Glossary SINAMICS S120 drive system

Absolute encoder

Position encoder which immediately provides the actual position of the drive as an absolute actual value after its power supply voltage has been switched on. For single-turn encoders, the detection range is one revolution, whereas multi-turn encoders have a detection range of several revolutions (typical example is 4096 revolutions). If an absolute encoder is used as a position encoder, no search for reference is required after the switch-on and the reference switch (e.g. BERO) which may normally be required is not necessary in this case.

There are rotary and linear absolute encoders.

Example of an absolute encoder:

SIMOTICS 1FK and 1FT motors can be supplied with integrated multi-turn absolute encoders with 2048 sine/cosine signals per revolution, over 4096 revolutions absolute and → "EnDat protocol".

Active Infeed

Overall functionality of an infeed with → Active Line Module, including the required additional components (filters, switching devices, computing power portion of a → Control Unit, voltage detection, and so on).

Active Interface Module

This module contains the line-side components required for an → Active Line Module, e.g. the pre-charging circuit (pre-charging resistors and bypass contactor).

Active Line Module

A regulated, self-commutated infeed/regenerative feedback unit (with IGBTs in infeed/feedback direction) which supplies a constant DC link voltage for the → Motor Modules. The Active Line Module operates in conjunction with the → line reactor to provide a step-up converter function.

Drive system

A drive system comprises all of the components belonging to a drive of a product family, e.g. SINAMICS. A drive system includes components such as → Line Modules, → Motor Modules, → Encoders, → Motors, → Terminal Modules and → Sensor Modules, as well as supplementary components such as reactors, filters, cables, etc.

Asynchronous (induction) motor

An asynchronous motor is a 3-phase motor whose speed lags somewhat behind the synchronous speed.

Asynchronous motors can be connected to the three-phase system either directly in a star or delta connection or via a converter.

In combination with a converter, the asynchronous motor becomes a variable-speed drive system.

Other commonly used terms: squirrel-cage motor, cage motor.

See also → Synchronous motor.

Skip frequency band

A skip frequency band is a speed or frequency setpoint range that is not permitted. The upper and lower limits of the skip frequency band can be parameterized. If a signal value is specified by an external or internal setpoint source within the skip frequency band, this signal value is replaced by one of the skip frequency limits. This function allows for the suppression of undesirable mechanical resonant oscillation by suppressing those speeds which could possibly excite this type of resonant oscillation.

Output reactor

Reactor (inductance) in the converter or inverter output for reducing the capacitive charge/discharge currents of long power cables.

Basic Line Filter

In combination with a line reactor, line filters limit the conducted electromagnetic interference emission in accordance with EMC legislation.

Basic Line Module

Unregulated infeed unit (diode bridge or thyristor bridge, without regenerative feedback) for rectifying the line voltage of the → DC link.

Basic Operator Panel

Simple small operator panel for plugging on a SINAMICS → Control Unit with numeric display and some keys.

The BOP20 is available in the SINAMICS product range.

Command data set

Parameter data set consisting of binector inputs (e.g. for control commands) and connector inputs (e.g. for setpoints).

The individual data sets are represented as indexed parameters. The changeover is performed via input signals.

The appropriate parameterization of several command data sets and the changeover of the data sets allows the optional operation of the drive with different preconfigured signal sources.

Blocksize

Volume-optimized, cubic construction of a drive unit. Mostly used for operating a motor.

See → Booksize, → Chassis unit.

Booksize

Book-shaped construction of the components suitable for lining up drives in a group. Designed primarily for operating several → Motors.

Brake Relay

Component with a 24 V relay for brake control. Brakes can be switched using this relay with a rating of 24 V DC/12 A or 440 V AC/12 A.

Braking Module

Electronic switch or chopper (brake chopper), which connects a → braking resistor with a specific pulse/pause ratio to the DC link voltage to convert regenerative (braking) energy into thermal energy and to ultimately limit the DC link voltage to permissible values. For SINAMICS, no braking resistor is incorporated in the Braking Module. It must be mounted outside the Braking Module.

