Motion Control

Presented by Tom Gray

 Overview
• Part I: Architectures
• Part II: Feedback Loops and Tuning
• Part III: Servo vs. Stepper Theory
• Part IV: Communications
Motion Control I

Architectures
Architecture - Stand Alone
Programmable
Motion Controller

Cutting tool

Bit

Drives
Info Flow-Motion Controller
• Input
– Stored Program
Commands
– Serial/Ethernet
Commands
• Output
– +/- 10 V signal
(servo)
– 5V TTL pulses
(stepper)
 Info Flow - Drive/Amplifier
• Input
– +/- 10 V signal
– 5V TTL pulses
• Output
– Commutated
Current to motor
windings
 Info Flow - Motor
• Input
– Commutated
current to motor
windings
• Output
– Rotary or linear
motion
 Info Flow - Mechanics
• Input
– Rotary or Linear
Motion from motor
• Output
– Rotary or Linear
Motion with
mechanical
advantage.
Info Flow-Feedback Device
• Input
– Encoder Pulses
– Resolver Position
• Output
– Quadrature signal
– Analog Position
Signal
Architecture - PC-Based
Carbide Grinding
Encoder Tips Wheel

15:1 gearbox
Drive Drive 1st Machine 2nd Machine 3rd Machine

Multiple cards CPU

in each
computer
 Architecture - PLC Based
Leadscrew Overhead Empty
Gantry Tray

Row of 10
Batteries
Photo
Sensor
Armature
Tray

PMC/Drive
PLC
Conveyor Chain Drive
 Architecture - Integrated
Belt & Pulley

Measuring Wheel

Cutting Wheel Encoder

Servo Motor/Drive/Controller
 Motion Control II

Feedback Loops and Tuning

 Feedback Overview
• Brief History of the Servo System
– Examples of Historical Servo Systems
– Motivation for Mathematical Servo Theory
– Servo Development in Recent History
• Servo Theory
– Development of Gain Equations
• Open Loop
• Closed Loop
– Advantages of a Servo System
• Embedded Loops
 Servo Systems
• Servo Systems Date Back to 300
BC
– Float Regulator Mechanisms
Wat er

Float Mechanism

St eam

Water Clock

Boiler Regulator
 First Servo Motor
• Steam Flyball Governor Developed
by James Watt in 1769
Boiler

Governor
Steam

Valve

Engine
 Mathematical Model
• Prior to 1868, Feedback Systems were
intuitive
– Attempts to increase accuracy led to:
• Slower Attenuation
• Unstable Systems
– Mathematical Prediction became necessary.
• J.C. Maxwell Developed a Mathematical Theory
Based on a Governor
• I.A. Vyshnegradskii Developed a Mathematical
Theory Based on a Regulator
Servo Development in U.S.
• Bell Labs in the 1920’s
– Telephone Development
– Need for Stable Amplifier
Systems
– Carry Conversations
Over Thousands of Miles
• World War II
– Automatic Pilots
– Gun Positioning
Systems
– Radar Tracking Systems
• Space Age
– Missile Control
– Satellite Control
 Servo Theory
• Components
– Summing Junction
• Sums Negative Feedback and Command
• Generates Error
– Amplifier
• Amplifies the Error Signal
C C-F=E E EA=F
+ A
-
F

Summing Junction Amplifier

 Basic Servo Drive
• Summing Junction + Amplifier =
Basic Servo
C E F
+ A
-
F

Question:
What do we mean when we talk about the gain of a servo system?
 System Gain
C G F
System Gain

• System Gain is Comprised of Many Factors

– Amplifier Gain (A)
– Friction
– Slippage
– Environmental Constraints
– G = Amp Gain+ Friction Effects + Environment + ...
• We Can Change the System Gain!!!
– Changing System Components
– Adjusting Amplifier Gain
– Changing Loads
 System Gain (Open Loop)
• System Gain is a Ratio of How
Closely the Output Matches the
Command
C F
G

F
(C )
F = CG
The gain of an open loop system is G
F
= G
C
System Gain (Closed Loop)
• System Gain is a Ratio of How Closely
the Output Matches the Command
C E F
+ G
-
F

