able to capture the input wave forms when the fault occurs. IF it is an input power issue, I do not know what to do to make it better.
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That is why I want to try minimizing the inrush current from the spindle controller, it seems a lot easier to deal with.4) I really have no way of confirming this. But, the spindle does run fine at almost any speed(I have only tried up to 2500 rpm) but once you try to do a step increase greater than 200 rpm in the speed, the fault occurs. So I do not know if the power filter caps in the power supply are toast or if the issue is else where.There are a couple ways to look at what might be happening:1) The speed increase causes the controller to apply the max current and duty cycle to the motor to get to the target speed asap. The fault could occurs due to the inrush current causing a voltage drop on the supply.2) Or, if the slip condition existed the fault would be set because it took too long to achieve the target speed.
After seeing the scope plot on the DC bus, I am betting on the first scenario.So, any idea which parameters would be the right ones? Changing parameters is a lot easier and cheaper than trying to fix a power supply issue. Or something else to check? LIsten, I could talk at ya and Issaac until I am blue in the face about RPCs and guarantee you can run these machines at full tilt with the right tuning. No way would I accept slowing one down!I will just PM ya.Mine's in a building that doesn't have a big enough service to run at full tilt, so I never bothered balancing the RPC properly.
I think if you have the power you should fix the problem instead of masking it, though.I'm definitely interested in hearing what you have to say, though, so feel free to post it in this thread! I'll send you a PM in a sec, I think we actually spoke briefly before. I run a robotics team for the local High School and we were donated a VMC760 we're having similar issues getting over 1200 RPM with as StickShifter. We were recently (last week) donated a brand new American Rotary RPC that should be more-than-enough for our whole shop, and we're still seeing issues with higher RPMs, now I'm thinking its the acceleration of our spindle.
I moddified my post processor to basically do a manual ramp over 5 seconds and no issues at all hitting 6000RPM, but with a group of high school students running this thing I'd rather sovle the issue and be able to issues a simple S6000M03!