Brake control

A software function which defines when an available mechanical holding brake or service brake should be applied, either as part of a duty cycle for momentary standstill or in the event of a fault.

Braking power

Regenerative power injected into the → DC link by one or several → Motor Modules, e.g. when lowering a load or decelerating a motor.

See → Braking resistor.

Braking resistor

Resistor which reduces the excess energy in the → DC link. The resistor is connected to a → Braking Module.

In this way, the resulting heat loss is dissipated outside the control cabinet.

See → Braking power.

Capacitor Module

This module is used for increasing and buffering the DC link capacity.

It can be used to compensate a brief power failure or to buffer the braking energy.

Chassis unit

In the upper power range, chassis units are mostly used for installation in control cabinets. The components are mounted on mounting plates or in racks.

See → Booksize → Blocksize.

Communication Board

A module for external communication, e.g. → PROFIBUS, → PROFINET, CAN or Ethernet. It is plugged into the option slot of a → Control Unit.

Communication Board Ethernet 20

A module for operation with → PROFINET (the open Industrial Ethernet standard of PROFIBUS user organization for automation systems).

PROFINET IO with IRT (Isochronous Real Time) and PROFINET IO with RT (Real Time) are supported. It is plugged into the option slot of a → Control Unit.

CompactFlash card

Memory card for non-volatile storing of the drive software and of the associated parameters. The memory card can be plugged into the → Control Unit from outside.

Control Supply Module

24 V power supply module for the electronic circuitry of components in a SINAMICS drive line-up.

The Control Supply Module is supplied via two inputs: The incoming supply and the → DC link. The DC link connection ensures that the electronics power supply is buffered in the event of a power failure or voltage dip, thereby enabling emergency retraction and kinetic buffering.

Control Unit

Central control module in which the closed-loop and open-loop control functions for one or more SINAMICS → Line Modules and/or → Motor Modules are implemented.

Control Unit Adapter

A module for → DRIVE-CLiQ communication between a → Power Module in blocksize format and a → Control Unit for several drives (e.g. CU320‑2).

The Control Unit Adapter is connected through the Power Module Interface (PM-IF) to the → Power Module and through → DRIVE-CLiQ to the → Control Unit.

Direct measuring system

Position encoder which is connected directly to the moving machine part as well as to the associated evaluation electronics. In the case of linear axes, it is also possible to use linear scales for this purpose.

In many cases, a direct measuring system must be used because the → Motor encoder for position sensing and control does not suit this purpose, e.g. due to excessive elasticity and backlash in the drive train.

Double Motor Module

Two motors can be connected to and operated with a Double Motor Module.

See → Motor Module, → Single Motor Module.

DRIVE-CLiQ

Abbreviation for Drive Component Link with IQ.

Communication system for connecting the various components of a SINAMICS drive system, such as the → Control Unit, the → Line Modules, the → Motor Modules, the → Motors and speed/position encoders.

The DRIVE-CLiQ hardware is based on the Industrial Ethernet standard and uses twisted-pair cables. The DRIVE-CLiQ cable provides the send and receive signals, as well as the +24 V power supply.

Dynamic Servo Control

Dynamic Servo Control (DSC) allows the position actual value to be evaluated in a fast speed control clock cycle directly in the drive. The position reference value (position setpoint) is entered in the position controller clock cycle from the higher-level control via the isochronous → PROFIBUS with → PROFIdrive telegrams.

With sophisticated signal filtering and pre-control, DSC ensures optimum dynamics in the position control loop with a low bus bandwidth load.

DSC allows high control gains to be achieved and therefore a high level of stiffness - for instance to quickly compensate and correct load-related track/path deviations.

Electronic rating plate

Each component of the SINAMICS drive system, which is connected via → DRIVE-CLiQ has an electronic rating plate.

The electronic rating plate can be read out via the → STARTER commissioning tool and provides the following information: Type, article number, version, manufacturer, serial number and rated data.

EnDat protocol

Serial transmission protocol for transmitting position/angle actual values from an → Absolute encoder to the drive or positioning control.

