5.

CALCULATION METHODS FOR DESIGNING

5. CALCULATION METHODS FOR DESIGNING

5.1 Specification symbol list

The following symbols are required for selecting the proper servo.
Ta : Acceleration torque [N m] : Friction coefficient
Td : Deceleration torque [N m] : Circle ratio (3.14)
TMa : Servo motor torque necessary for [N m] Pt : Number of feedback pulses in [pulse/rev]
acceleration position control mode
TMd : Servo motor torque necessary for [N m] f : Input pulse frequency in [pps]
deceleration position control mode
TL : Load torque converted into equivalent [N m] f0 : Input pulse frequency during fast [pps]
value on servo motor shaft feed in position control mode
TLM : Load torque converted into [N m] tpsa : Acceleration time constant of [s]
equivalent value on servo pulse frequency command in
motor shaft during stop position control mode
TU : Unbalance torque [N m] tpsd : Deceleration time constant of [s]
TF : Load friction torque [N m] pulse frequency command in
TB : Brake static friction torque position control mode
TL0 : Load torque on load shaft [N m] Kp : Position control gain 1 [rad/s]
Trms : Continuous effective load torque [N m] Tp : Position control time constant (Tp 1/Kp) [s]
converted into equivalent value : Feed per feedback pulse
on servo motor shaft in position control mode [mm/pulse]
JL : Load inertia moment converted [ 10-4kg m2] 0 : Feed per command pulse
into equivalent value on servo in position control mode [mm/pulse]
motor shaft : Feed [mm]
JL0 : Load inertia moment on load shaft [ 10-4kg m2] P : Number of internal command pulses [pulse]
JM : Servo motor's rotor inertia moment ts : Internal settling time [s]
[ 10-4kg m2] t0 : Positioning time [s]
N : Servo motor speed [r/min] tc : Time at constant speed of servo [s]
N0 : Servo motor speed during fast feed [r/min] motor in 1 cycle
NL0 : Load shaft speed during fast feed [r/min] t : Stopping time in 1 cycle [s]
V : Moving part speed [mm/min] : Positioning accuracy [mm]
V0 : Moving part speed during fast feed [mm/min] : Number of droop pulses [pulse]
Pb : Ball screw lead [mm] S : Feed per servo motor revolution [mm/rev]
Z1 : Number of gear teeth on servo motor shaft W : Mass [kg]
Z2 : Number of gear teeth on load gear Lmax : Maximum coasting distance [mm]
Z2
n : Gear ratio n
Z1
Speed reduced when n 1,
Speed increased when n 1
: Drive system efficiency
g : Gravitational acceleration (9.8[m/s2])

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5. CALCULATION METHODS FOR DESIGNING

5.2 Position resolution and electronic gear setting

Position resolution (travel distance per pulse ) is determined by travel distance per servo motor revolution
S and the number of encoder feedback pulses Pt, and is represented by Equation 5.1. As the number of
feedback pulses depends on the servo motor series, Refer to "Standard specifications list" in the chapter of
each servo motor series.

S
................................................................................................................................................ (5.1)
Pt

: Travel distance per pulse [mm/pulse]

S : Travel distance per servo motor revolution [mm/rev]
Pt : Number of feedback pulses [pulse/rev]

Since has the relationship represented by Equation 5.1, its value is fixed in the control system after
the drive system and encoder have been determined. However, travel distance per command pulse can
be set as desired using the parameters.
Servo motor
Command pulse CMX Deviation
M
frequency f0 CDV counter

Electronic gear
CMX Pt 262144pulse/rev
CDV Encoder

As shown above, command pulses are multiplied by CMX/CDV set in the parameters to be position
control pulses. Travel distance per command pulse is expressed by Equation 5.2.

Pt CMX CMX
0 .......................................................................................................... (5.2)
S CDV CDV

CMX : Electronic gear (Command pulse multiplication numerator)

CDV : Electronic gear (Command pulse multiplication denominator)

Using the above relationship, travel distance per command pulse can be set to a value without fraction.

