Back to top

How to Configure an AKD Drive with Hall Feedback as the Primary Feedback Device

Click here to download this page as a pdf.

 

Purpose of the Content of this Document: This document explains how to configure the wiring to the AKD for operation with typical Kollmorgen motors that “only” incorporates Hall feedback.  It also will cover the necessary work to be done in the Workbench setup software.

  • AKD Systems wiring.  Motor Power to X2. 
  • AKD Systems wiring.  Hall wiring into x10.
  • Description for motor phase / hall phase relationship when wiring into the AKD.
  • Workbench setup, Motor selection:  How to select the correct Kollmorgen motor to be used.
  • Workbench setup, Feedback selection and system test - torque mode.
  • Workbench System Test “Torque Mode”
  • Workbench setup, Velocity operation, Luenberger Observer settings for Halls Only feedback.
  • Workbench System Test “Velocity Mode”
  • Comments for Hall system performance and low speed operation.

AKD Systems wiring.  Motor Power to X2.

From the AKD installation manual

Identify the motor phases UVW & PE, Note (ABC = UVW), connect the motor phases and PE to the drive on connector X2. (See below).

AKD-x003 to 024, power connector X2

AKD-x048, power connector X2

Note: Cable length maximum 25m.

AKD Systems wiring.  Hall wiring into x10.

*** Basically the Motor HALL signals are  shifted 120 degrees “out of phase” with the Motor Power phases.

Feedback connector (X10)

AKD

 

KBM(S)

 

TBM(S)

 

VLM (H)

 

 IC, ICH, IL, ID

Pin

Signal

Color

Name

Color

Name

Color

Name

Color

Pin

Name

X2/3

PE

added

GND

added

GND

Yel/Grn

GND

Yel/Grn

Shell

GND

X2 /4

Power U

Blue

U

Red

A

Blue

U

Red

1

A

X2 /5

Power V

Brown

V

White

B

Brown

V

White

2

B

X2 /6

Power W

Violet

W

Black

C

Violet

W

Black

3

C

X10 /2

Hall V

Brown

H1

Brown

H-AB

Brown

Hall V

Green

SubD 9/2

 S1

X10 /3

Hall W

Orange

H2

Orange

H-BC

White

Hall W

Yellow

SubD 9/3

S2

X10 /1

Hall U

Yellow

H3

Yellow

H-CA

Green

Hall U

Brown

SubD 9/4

S3

X10/8

Temp +

 

Violet

Temp +

 

(special)

Temp +

 

Gray

Temp +

 

BLK/WHT

Molex 1

Temp +

X10/9

Temp -

 

Violet

Temp -

 

(special)

Temp -

 

Violet

Temp -

 

BLK/WHT

Molex 2

Temp -

    X10/10

   +5V

 

     Blue

   +5V

 

     Blue

   +5V

 

      Red

   +5V

 

    Gray

SubD 9/1

   +5V

    X10/11

    0V

 

   Green

    0V

 

   Green

    0V

 

     Black

    0V

 

   White

SubD 9/5

    0V

VLM motor “Labeling” of Hall channels do not reflect the relationship to the VLM motor phases, Halls signals are actually 120 degrees shifted. This shift resolves the AKD wiring requirement.

Description for Motor Phase / Hall “relationship” for wiring into the AKD.  

1st.  Identify each Motor Phase and it’s associated Hall by their positive transistion. The transistion occurs when the Motor Phase BEMF is crossing zero and moving positive (+)  and it’s associated Hall is also transisitioning positive (+) at that  “same” point.  The table below shows this relationship for Motor Phases and Halls by the sequence U , V , W for a positive direction.  The identification of labels for Motor Phase and Halls can vary based on the motor mfg. standards.

2nd. The following table is used to wire motor power and feedback to the AKD.

*(AKD 3-24amp vs. AKD 48 amp) - reference page 2 in this document for the correct pinout of X2 power wiring.

The AKD has a requirement for Hall phasing “120 deg shift” see example below.

Workbench setup, Motor selection:  How to select the correct Kollmorgen motor to be used.