The EnDat protocol also allows parameterization and diagnostics of the encoder.

Heat dissipation

The thermal losses are conducted away from the converter and/or motor so that the permissible temperatures are not exceeded.

Travel to a fixed stop

Using this function, a motor can be traversed to a fixed end stop with a defined torque/force without a fault being signaled. When the stop is reached, the torque/force defined using a parameter is established and maintained.

Flying restart

After Power on, the "flying restart" function automatically switches a converter to a possibly coasting motor. When switching to the rotating motor, the motor first needs to be magnetized by an → Asynchronous motor. For drives not equipped with an encoder, a search for the current speed is carried out. The current speed setpoint in the ramp-function generator is then set to the current actual speed value. The ramp-up to the final speed setpoint starts with this value. The flying restart function can help to shorten the ramp-up procedure following power-up when the load is still coasting down.

Application example:

After a power failure, a fan drive can be quickly reconnected to the running fan impeller by means of the flying restart function.

See → Automatic restart.

Field weakening

The term field weakening designates the reduction of the magnetizing current of an electric motor to further increase the speed upon reaching the rated current.

Edge modulation

Type of modulation for a drive converter gating unit, where the pulses "chopped" from the DC link voltage do not appear in a fixed time grid. The edges of the output voltage which is generated are formed by several short pulses near the zero crossover, while a wide pulse is generated at the center of every half-wave. This allows a high output voltage roughly approximating to 100% of the line connection voltage and therefore ensuring good motor utilization.

Flexible response

With this function, the converter can be operated even in case of a voltage dip up to a minimum DC link voltage of approx. 50% of the rated value (or of the parameterized line connection voltage value). In case of a voltage dip, the maximum output power of the converter decreases analogously to the current line voltage.

In contrast to kinetic buffering, a significant speed decrease can be avoided as long as the remaining power is sufficient for operating the drive with the required torque.

Flying measurement

When a hardware signal is received, the instantaneous position actual value is saved and, for example, is made available via PROFIBUS. The hardware signal can, for example, originate from a probe or a print-mark detection sensor (mechanical switch, BERO or optical sensor). The active edge of the hardware signal can be parameterized (rising, falling or both).

Liquid cooling

Liquid cooling is a cooling method for SINAMICS power units and is only available for the → Chassis Units. For this cooling method, a liquid cooler with inlet and outlet nozzles is permanently integrated. The specifications quoted by Siemens AG are applicable to the liquid quality, volumetric flow (quantity of liquid per time unit) and liquid pressure.

Third-party motor

A motor is considered to be a third-party motor if its motor data are not known to the drive line-up and cannot be identified using its article number.

The motor data of a third-party motor is required for commissioning. It must be manually entered in the corresponding parameters.

Encoder

An encoder is a measuring system that senses actual values for speed and/or angle/positions and makes them available for electronic processing. Depending on the mechanical design, encoders can be incorporated in the → Motors (→ Motor encoder) or mounted on the external mechanical components. Depending on the type of motion, a distinction is made between rotary encoders and translatory encoders (e.g. linear scale). In terms of measured-value provision, we distinguish between → Absolute encoders (code sensors) and → Incremental encoders.

See → Incremental encoder TTL/HTL, → Incremental encoder sin/cos 1 V_pp, → Resolver.

Hub

Central connecting element in a network with a star-type topology. A hub distributes arriving data packages to all devices connected.

Incremental encoder

Incremental position and speed encoder. Unlike the → Absolute encoder, this encoder does not output a position actual value signal corresponding to the absolute position, but instead outputs incremental delta position or angular signals.

The following three types of incremental encoders are available: → Incremental encoder TTL/HTL, → Incremental encoder sin/cos 1 V_pp or → Resolver.

Incremental encoder sin/cos 1 V_pp

This is a high-resolution optical sine/cosine encoder that can be incorporated into SIMOTICS 1FK motors as a → Motor encoder, for example.