[Setting example]
Find a parameter value for 0 0.01 [mm] in a drive system where ball screw lead PB 10 [mm/pulse] and
reduction ratio 1/n 1.
The encoder feedback pulses Pt of the HF-KP 262144 [pulses/rev].
Since s 10 [mm/rev], the following is obtained according to Equation 5.2.

CMX Pt 262144 32768

0 0.01
CDV S 10 125

<Relationship between position resolution and overall accuracy>

Positioning accuracy of machine is the sum of electrical errors and mechanical errors. Normally, provisions
should be made so that positioning accuracy are not affected by electrical system errors. As a guideline,
Equation 5.3 should be satisfied.

1 to 1
5 10 D ........................................................................................................................... (5.3)

where, : Travel distance per feedback pulse [mm/pulse]

: Positioning accuracy [mm]

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5. CALCULATION METHODS FOR DESIGNING

5.3 Speed and command pulse frequency

The servo motor is run at a speed where the command pulses and feedback pulses are equivalent. Therefore,
the command pulse frequency and feedback pulse frequency are equivalent. The relation including the
parameter settings (CMX, CDV) is as indicated below (refer to the following diagram).

f0 CMX Pt N0 ....................................................................................................................... (5.4)

CDV 60

f0
: Command pulse frequency (Differential line driver)
Electronic [pps]
gear CMX : Electronic gear
f0 CMX (Commanded pulse multiplication numerator)
CDV
CDV : Electronic gear
(Commanded pulse multiplication denominator)
Feedback pulse N0 : Servo motor speed [r/min]
frequency Servo motor
Pt : Number of feedback pulses [pulses/rev]
(Pt 262144 for HF-KP)
According to Equation 5.4, the following equations may be used to obtain the electronic gear and command
pulse frequency to rotate the servo motor at N0.

Electronic gear

CMX 1
Pt N0 f0 ............................................................................................................................. (5.5)
CDV 60

Command pulse frequency

N0 CDV ............................................................................................................................. (5.6)

f0 Pt 60
CMX

[Setting example]
Obtain the command pulse frequency required to run the HF-KP at 3000r/min.
When the electronic gear ratio 1 (initial parameter value) is used, the following result is found according to
Equation 5.6.

f0262144 N0 CDV
60 CMX
(Command pulse frequency)
262144 3000 1
60
13107200[pps]

However, as the maximum input command pulse frequency in the differential line driver type is 1Mpps, for
general-purpose servo 13107200pps cannot be entered.
To run the servo motor at the speed of 3000r/min at not more than 1Mpps, the electronic gear setting must be
changed. This electronic gear is found by Equation 5.5.

CMX 1
262144 3000
CDV 60 1 10 6
(Electronic gear)
8192
625
Therefore, the parameters are set to CMX 8192 and CDV 625.

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5. CALCULATION METHODS FOR DESIGNING

5.4 Stopping characteristics

(1) Droop pulses ( )

When a pulse train command is used to run the servo motor, there is a relationship between the command
pulse frequency and servo motor speed as shown in the figure. The difference between the command
pulses and feedback pulses during acceleration are called droop pulses, which are accumulated in the
servo amplifier (drive unit) deviation counter. Equation 5.7 defines a relationship between the command
pulse frequency (f) and position control gain 1(Kp).

f0
[pulse] ......................................................................................................................................... (5.7)
Kp

Supposing that the value of position control gain 1 is 70 [rad/s], the droop pulses during operation will be as
follows at the command pulse frequency of 200 [kpps] according to Equation 5.7.