1. C - F = E 5. CG = F + FG
The gain of a closed loop
2. EG = F 6. CG = F(1+G) system is G

3. (C-F)G = F F G 1 +G
7. =
C 1 +G
4. CG - FG = F
 Question
• Can an Open Loop System Achieve
a 1:1 Relationship between Output
and Input?
• Can a Closed Loop System Achieve
a 1:1 Relationship between Output
and Input?
Question:
If an open loop system can achieve a 1:1 correspondence of input and
output and a servo system cannot, why in the world would we choose a
servo system over an open loop system?
 Four Reasons
• Sensitivity
– We want the system to be as insensitive as possible to
system gain changes
• Transient Response
– We can manipulate the responsiveness of the system
– We actually can achieve a 1:1 correspondence
• Disturbance Rejection
– Disturbances are changing loading conditions
– We would like the system to be able to filter the effects of
changing load conditions
• Steady State Error
– A system wit h little error after the transient response is
desirable.
• Let’s examine each one of these issues more closely...
 Sensitivity
• The prime advantage of a servo system is its
reduced sensitivity to changes in the system
gain G.
• Example
– Belt & Pulley System
• The system may have gain G before the belt stretches.
• The system gain after the belt stretches will be G - ∆G.
– Lets compare the change in output (∆F) due to G - ∆G
in an open and closed loop system to see the
difference...

G G - ∆G
 Sensitivity
Open Loop Closed Loop

F= G
F = GC C
1+G
F - ∆F = C(G - ∆G)
F - ∆F = G - ∆G C
1 + G - ∆G
∆ F = ∆GC

G - ∆G G
- ∆F = - C
1 + G - ∆G 1+G

- ∆G
- ∆F = C
(1 + G) (1 + G - ∆G)

∆G
For G>> ∆G ∆F = C
(1 + G)2
 Sensitivity
Open Loop Closed Loop

G=1 G = 50
C = 10 C = 10

F = 10 F = 9.8
G

∆G = .1G = .1 ∆G = .1G = 5
C = 10 G = 50
C = 10
∆F = 1
G - ∆G ∆F = .019

In this case the change in output of the open loop system due to an incremental
change in the system gain is 50 times worse than the closed loop system.
 Transient Response
• The transient response is the
system response as a
function of time.
• Most systems have a Actual
required transient response.
• Open loop
– If an open loop system does Desired
not meet the required
response, a different v
system gain must be
selected. t

• Closed Loop
– We can adjust the closed C E F
loop transient by altering + G
the feedback. -
– We will see another way
later.
H
 Transient Response
C + E G
-

• The gain of the system now becomes:

Magic:
F = EG = G(C - HF)
We
F can compensate for
F(1 + GH) = GC changes in the system gain G
by adjusting the feedback H.
F G
= Notice that due to this we can
C 1 + GH
now achieve a 1:1 input to
output ratio.
 Disturbance Rejection
• Example - Pinch Roller System
A. Before the material reaches the
system the motors turn unloaded
B. When the material reaches the rollers
they impart what is termed a
“disturbance” on the system gain.

A. Prior to disturbance B. Load imparts disturbance

 Disturbance Rejection
D

F
G1 - G2
+
-

• The disturbance gain disrupts the process.

• We must now look at two components of the system gain
(G1 & G2).

• We can analyze the effect of the disturbance by

diagramming it as shown above
 Disturbance Rejection
D

F
G1 - G2
+
-

F = G2 (-D - G1HF)

F = -G2D - G1G2HF You can see that we can reduce the

effect of the disturbance D on the
F -G2 output by increasing G1.
=
D 1 + G1G2H
 Steady State Error
• Steady State Error
– Error remaining after the transient
response has decayed.
V Steady State Error

t
 Steady State Error
• Let’s look at Steady State Error in an
open and closed loop system:
C E F
+- G
C F
G
F

E=C-F E=C-F

E = C - CG F = GE

E = (1 - G)C E = C - GE

E(1 + G) = C

E= [ 1
1+G ]C
 Steady State Error
• Open Loop Error
– 1-G
– Very subject to system gain changes
– G can be initially 1
• Will change due to factors such as belt slippage

• Closed Loop Error

– 1
1+G
– If the system gain is high, closed loop error is low
– Not as susceptible to system gain changes.
 Embedded Feedback Loops
• Torque Loop
• Velocity Loop
• Position Loop
• Application Loop
 Feedback - Torque Loop

Command
signal
+
- K Amp Amp

Simple Transconductive Amplifier

 Feedback - Velocity Loop

K FF

+
+ E
- KP + E
- KAmp Amp
Velocity
Command

KTach
Feedback - Position Loop

K FF

KPP
+
+ E
-
K PI + E
- K VP TAmp
K PD

KTach
 Feedback - App. Logic

KFF
KPP
Application +
Logic
+-E KPI +-E KVP TAmp
KPD
KTach

External
Inputs
 Feedback Review
• Servo Systems Date Back to 300 B.C.
– Servo Systems are not only motor drives
• Several Factors make servos desirable
– Low Sensitivity to System Gain changes
– Ability to change the Transient Response
– Ability to reject Disturbances
– Low Steady State Error
• Embedded Loops provide layers of
control
 Motion Control III

Servo and Stepper Theory

 Servo/Stepper Overview
• Physics of Motors
• Common Components
• Stepper Motor Components
• Servo Motor Components
• Stepper Motor Operation
• Servo Motor Operation
 The Physics of Motion