As a rule, the following signals are output:

• Two signals displaced by 90 degrees each with 2048 sinusoidal signals per revolution as differential signals with an amplitude of 1 V_pp (A and B fine tracks).
• A reference signal (zero pulse) per revolution as a differential signal with a 0.5 V_pp amplitude.
• For some types, additionally two sinusoidal signal periods displaced by 90 degrees as differential signals with a 1 V_pp amplitude (C and D track).

To determine the actual position/angular value, the zero crossovers of the sinusoidal encoder tracks are evaluated first (rough evaluation, e.g. in total 4 x 2048 = 8192 zero crossovers per revolution). In addition to this, a fine evaluation can be performed by means of an analog detection of the amplitude. Resolutions of over 1 million increments for each encoder revolution can be achieved by combining coarse and fine evaluation.

Examples of typical sin/cos encoders: ERN1387, ERN1381.

Incremental encoder TTL/HTL

Incremental position and speed measuring encoder (→ Incremental encoder). In most cases, it outputs two pulse chains (tracks) displaced by 90 degrees with rectangular output signals and often additionally one zero pulse per revolution, respectively. The output signals feature TTL levels (in most cases +5 V RS422 differential signals; TTL = Transistor-Transistor Logic) or HTL levels (+15 or +24 V logic level; HTL = High Level Transistor Logic).

Line Module

A Line Module is a power component which creates the DC link voltage for one or several → Motor Modules from a three-phase line voltage.

The following three Line Module types are used for SINAMICS:

→ Basic Line Module, → Smart Line Module and → Active Line Module.

Motor

For the electric motors which can be controlled by SINAMICS, a principle distinction is made between rotary and linear motors with regard to their direction of movement, and between synchronous and asynchronous (induction) motors with regard to their electromagnetic operating principle. For SINAMICS, the motors are connected to a → Motor Module.

See → Synchronous motor, → Asynchronous (induction) motor, → Motor encoder.

Motor with DRIVE-CLiQ

The motors with → DRIVE-CLiQ comprise a motor, encoder and an integrated encoder evaluation system. To operate these motors, a power cable and a → DRIVE-CLiQ cable must be connected to the → Motor Module.

Motor encoder

An → Encoder, e.g. → Resolver, → Incremental encoder TTL/HTL or → Incremental encoder sin/cos 1 V_pp, built into or onto the motor.

The encoder detects the motor speed and, in the case of synchronous motors, also the rotor position angle (of the commutation angle for the motor currents).

For drives without an additional → Direct measuring system, it is also used as a position encoder for position control.

Motor Module

A Motor Module is a power unit (DC-AC inverter) which provides the energy for the connected motor.

Power is supplied through the → DC link of the drive line-up.

A Motor Module must be connected to a → Control Unit via → DRIVE-CLiQ. The open-loop and closed-loop control functions of the Motor Module are stored in the Control Unit.

There are → Single Motor Modules and → Double Motor Modules.

Motor potentiometer

This function is used to simulate an electromechanical motor potentiometer for setpoint input. The setpoint is adjusted via one control command for "higher" and one for "lower".

Motor-side power components

Power components arranged between the converter unit and the motor, e.g. output filters, output reactors, etc.

Line reactor

Line reactors are used to limit low-frequency line harmonics to permissible values. In conjunction with → Active Line Modules, they are also used to store energy.

Line filter

Line filters are filters in the converter input which protect the network from harmonic loads and/or interference voltages created in the converter.

Line filters can be passive or active filters, for the lower-frequency harmonics (designated with the term line feedback) with 5, 7, 11, 13, etc. times the line frequency, and also filters for high frequency interference voltages from 10 kHz onward (i.e. RFI suppression filters).

With SINAMICS, the term line filter only designates passive RFI suppression filters.

Line-side power components

Power components arranged between the line and the converter unit, such as line reactors, line filters, line contactors.

Optimized pulse patterns

Complex modulation procedure carried out by a converter gating unit, whereby the voltage pulses are arranged so that the output current closely approximates a sinusoidal waveform. This is essential if high modulation depths and an optimally low torque ripple are to be achieved.

Power Module

A Power Module is an AC-AC converter which does not have a built-in → Control Unit.