200 10 3
2858[pulse]
1
Command pulse frequency f

Command Droop pulses

Servo motor speed

Servo motor
speed

0 Time
[r/min] [pps] Tp
tpsa tpsd ts

ts 3 1
70
0.04

(2) Settling time (ts) during linear acceleration/deceleration

Since droop pulses still exist when there are no command pulses, settling time (ts) is required until the
servo motor stops. Set the operation pattern in consideration for the settling time.
The settling time (ts) value is obtained according to Equation 5.8.

ts 3 Tp

1
3 [s] ............................................................................................................................................. (5.8)
Kp

*When Kp 70 [rad/s], ts 0.04 [s]. (Refer to the above diagram.)

The settling time (ts) indicates the time required for the servo motor to stop in the necessary positioning
accuracy range. This does not always mean that the servo motor has stopped completely. Thus, especially
when the servo motor is used in high-duty operation and positioning accuracy has no margin for travel
distance per pulse ( ), the value obtained by Equation 5.8 must be increased.
The settling time (ts) will vary with the moving part conditions. Especially when the load friction torque is
large, movement may be unstable near the stopping position.

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5. CALCULATION METHODS FOR DESIGNING

5.5 Capacity selection

As a first step, confirm the load conditions and temporarily select the servo motor capacity. Then, determine
the operation pattern, calculate required torques according to the following equations, and check that the servo
motor of the initially selected capacity may be used for operation .

(1) Initial selection of servo motor capacity

After calculating the load torque (TL) and load inertia moment (JL), select a servo motor which will satisfy
the following two relationships.

Servo motor's rated torque TL

Servo motor JM JL/m
m 3 : High duty (more than 100 times/min.)
Settling time 40ms or less
m 5 : Middle duty (60 to 100 times/min.)
Settling time 100ms or less
m permissible load inertia moment : Low duty (less than 60 times/min.)
Settling time more than 100ms
Find the acceleration and deceleration torques and continuous effective load torque as described in (2) to
make a final selection. For high-duty positioning, the load inertia moment (JL) value should be as small as
possible. If positioning is infrequent as in line control, the load inertia moment (JL) value may be slightly
larger than in the above conditions.

(2) Acceleration and deceleration torques

The following equations are used to calculate the acceleration and deceleration torques in the following
operation pattern.
Servo motor speed [r/min]

Command
frequency f [pps]
Command pulse

N0f0

Servo motor
speed

0
Time
tpsa tpsd

Acceleration
Ta
torque
0
Time
Deceleration
Td
torque

(JL JM) N0 1
Acceleration torque Ta 9.55 104 tpsa ........................................................................................ (5.9)

(JL JM) N0 1
Deceleration torque Tb 9.55 104 tpsd ...................................................................................... (5.10)

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5. CALCULATION METHODS FOR DESIGNING

(3) Torques required for operation

POINT
Consider individual machine differences, and do not adjust gain too strictly. It is
recommended to keep the servo motor torque to 90 or less of the maximum
torque of the servo motor during the operation.

Torques required for the servo motor are the highest during acceleration. If the servo motor torque found
with equation 5.11 to 5.13 exceed the maximum torque, the motor will not accelerate as commands. Set
the calculated value within the servo motor's maximum torque. Since a friction load is normally applied
during deceleration, only the acceleration torque needs to be considered. In the regenerative mode, the
value found by equation 5.13 is negative. Command pulse frequency f [pps]
Servo motor speed [r/min]

Command

N0f0

Servo motor
speed

0 Time
tpsa tpsd

T1
Servo motor torque

TMa Ta
T2
TL
0 Time
TMd Td

T1 TMa Ta TL ................................................................................................................................ (5.11)

T2 TL................................................................................................................................................... (5.12)
T3 TMd Td TL ............................................................................................................................. (5.13)

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5. CALCULATION METHODS FOR DESIGNING

(4) Continuous effective load torque

If the torque required for the servo motor changes with time, the continuous effective load torque should be
lower than the rated torque of the servo motor. There may be a servo motor torque delay at the start of
acceleration or deceleration due to a delay in the control system. To simplify the calculation, however, it is
assumed that constant acceleration and deceleration torques are applied during tpsa and tpsd. The following
equation is used to calculate the continuous effective load torque in the following operation pattern. TLH
indicates the torque applied during a servo motor stop. A large torque may be applied especially during a
stop in vertical motion applications, and this must be fully taken into consideration. During vertical drive, the
unbalanced torque TU will become TLH.
Servo motor
speed

