Yaskawa Sigma-X Servo System: Complete Technical Guide for Industrial Automation
Yaskawa Sigma-X Servo System: Complete Technical Guide for Industrial Automation
The Yaskawa Sigma-X series represents the latest evolution in over 30 years of AC servo drive innovation. As the successor to the acclaimed Sigma-7 series, Sigma-X sets new benchmarks in motion performance, ease of use, and predictive maintenance capabilities. This comprehensive technical guide covers everything you need to know about implementing Sigma-X servo systems in your industrial automation applications.
Key Performance Specifications
The Sigma-X series delivers industry-leading motion control performance through several breakthrough technologies:
- Speed Response Frequency: 3.5 kHz – The world’s highest level, enabling superior command tracking and stable operation
- Maximum Motor Speed: 7,000 min⁻¹ – Increased from 6,000 min⁻¹ in previous generations
- Encoder Resolution: 26-bit (67 million pulses/revolution) – Four times higher than Sigma-7’s 24-bit encoder
- Settling Time: 1/12 of previous models – Dramatically reduced positioning cycles
Sigma-X vs Sigma-7 vs Sigma-V Comparison
| Specification | Sigma-X | Sigma-7 | Sigma-V |
|---|---|---|---|
| Speed Response Frequency | 3.5 kHz | 3.1 kHz | 1.6 kHz |
| Encoder Resolution | 26-bit (67M pulses/rev) | 24-bit (16M pulses/rev) | 20-bit (1M pulses/rev) |
| Maximum Speed | 7,000 min⁻¹ | 6,000 min⁻¹ | 5,000 min⁻¹ |
| Communications | MECHATROLINK-4/III, EtherCAT | MECHATROLINK-II/III | MECHATROLINK-II/III |
| Tuning-less Ratio | 100:1 | 30:1 | 30:1 |
Sigma-X Motor Family Overview
The Sigma-X series offers three distinct rotary servo motor lines, each optimized for specific application requirements:
SGMXA – Low Inertia, High Speed
The SGMXA represents the general-purpose workhorse of the Sigma-X line. Available in sizes from 50W to 1kW, these low-inertia motors excel in applications requiring rapid acceleration and deceleration cycles.
| Model | Rated Power | Rated Torque | Max Torque | Rated Speed |
|---|---|---|---|---|
| SGMXA-A5A | 50W | 0.159 Nm | 0.557 Nm | 3,000 min⁻¹ |
| SGMXA-01A | 100W | 0.318 Nm | 1.11 Nm | 3,000 min⁻¹ |
| SGMXA-02A | 200W | 0.637 Nm | 2.23 Nm | 3,000 min⁻¹ |
| SGMXA-04A | 400W | 1.27 Nm | 4.46 Nm | 3,000 min⁻¹ |
| SGMXA-06A | 600W | 1.91 Nm | 6.69 Nm | 3,000 min⁻¹ |
| SGMXA-10A | 1,000W | 3.18 Nm | 11.1 Nm | 3,000 min⁻¹ |
SGMXJ – Medium Inertia, High Speed
Designed for applications requiring precise load matching, the SGMXJ series offers medium inertia characteristics with rated speeds up to 3,000 min⁻¹ and maximum speeds of 6,000-7,000 min⁻¹. These motors are ideal for packaging machines, material handling, and general automation where load variations are common.
SGMXG – Medium Inertia, High Torque
The SGMXG series addresses high-power applications with rated torques reaching up to 95.2 Nm. Operating at rated speeds of 1,500 min⁻¹, these medium-inertia motors provide robust performance for heavy-duty industrial applications.
SERVOPACK Compatibility Matrix
| SERVOPACK Model | Communications | Compatible Motors | Power Range |
|---|---|---|---|
| SGDXS-R70A | Analog/Pulse | SGMXA-A5A to 01A | 50-100W |
| SGDXS-1R6A | Analog/Pulse | SGMXA-C2A to 02A | 150-200W |
| SGDXS-2R8A | Analog/Pulse | SGMXA-04A | 400W |
| SGDXS-5R5A | Analog/Pulse | SGMXA-06A to 10A | 600-1000W |
| SGDXW-1R6A | MECHATROLINK-4/III | SGMXA-C2A to 02A | 150-200W |
| SGDXW-2R8A | MECHATROLINK-4/III | SGMXA-04A | 400W |
| SGDXW-5R5A | MECHATROLINK-4/III | SGMXA-06A to 10A | 600-1000W |
| SGDXT-1R6A | EtherCAT | SGMXA-C2A to 02A | 150-200W |
| SGDXT-2R8A | EtherCAT | SGMXA-04A | 400W |
| SGDXT-5R5A | EtherCAT | SGMXA-06A to 10A | 600-1000W |
Advanced Tuning Functions
One of Sigma-X’s most significant improvements is the advanced servo tuning capability that reduces commissioning time while achieving superior motion performance:
1. Tuning-less Function
Out-of-the-box automatic tuning enables stable operation for loads up to 100 times the motor’s own inertia. This represents a 3x improvement over the Sigma-7’s 30:1 ratio. Settling time at this level reaches 100-150ms, making it suitable for approximately 80% of all applications without manual tuning.