PROFIBUS

Fieldbus in accordance with standard IEC 61158, sections 2 to 6.

PROFIdrive

PROFIBUS profile specified for speed and position-controlled drives by the PROFIBUS user organization (German: PNO).

The latest version is PROFIdrive V4.0.

PROFINET

This is an open component-based industrial communication system using → Ethernet for distributed automation systems.

Resolver

Mechanically and electrically very rugged and cost-efficient → Motor encoder which does not require any incorporated electronics and which operates according to a fully electromagnetic principle: one sine and cosine signal, respectively, are induced in two coils displaced by 90 degrees. The resolver delivers all signals required for speed-controlled operation of the converter or for position control. The number of sine and cosine periods per revolution is equal to the number of pole pairs of the resolver. In the case of a 2-pole resolver, the evaluation electronics may output an additional zero pulse per encoder revolution. This zero pulse ensures a unique assignment of the position information in relation to an encoder revolution. A 2-pole resolver can be used as a single-turn encoder.

2-pole resolvers can be used for motors with any number of poles. In the case of multi-pole resolvers, the pole pair number of the motor and of the resolver are always identical. For this reason, multi-pole resolvers ensure a higher resolution than 2-pole resolvers.

Safe Brake Relay

Certified components for the safe control of a 24 V brake coil.

See → Brake Relay.

Safety Integrated

These safety functions are integrated into the products and ensure efficient personal and machine protection in accordance with the EC Machinery Directive 98/37/EC.

By means of the integrated safety functions, the requirements of safety category 3 in accordance with EN 954-1 can be met in a simple and efficient way.

Sensor Module

Hardware module for evaluating speed/position encoder signals.

Safe Brake Control

Function of → Safety Integrated.

On SINAMICS → booksize format units, the motor holding brake is controlled on a two-channel basis by one electronic switch in the +24 V channel and one in the ground channel. Both of these channels are monitored. If one of the two channels fails, then this is detected and signaled. For booksize devices, the brake cable is integrated in the power cable.

See → Brake control.

Safe standstill

Function of → Safety Integrated.

In the event of a fault or in conjunction with a machine function, this function is used to safely disconnect the torque-generating energy flow to the motor. This is performed drive-specifically and is contact-free. See → Safety Integrated.

Single Motor Module

A Single Motor Module is a → Motor Module to which one single motor can be connected and operated.

See also → Double Motor Module.

Sine-wave filter

The sine-wave filter is connected to the converter or inverter output on the motor side. This filter has been designed for the generation of a converter output voltage with an almost sinusoidal characteristic.

This protects motors whose insulation system could be damaged by voltage peaks.

In addition to this, a shielded power cable is not required in many cases.

Sine-wave filters are often required in the chemical industry, e.g. to ensure that the permissible insulation voltage e.g. in the motor terminal box is not exceeded.

SIZER for Siemens Drives

SIZER for Siemens Drives is the engineering tool for the SINAMICS and MICROMASTER drive systems. SIZER for Siemens Drives can be used to engineer drive systems and to select the drive components required for the system.

See → STARTER.

Smart Line Module

Unregulated infeed/regenerative feedback unit with diode bridge for the infeed and stall-protected, line-commutated regenerative feedback via IGBT (Insulated Gate Bipolar Transistor).

The Smart Line Module provides the DC link voltage for the → Motor Modules.

STARTER

The STARTER commissioning tool is used to commission and parameterize drive units. Further, if service is required, the necessary diagnostic functions can be executed (e.g. PROFIBUS diagnostics, function generator, trace).

See → SIZER for Siemens Drives.

Droop

Droop involves making the speed controller artificially "soft" by entering an adjustable percentage of the speed controller output signal with negative sign at the speed controller input. This means that the speed is slightly reduced at higher load torques. The droop function is used to reduce the response to load surges and for certain variations of load equalization control for drives which are coupled with one another through a continuous material web. The I component or the summed output signal can be used as speed output signal. The droop can be switched on and switched off using a control command.