N 0
[r/min] Time
Servo motor torque

TMa Ta
TLH
TL
0
Td TMd Time
tpsa tc tpsd t
tf (1 cycle)

2 2 2 2
TMa tpsa TL tc TMd tpsd TLH t
Trms .......................................................................... (5.14)
tf

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5. CALCULATION METHODS FOR DESIGNING

5.6 Load torque equations

Typical load torque equations are indicated below.

Type Mechanism Equation
F V F S
TL .................................... (5.15)
2 10 3 N 2 10 3

FG F : Force in the axial direction of the machine in linear motion [N]

Servo motor FC
F in Equation 5.15 is obtained with Equation 5.16 when the table is
Linear
Z2 W moved, for example, as shown in the left diagram.
movement

Z1 F Fc (W g FG) ....................................................... (5.16)

Fc : Force applied in the axial direction of the moving part [N]
FG : Tightening force of the table guide surface [N]
W : Full mass of the moving part [kg]
TL0
1 1
TL TL0 TF ........................................................... (5.17)
n
Rotary
movement Z1 Z2
TF : Load friction torque converted into equivalent value on servo
Servo motor motor shaft [N m]

During rise
TL TU TF ......................................................................... (5.18)
Servo motor
During fall
2
TL TU TF ................................................................ (5.19)
TF: Friction torque of the moving part [N m]
1/n
Counter
Vertical weight
(W1 W2 ) g V (W1 W2 ) g S
TU = .......................... (5.20)
movement 2 10 3 N 2 103
Guide W2
Load
(W1 W2 ) g S
TF = ........................................................ (5.21)
2 103
W1

W1: Mass of load [kg]

W2: Mass of counterweight [kg]

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5. CALCULATION METHODS FOR DESIGNING

5.7 Load inertia moment equations

Typical load inertia moment equations are indicated below.

Type Mechanism Equation
L 4 4 W 2 2
Axis of rotation is on the cylinder JL0 = (D D ) (D 1 D 2 ) .......................... (5.22)
32 1 2
8
center
: Cylinder material density [kg/cm3]
L : Cylinder length [cm]
D1 D1 : Cylinder outside diameter [cm]
D2
D2 : Cylinder inside diameter [cm]
W : Cylinder mass [kg]
L

Reference data: material density

Cylinder Iron : 7.8 10-3 [kg/cm3]
Axis of rotation Aluminum : 2.7 10-3 [kg/cm3]
Copper : 8.96 10-3 [kg/cm3]
Axis of rotation is off the cylinder
center R

W
JL0 (D 2 8R 2 ) .............................................................. (5.23)
8

Axis of rotation D

R
b a2 b2 2
a JL0 W R ......................................................... (5.24)
b 3
a
Square block
W : Square block mass [kg]
a, b, R : Left diagram [cm]
Axis of rotation
2 2
V W 1 V W S
V JL W ............. (5.25)
Servo motor 600 2 N 10 20
Object which V : Speed of object moving linearly [mm/min]
moves linearly S : Moving distance of object moving linearly per servo
W
N motor revolution [mm/rev]
W : Object mass [kg]
2
D D Jp .................................................................. (5.26)
JL W
2
Object that is
Servo motor JP : Pulley inertia moment [ 10-4kg m2]
hung with pulley
D : Pulley diameter [cm]
W W : Object mass [kg]

Load B
N3 JB J31
2 2
N2 (J31 JB) N3
JL J11 (J21 J22 J A) .................. (5.27)
N1 N1
J21
Converted load J A, J B : Inertia moments of loads A, B [ 10-4kg m2]

Load A N2 J11 to J31 : Inertia moments [ 10-4kg m2]