Workbench setup, Custom Motor “create a motor file” it is used for Kollmorgen brand motors not found in the Workbench motor data base or it can be used for 3rd party motors file creation.   * F1 for HELP- * Definitions for the parameters used in motor setup can be found in the help section (F1) of the Workbench.  “MOTOR”.

Workbench setup, Feedback selection:  Selection for the Feedback - Halls Only

Once the selection for Halls only is made, a test can be performed to verify the hall signals with reference to the direction of motor rotation.

FB1.SELECT

General Information

Type

NV Parameter

Description

Sets user entered type or identified type (–1).

Units

N/A

Range

-1, 1, 10, 11,12, 20, 21, 30, 31, 32, 33, 34, 40, 41, 42, 43, 45, 46, 50

Default Value

-1

Data Type

Integer

Start Version

M_01-00-00-000

Input Value

Description

12

Manually sets the type to Halls Only feedback (added 01-13-08-000).

This feedback type only supports operating in Torque mode and Velocity mode.

Due to heavy quantization, large current spikes occur at hall transition points, it is advisable to tune the observer to a low frequency (like 10Hz) and set the observer gain appropriately to achieve the best operating results

Workbench setup, Feedback selection and system test in the drive Torque mode.

Drive / motor wiring complete.

Motor disconnected from the load, (motor shaft only, remove or secure any loose keys)

Workbench setup - Limit the speed of the system to a safe value by lowering the velocity parameter, VL.THRESH

 

Drive setup should be completed.

Torque Mode” selected and command source “Service Motion” selected.

The AKD system can be enabled. Using a current command "continuous" at a low value should overcome the motor friction and rotate. Complete rotation and the direction of rotation should be noted. (Based on motor configuration) a positive command should generate a positive direction of rotation and positive velocity.

 

Workbench setup, Velocity operation, Luenberger Observer settings for Halls Only feedback.

Due to heavy quantization, large current spikes occur at hall transition points, it is advisable to tune the observer to a low frequency (like 10Hz) and set the observer gain appropriately to achieve the best operating results.

Workbench System Test “Velocity Mode”

Operation test in the torque mode successfully.

Motor disconnected from the load, (motor shaft only), Workbench - Increase the velocity limit VL.THRESH, back to a normal value.

 “Velocity Mode” selected and command source “Service Motion” selected.

 

Luenberger Observer - enabled and values set. The AKD system can now be enabled. Using a velocity command "continuous” at a higher velocity approximately 500 to 1000rpm should be issued and system operation noted. The direction of rotation should be following the command. (Based on motor configuration) a positive command should generate a positive direction of rotation and positive velocity.  Following stability and control of the motor in the unloaded condition, velocity tuning will need to be optimized for the system once the application load is attached.

 

*Note when using AKD systems with Halls only feedback -  Workbench  -  Performance Tuner is not operational due to the low resolution of the Hall feedback !

Workbench tuning options for these systems are the “Slider Tuner’ or the manual method of tuning. The Workbench O’scope sections provide a quick access to the tuning variables you will need and the scope is fully functional to verify system performance.

 

Comments for Hall system performance at zero rpm and low speed operation.

  1. Stability at zero rpm can oscillate if velocity gains are set high and loads have low friction.

Low speed operation can be difficult based on the motor size and pole count.

The following is a description of motor speed vs. frequencies for estimating the minimum system velocity’s when using HALL feedback and AKD drives.

*********************************************************************************************************

  With the AKD and using the observer you should be able to duplicate that performance metric easily.  We just need the Hall edge rate to be about 5 times the filter frequencies we use.

Example for the AKD we will use 25 Hz implying a 125 Hz edge rate needed.  125 Hz edge rate with 10 pole (AKM 4) is only (125/6/5*60) = 250 RPM.

Really only good for applications with the Hall frequency above 15 Hz.  This sets a lower mechanical usability speed of (15*P/2*60) in RPM.  For Kollmorgen AKM motors this gives:

 

   AKM1, 2 6 Pole    > 500 RPM

   AKM3 8 pole        > 350 RPM

   AKM4-8 10 pole > 250 RPM

We have rounded the number in the above.  The usable speed goes even lower with the relatively speaking higher pole counts of the part set motors. (KBM(S), TBM(S).