Fault buffer

The drive enters faults that have occurred into a fault buffer. The fault buffer can be read out via parameters.

Power supply unit

This component provides electric energy for electric and electronic components.

For SINAMICS, all components are internally connected via 24 V terminals or rails.

The power supply can be provided by a commercially available power supply unit (e.g. SITOP) or a → Control Supply Module.

Synchronous motor

Synchronous motors operate precisely with the frequency with which they are operated. They do not have a slip (like → Asynchronous (induction) motors). Depending on their design, synchronous motors require different open-loop and closed-control concepts so that they can be operated using a converter.

Synchronous motors are distinguished by the following features:

• Permanent-magnet/separately excited
• With/without damping cage
• With/without position encoder

Synchronous motors are used for different reasons:

• High drive dynamic response (→ Synchronous servomotors)
• High overload capability
• High-speed accuracy when the frequency is precisely specified (SIEMOSYN motors)

Synchronous servomotor

Synchronous servomotors (e.g. SIMOTICS S-1FK/-1FT) are permanent-magnet → Synchronous motors with position encoders such as → Absolute encoders. The low intrinsic moments of inertia permit an extremely highly dynamic drive performance. The combined advantage of high power density and compact dimensions is partially attributable to the absence of rotor copper losses. Synchronous servomotors can only be operated in conjunction with converters. The servo control required results in a torque-dependent motor current, whose instantaneous phase position is derived from the (mechanical) rotor position, determined using a position encoder.

Terminal Board

Terminal expansion board for plugging into a → Control Unit.

For SINAMICS, the TB30 Terminal Board is available with analog and digital I/O terminals.

Terminal Module

Terminal expansion module that is snapped onto a mounting rail in the control cabinet.

Topology

The topology describes the structure of a drive system with → Control Unit, → Motor Modules, → Motors, → Encoders, → Terminal Modules, including the connection system.

Vector control

Vector control (field-oriented control) is a high-performance control type for induction machines. It is based on an exact model calculation of the motor and of two current components which control the flow and the torque by means of software algorithms. This means that speed and torque setpoints can be precisely maintained and limited with a good dynamic response.

There are two vector control types:

• frequency control (encoderless vector control)
• speed-torque control with speed feedback (→ Encoder).

Voltage Sensing Module

Component which measures the actual line voltage and makes the measured data available via → DRIVE-CLiQ. Used in conjunction with an → Active Line Module for feeding back the actual line voltage value.

It can be mounted on a top-hat rail and also features 2 analog inputs and a connection for a temperature sensor.

Automatic restart

After a power failure, the automatic restart function automatically restarts a converter when the supply voltage recovers. It does not require acknowledgement of the power failure fault. The automatic restart function can, for example, minimize drive downtimes and production failures.

However, operators must be aware of the dangerous situation which can occur when a drive recovers automatically after a longer power failure period without any operator intervention. To ensure the safety of personnel in this potentially hazardous situation, it may be necessary to implement external control measures (e.g. cancelation of the ON command).

Typical applications for the automatic restart function are pump, fan and compressor drives which operate as stand-alone drives and frequently have no local control (LOCAL Mode). The automatic restart function is not used for coordinated drives for continuous material webs and motion control.

With SINAMICS, the following versions of the automatic restart function can be set by parameters:

• Restart after failure of power supply if the 24 V electronics supply is still connected (brownout)
• Restart after failure of the 24 V electronics power supply (blackout)
• Restart after any type of shutdown on faults.

The following actions can be parameterized:

• Only acknowledgment of the power failure signal (e.g. for multi-motor drives, DC link network)
• ON command upon expiry of the parameterized delay time
• ON command with flying restart

The number of start attempts initiated within a parameterizable time period can be set.

It is also possible to activate the → Flying restart function in addition to the automatic restart function to ensure a smooth connection to a motor that is still rotating.

DC link

A part of the converter (or converter system) that connects the input converter (rectifier) with the output converter (one or several inverters).

With voltage source DC link converters such as SINAMICS, a constant DC voltage is present in the DC link (rectified line voltage).