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, 11 Design
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1.10 Sequential Design Example: Disk Drive Read
System
We will use the design process of Figure 1.17 in each chapter to identify the steps that we are
accomplishing. For example, in Chapter 1 we (1) identify the control goal, (2) identify the variables to
control, (3) write the initial specifications for the variables, and (4) establish the preliminary system
configuration.
The first step in the design process consists of establishing the system goals. For example, we may state
that our goal is to control the velocity of a motor accurately. The second step is to identify the variables
that we desire to control (for example, the velocity of the motor). The third step is to write the
specifications in terms of the accuracy we must attain. This required accuracy of control will then lead to
the identification of a sensor to measure the controlled variable. The performance specifications will
describe how the closed-loop system should perform and will include (1) good regulation against
disturbances, (2) desirable responses to commands, (3) realistic actuator signals, (4) low sensitivities,
and (5) robustness.
As designers, we proceed to the first attempt to configure a system that will result in the desired control
performance. This system configuration will normally consist of a sensor, the process under control, an
actuator, and a controller, as shown in Figure 1.3. The next step consists of identifying a candidate for
the actuator. This will, of course, depend on the process, but the actuation chosen must be capable of
effectively adjusting the performance of the process. For example, if we wish to control the speed of a
rotating flywheel, we will select a motor as the actuator. The sensor, in this case, must be capable of
accurately measuring the speed. We then obtain a model for each of these elements.
Students studying controls are often given the models, frequently represented in transfer function or
state variable form, with the understanding that they represent the underlying physical systems, but
without further explanation. An obvious question is, where did the transfer function or state variable
model come from? Within the context of a course in control systems, there is a need to address key
questions surrounding modeling. To that end, in the early chapters, we will provide insight into key
modeling concerns and answer fundamental questions: How is the transfer function obtained? What
basic assumptions are implied in the model development? How general are the transfer functions?
However, mathematical modeling of physical systems is a subject in and of itself. We cannot hope to
cover the mathematical modeling in its entirety, but interested students are encouraged to seek outside
references (see, for example, [76–80]).
Figure 1.17 The control system design process.

The next step is the selection of a controller, which often consists of a summing amplifier that will
compare the desired response and the actual response and then forward this error-measurement signal to
an amplifier.

The final step in the design process is the adjustment of the parameters of the system to achieve the
desired performance. If we can achieve the desired performance by adjusting the parameters, we will
finalize the design and proceed to document the results. If not, we will need to establish an improved
system configuration and perhaps select an enhanced actuator and sensor. Then we will repeat the design
steps until we are able to meet the specifications, or until we decide the specifications are too demanding
and should be relaxed.

The design process has been dramatically affected by the advent of powerful and inexpensive computers
and effective control design and analysis software. For example, the Boeing 777 was almost entirely
computer-designed [56, 57]. Verification of final designs in high-fidelity computer simulations is
essential. In many applications, the certification of the control system in realistic simulations represents
a significant cost in terms of money and time. The Boeing 777 test pilots flew about 2400 flights in
high-fidelity simulations before the first aircraft was even built.
Another notable example of computer-aided design and analysis is the McDonnell Douglas Delta
Clipper experimental vehicle DC-X, which was designed, built, and flown in 24 months. Computer-
aided design tools and automated code-generation contributed to an estimated 80 percent cost savings
and 30 percent time savings [58].
In summary, the controller design problem is as follows: Given a model of the system to be controlled
(including its sensors and actuators) and a set of design goals, find a suitable controller, or determine
that none exists. As with most of engineering design, the design of a feedback control system is an
iterative and nonlinear process. A successful designer must consider the underlying physics of the plant
under control, the control design strategy, the controller design architecture (that is, what type of
controller will be employed), and effective controller tuning strategies. In addition, once the design is
completed, the controller is often implemented in hardware, and hence issues of interfacing with
hardware can appear. When taken together, these different phases of control system design make the
task of designing and implementing a control system quite challenging [73].
Design Problems
Design problems emphasize the design task. Continuous design problems (CDP) build upon a design
problem from chapter to chapter.

CDP1.1 Increasingly stringent requirements of modern, high-precision machinery are placing increasing

demands on slide systems [53]. The typical goal is to accurately control the desired path of the table
shown in Figure CDP1.1. Sketch a block diagram model of a feedback system to achieve the desired
goal. The table can move in the x direction as shown.

Figure CDP1. 1 Machine tool with table.

2.10 Sequential Design Example: Disk Drive Read
System

Figure 2.70 Head mount for reader, showing flexure.

Figure 2.71 Block diagram model of disk drive read system.
Figure 2.72 Block diagram of closed-loop system.
Design Problems
CDP2.1

Figure CDP2.1 (a) Traction drive, capstan roller, and linear slide. (b) The block diagram model.