J22
JA N1 to N3 : Speed of each shaft [r/min]
N1
J11

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5. CALCULATION METHODS FOR DESIGNING

5.8 Precautions for home position return

When a general positioning unit is used, the sequence of events is as shown in the following figure.
Home position return speed V1

Proximity dog on starts deceleration

Creep speed V2

Proximity dog

Zero pulse signal On Off

Considering the variations of the proximity dog

operation, adjust the proximity dog so that it
When determining the on duration of the proximity dog, switches off at the middle during the zero pulse
consider the deceleration time so that the speed reaches signal on.
the creep speed.

(1) When determining the on duration of the proximity dog, consider the delay time of the control section and
the deceleration time so that the creep speed is attained. If the proximity dog signal switches off during
deceleration, precise home position return cannot be performed.
Home position Travel distance until reaching the
return speed V1 creep speed after proximity dog is
detected L1

Creep speed V2

Deceleration
Control delay time td
time t1
On duration of the
proximity dog LD

Travel distance L1 in the chart can be obtained by equation 5.28.

2
1 1 1 V2 1
L1 V1 t1 V1 td V1 V1 Tp.............................................................. (5.28)
60 120 60
ON duration of the actuator LD [mm] must be longer than L1 obtained by Equation 5.28, as indicated in
Equation 5.29.
LD L1 ................................................................................................................................................ (5.29)
where,
V1, V2 : As shown in the chart [mm/min]
t1, td : As shown in the chart [s]
L1 : As shown in the chart [mm]
LD : As shown in the chart [mm]

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5. CALCULATION METHODS FOR DESIGNING

(2) Set the end (OFF position) of the actuator signal at the middle of two ON positions (Lows) of the zero pulse
signal. If it is set near either ON position of the zero pulse signal, the positioning unit is liable to misdetect
the zero pulse signal. In this case, a fault will occur, e.g. the home position will shift by one revolution of the
servo motor.
The zero pulse output position can be confirmed by OP (encoder Z-phase pulse) on the external I/O signal
display.

5.9 Selection example

Machine specifications Speed of moving part during fast feed V0 30000[mm/min]

Feed per command pulse 10[ m]
Travel 400[mm]
Positioning time t0 within 1[s]
Servo
Number of feeds 40[times/min]
motor
Gear ratio 5:8 Operation cycle tf 1.5[s]
Servo Gear ratio n 8/5
amplifier
(drive unit) Moving part mass W 60[kg]
Drive system efficiency 0.8
Friction coefficient 0.2
Ball screw lead Pb 16[mm]
Ball screw diameter 20[mm]
Ball screw length 500[mm]
Gear diameter (servo motor) 25[mm]
Gear diameter (load shaft) 40[mm]
Gear face width 10[mm]

(1) Selection of control parameters

Setting of electronic gear (command pulse multiplication numerator, denominator)
There is the following relationship between the multiplication setting and travel per pulse .

(ball screw lead) CMX

262144 (gear ration) CDV

When the above machining specifications are substituted in the above equation.

16 CMX
10 10 -3
262144 8/5 CDV

CMX 10 262144 8/5 262144 32768

CDV 1000 16 1000 125

Acceptable as CMX/CDV is within 1/10 to 2000.

(2) Servo motor speed

V0 30000 8
N0 n 3000[r/min]
Pb 16 5

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5. CALCULATION METHODS FOR DESIGNING

(3) Acceleration/deceleration time constant

tpsa tpsd ts 0.05[s]
t0
V0/60
ts: settling time.(Here, this is assumed to be 0.15s.)