Hybrid Step Brushed Servo Brushless Servo

 Principles of Magnetism

Opposite poles attract

N
S
Like poles repel N
S
 Principles of
Electromagnetism
Current carrying conductor wrapped around
a ferromagnetic material generates a magnetic field

Current
 Electromagnets and
Magnets Interact
Current flowing through a conductor in a
magnetic field induces a force perpendicular
to the field and to itself

Force

Magnetic field
N S
Current
 Common Components
• Each of these motors have:
– Permanent magnets, on the rotor or
stator
– Electromagnets, on the stator or rotor
– Commutation devices, internal or
external to the motor
 Stepping Motor Types
• Stepping motors
– Variable reluctance (VR)
– Permanent magnet (PM)
– Hybrid
• Rotary & Linear
 Stepping Motor

COMMUTATION
FIXED SWITCHING
SEQUENCE

ELECTROMAGNETS STATOR

PERMANENT MAGNETS ROTOR

MOTOR
Servo Motor Types
Brushed Brushless
 Brushed Motor

COMMUTATION BRUSHES

ELECTROMAGNETS ROTOR

PERMANENT MAGNETS STATOR

MOTOR
 Evolution of the
Brushless Motor
• Brushed motors are thermally limited due
to the heat dissipation of the motor
• The heat generated in the windings must
dissipate through the air gap to the
magnets, through the case to the outside
air or through the shaft
• In order to make it more efficient, the
windings were placed on the outside
(stator), and the magnets were moved to
the inside (rotor)
 Brushless Motor
COMMUTATION ROTOR POSITION
SENSOR

ELECTROMAGNETS STATOR

PERMANENT MAGNETS ROTOR

MOTOR
 Motor Operation
• Stepper Motor
• Brushed Servo
• Brushless Servo
Step Motor Operation
Step Motor
 Brushed Servo Operation
Brushed Servo
Brushed Tachometer

Output

Velocity

Voltage
Brushless Servo Operation
Brushless Servo

Motion Amplifier
Controller Motor

Electronic
Commutator
 Application
• Stepper Motor • Brushed Servo
– Open Loop – Lowest Cost
– Slower Speeds – Low duty cycle
– Lower Cost – Smoothness
– Less Cables
• Brushless Servo
– High Speed
– Large Torque/Size
– Torque Control
– Closed Loop
 Step Motor App
• Application #52
– Customer is a fireworks supplier that
manufactures his own processing
equipment
– Accuracy's are +/-0.003”
– Looking for cost effective solution to
automate two stations
 Step Motor App
I/O for Station #2
Solenoid-Operated
Dispenser
PLC

SD/IFX
Rack

Cap Filling
Station #1
Control for motors on
Cap Filling Station #2
(same as Station #1)
 Brushed Servo Motor App
• Application for a brushed servo motor
– Customer needs to very accurately machine
a piece of quartz used as a dielectric
– The quartz needs to be hollowed out on both
sides until the correct amount of material is in
the center
– The cut is made at an exceptionally slow
speed
– The final drill speed is .001 in/sec
 Brushed Servo Motor App
• Using a real time velocity loop with
a tachometer, tuning can minimize
velocity ripple
• The brushed motor is smoother than
a microstepping step motor in this
application
Brushless Servo Motor App
• Application #34
– Customer bales crimped acetate fiber
used in cigarette filters
– The duty cycle on these machines is
24 hours a day, 364 days a year
– The acceleration commands are
instantaneous for the X and Y motors
 Brushless Servo Motor App
1:1 Right Angle Gearboxes

Nip Roller Motor

Drive Shaft
Y Traverse
Motor Belt

X Traverse
Motor

Fiber Material Ball Screws

 Servo/Stepper Review
• Motors use a combination of
permanent magnets and
electromagnetism to create rotation
• Step motors use a preset sequence
to create open loop motion
• Servo motors use motor feedback to
determine position and react.
Motion Control IV

Communications
Communications Overview
• RS-232
• RS-485
• Ethernet
• Ethernet/IP
• DeviceNet
• Profibus
• CAN Open
 Why is this important?
• Interchangeable Hardware
• Future Connectivity
• Cost Driver
• Bandwidth
• Future Expansion
• Industry Specification
RS-232
RS-485
Ethernet
Ethernet/IP
DeviceNet
Profibus
CAN Open
Communications Review
 Motion Control Review
• Architectures – There are a variety of
different ways to connect components to
achieve the same result
• Feedback Loops – You really can’t
control things without feedback
• Servo vs Stepper Theory – Servo motors
provide high speed and torque control
while stepper motors provide low cost
smooth position control
• Communications – Application needs,
existing equipment and cost drive the
bus.