We want to accurately position a table for a machine as shown in Figure CDP2.1. A traction-drive

motor with a capstan roller possesses several desirable characteristics compared to the more popular ball
screw. The traction drive exhibits low friction and no backlash. However, it is susceptible to
disturbances. Develop a model of the traction drive shown in Figure CDP2.1(a) for the parameters
given in Table CDP2.1. The drive uses a DC armature-controlled motor with a capstan roller attached to
the shaft. The drive bar moves the linear slide-table. The slide uses an air bearing, so its friction is
negligible. We are considering the open-loop model, Figure CDP2.1(b), and its transfer function in this
problem. Feedback will be introduced later.
Figure 2.20 Armature-controlled DC motor.
3.10 Sequential Design Example: Disk Drive Read
System
Figure 3.37
(a) Model of the two-mass system with a spring flexure. (b) Simplified model with a rigid spring.
Figure 3.38
Transfer function model of head reader device with a rigid spring.
Figure 3.39
Response of y for a step input for the two-mass model with k=10.
Design Problems
4.10 Sequential Design Example: Disk Drive Read
System
The design of a disk drive system is an exercise in compromise and optimization. The disk drive must
accurately position the head reader while being able to reduce the effects of parameter changes and
external shocks and vibrations. The mechanical arm and flexure will resonate at frequencies that may be
caused by excitations such as a shock to a notebook computer. Disturbances to the operation of the disk
drive include physical shocks, wear or wobble in the spindle bearings, and parameter changes due to
component changes. In this section, we will examine the performance of the disk drive system in
response to disturbances and changes in system parameters. In addition, we examine the steady-state
error of the system for a step command and the transient response as the amplifier gain Ka is adjusted.
Figure 4.27 (a) System sensitivity to plant variations (s=jω).(s=jω). (b) m-file script.
5.11 Sequential Design Example: Disk Drive Read
System
Figure 5.39 Control system model with a second-order model of the motor and load.
Figure 5.41 Response of the system to a unit step disturbance, Td(s)=1/s. (a) m-file script. (b)
Response for Ka=30 and 60.
Design Problems
6.7 Sequential Design Example: Disk Drive Read
System
Figure 6.24 The closed-loop disk drive head system with an optional velocity feedback.

Figure 6.25 Equivalent system with the velocity feedback switch closed.

Figure 6.26 Response of the system with velocity feedback. (a) m-file script. (b) Response
with Ka=100 and K1=0.05.
Design Problems
CDP6.1 The capstan drive system of problem CDP5.1 uses the amplifier as the controller. Determine
the maximum value of the gain Ka before the system becomes unstable.
7.10 Sequential Design Example: Disk Drive Read
System
In this chapter, we will use the PID controller to obtain a desirable response using velocity feedback. We
will proceed with our model and then select a controller. Finally, we will optimize the parameters and
analyze the performance. In this chapter, we will use the root locus method in the selection of the
controller parameters.
8.8 Sequential Design Example: Disk Drive Read
System

Figure 8.48 (a) Engraving machine step response for K=2.K=2. (b) m-file script.

Figure 8.49 Spring, mass, friction model of flexure and head.
Figure 9.65 Remotely controlled vehicle. (a) Nichols chart. (b) m-file script.
Figure 9.66 (a) Nyquist plot for the remotely controlled vehicle with K=10.K=10.(b) m-file script.
Figure 9.67 Bode plot of the disk drive read system.

Figure 9.68 Response of the disk drive read system to a step input.

Design Problems
CDP9.1 The system of Figure CDP4.1 uses a controller Gc(s)=Ka. Determine the value of Ka so that
the phase margin is P.M.=70°. Plot the response of this system to a step input.
Figure 10.37 Disk drive control system with PD controller (second-order model).
Design Problems
CDP10.1 The capstan-slide system of Figure CDP4.1 uses a PD controller. Determine the necessary
values of the gain constants of the PD controller so that the deadbeat response is achieved. Also, we
want the settling time (with a 2% criterion) to be Ts≤250ms. Verify the results.
11.11 Sequential Design Example: Disk Drive Read
System
In this chapter, we will design a state variable feedback system that will achieve the desired system
response. The specifications for the system are given in Table 11.2. The second-order open-loop model
is shown in Figure 11.35. We will design the system for this second-order model and then test the
system response for both the second-order and third-order models.
Design Problems
CDP11.1 We wish to obtain a state variable feedback system for the capstan-slide the state variable
model developed in CDP3.1 and determine the feedback system. The step response should have a
percent overshoot of P.O.≤2% and a settling time of Ts≤250 ms.