2. Advanced Auto-Tuning
For applications requiring higher performance, Advanced Auto-Tuning automatically adjusts gain and filter parameters to minimize settling time and tracking error. The algorithm now includes:
- Feedforward gain automatic adjustment
- Friction compensation for irregular friction during operation
- Improved vibration detection algorithm
- Settling time target: 10ms level
3. One-Parameter Tuning
For fine-tuning after auto-tuning, the single-parameter adjustment allows operators to optimize machine performance without affecting system stability. This enables ultra-fast settling times of 0-4ms for the most demanding applications.
Compensation and Suppression Features
| Function | Description | Benefit |
|---|---|---|
| Vibration Suppression | Detects and counteracts machine resonances | Eliminates vibration at multiple frequencies |
| Speed Ripple Compensation | Suppresses cogging effects at low speeds | Superior speed stability |
| Resonance Suppression | Multiple adjustable filters for mechanical resonances | Handles complex mechanical systems |
| Friction Compensation | Automatic smoothing of irregular friction | Smooth starting characteristics |
| Load Disturbance Compensation | Reduces settling time variation with load changes | Stable operation under varying conditions |
Predictive Maintenance and Data Sensing
The Sigma-X series integrates advanced sensing capabilities that transform the servo drive from a motion controller into a predictive maintenance sensor:
Built-in Sensing Functions
- Vibration monitoring – Detects early signs of mechanical issues
- Temperature monitoring – Real-time motor and amplifier temperatures
- Torque monitoring – Load condition analysis
- Power consumption tracking – Energy efficiency optimization
- Maintenance cycle indicators – Proactive replacement scheduling
Σ-LINK II Sensor Network
The proprietary Σ-LINK II enables connection of additional sensors through the encoder signal line, providing:
- Wire-saving sensor integration
- High-speed synchronized data collection
- Reduced system complexity
- Enhanced machine monitoring capabilities
Functional Safety Features
Sigma-X supports comprehensive functional safety compliance through optional Advanced Safety Modules (ASM-X):
| Safety Standard | Compliance Level |
|---|---|
| ISO 13849-1 | PLe (Category 3) |
| IEC 61508 | SIL 3 |
| IEC 61800-5-2 | STO, SS1, SS2, SLS |
The ASM-X supports up to 10 simultaneous safety functions and compatible with FSoE (Safety over EtherCAT) for reduced wiring in safety systems.
Application Industries
Sigma-X servo systems are optimized for demanding applications across multiple industries:
- Semiconductor Manufacturing – High-precision positioning for wafer handling, lithography, and inspection equipment
- Electronic Assembly – Pick-and-place machines, component mounters, and PCB processing
- Packaging Machinery – High-speed wrapping, filling, sealing, and labeling operations
- Machine Tools – Precision cutting, drilling, and milling applications
- Industrial Robotics – Articulated arms, SCARA systems, and collaborative robots
- Food and Beverage – Hygienic processing, filling, and packaging lines
- Logistics Automation – Automated storage and retrieval systems, conveyor sorting
- Medical Devices – Precision laboratory automation and surgical equipment
Selection Guidelines
Motor Selection Criteria
| Application Type | Recommended Motor | Key Characteristics |
|---|---|---|
| High-speed positioning | SGMXA | Low inertia, 7,000 min⁻¹ max |
| General automation | SGMXJ | Medium inertia, 6,000 min⁻¹ max |
| High torque applications | SGMXG | Medium inertia, up to 95.2 Nm |
| Large equipment | SGMXG (400V) | Higher power (200W-15kW) |
Communication Interface Selection
| Interface | Best For | Transfer Cycle |
|---|---|---|
| Analog/Pulse (Σ-XS) | Simple applications, legacy systems | N/A |
| MECHATROLINK-4 (Σ-XW) | High-speed multi-axis systems | 31.25 μs minimum |
| EtherCAT (Σ-XT) | Industry 4.0 integration, open architecture | 31.25 μs minimum |
Engineering Tools
Yaskawa provides comprehensive software tools for Sigma-X system design and commissioning:
- SigmaJunmaSize+ – Motor and SERVOPACK sizing software based on application requirements
- SigmaWin+ – Configuration, tuning, and diagnostics software for servo systems
- SigmaSelect – Application-specific parameter optimization
Conclusion
The Yaskawa Sigma-X series represents a paradigm shift in industrial servo technology, combining industry-leading motion performance with intelligent sensing and predictive maintenance capabilities. With three motor families covering 50W to 15kW, multiple communication options, and advanced safety features, Sigma-X provides a scalable solution for applications ranging from precision electronics assembly to heavy industrial machinery.
The combination of 100:1 tuning-less capability, sub-millisecond settling times, and comprehensive data monitoring makes Sigma-X particularly well-suited for Industry 4.0 environments where machine performance optimization and predictive maintenance are critical success factors.
Product Range: 200V (50W-15kW) available now; 400V models (200W-15kW) released 2024
Warranty: 3-year manufacturer warranty
Safety: STO standard on all models; ASM-X for extended safety functions (SIL3/PLe)