(4) Operation pattern

3000
Servo motor speed

Time [s]
0.05 0.05 ts
tpsa tpsd 0.15
to 1.0
[r/min]
tf 1.5

(5) Load torque (converted into equivalent value on servo motor shaft)
Travel distance per servo motor revolution

1 5
S Pb 16 10[mm]
n 8

W g S 0.2 60 9.8 10
TL 0.23[N m]
2 10 3 2 10 3 3.14 0.8

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5. CALCULATION METHODS FOR DESIGNING

(6) Load inertia moment (converted into equivalent value on servo motor shaft)
Moving part

2
JL1 W S 1.52[ 10-4kg m2]
20

Ball screw

2
L 1
JL2 D4 0.24[ 10-4kg m2]
32 n

* 7.8 10-3 [kg cm3]

Gear (servo motor shaft)

L
JL3 32 D4 0.03[ 10-4kg m2]

Gear (load shaft)

2
L 1
JL4 D4 0.08[ 10-4kg m2]
32 n

Full load inertia moment (converted into equivalent value on servo motor shaft)

JL JL1 JL2 JL3 JL4 1.87[ 10-4kg m2]

(7) Temporary selection of servo motor

Selection conditions

(a) Load torque servo motor's rated torque

(b) Full load inertia moment 24 servo motor inertia moment

From the above, the HF-KP23 (200W) is temporarily selected.

(8) Acceleration and deceleration torques

Torque required for servo motor during acceleration

(JL/ JM) N0
TMa TL 1.85[N m]
9.55 104 Tpsa

Torque required for servo motor during deceleration

(JL JM) N0
TMd TL 0.86[N m]
9.55 104 Tpsd

The torque required for the servo motor during deceleration must be lower than the servo motor's maximum
torque.

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5. CALCULATION METHODS FOR DESIGNING

(9) Continuous effective load torque

2 2 2
TMa tpsa TL tc TMd tpsd
Trms 0.41[N m]
tf

The continuous effective load torque must be lower than the servo motor's rated torque.

(10) Torque pattern

1.85
[N m]

0.23
Torque

Time [s]
0.05 0.75 0.05 0.15
0.86
1.5

(11) Selection results

The HF-KP23 servo motor and MR-J3-20A servo amplifier are selected.

(a) Electronic gear setting

CMX 32768
CDV 125

(b) During rapid feed

Servo motor speed N0 3000 [r/min]

(c) Acceleration/deceleration time constant

tpsa tpsd 0.05[s]

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5. CALCULATION METHODS FOR DESIGNING

5.10 Coasting distance of electromagnetic brake

At an emergency stop, the servo motor with an electromagnetic brake stops in the pattern shown in the
following diagram. Here, the maximum coasting distance (during fast feed), Lmax, will be the area shown with
the diagonal line in the figure and can be calculated approximately with Equation 5.30. The effect of the load
torque is greater near the stopping area. When the load torque is large, the servo motor will stop faster than
the value obtained in the equation.

Emergency stop

Brake current

t1 t2 t3
Machine speed

V0

V0 t3
Lmax t1 t2 ...................................................................................................... (5.30)
60 2

Where,
Lmax : Maximum coasting distance [mm]
V0: Machine's fast feed speed [mm/min]
t1: Delay time of control section [s]
t2: Braking delay time of brake (Note) [s]
t3: Braking time [s]
(JL JL) N0
t3
9.55 104 (TL 0.8TB)
JL : Load inertia moment converted into equivalent [ 10-4kg m2]
value on servo motor shaft
JM : Servo motor's rotor inertia moment [ 10-4kg m2]
N0 : Servo motor speed during fast feed [r/min]
TL : Load torque converted into equivalent [N m]
value on servo motor shaft
TB : Brake static friction torque (Note) [N m]
Note. t2 and TB are Refer to the chapter of Servo Motor Series. JL is the machine's inertia moment at the servo motor shaft.

5.11 Expression for calculating the electromagnetic brake workload

Calculate the brake workload Eb [J] at an emergency stop with the following expression.
(JM JL) N 2 4
Eb 182 10

N: Servo motor speed [r/min]

JM: Servo motor's rotor inertia moment [ 10-4kg m2]
JL: Load inertia moment converted into equivalent value on servo motor shaft [ 10-4kg m2]

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