Vietnam National University Ho Chi Minh City

Ho Chi Minh City University of Technology

Faculty of Mechanical Engineering
Department of Mechatronics Engineering

Subject:
Industrial Motion Control System

Overview

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

 Content

▪ Introduction

▪ Practical application

▪ Review on Electric Device

▪ Servo system

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

Introduction
 Contact Address
► Office:
▪ Department of Mechatronics Engineering-Faculty of Mechanical
Engineering
▪ Ho Chi Minh City University of Technology
▪ 268 Ly Thuong Kiet, District 10

► Lecturer: Dr. Ngô Hà Quang Thịnh

▪ Mobile: 0961382007
▪ Mail: nhqthinh@hcmut.edu.vn

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

 Purpose & Content
● This course aims at giving students basic knowledges about industrial
motion control and their applications in industry.
● The subject includes knowledge such as: structural principles,
kinematics and modeling, statics and control simulation and their
applications in industry.
o Definitions, operating principles
o Classifications of Motion Control System
o Components of Motion Control System
o Dynamics of Servo Model
o Simulation, Modeling and Experiments

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

 References

● N. H. Q. Thinh, Điều khiển Servo trong hệ thống cơ điện tử, Drafted

version, HCMUT
● Chuck Lewin, Mathematics of Motion Control Profiles, PMD
Motion
● Luigi Biagiotti, Claudio Melchiorri, Trajectory Planning for
Automatic Machines and Robots, Springer, 2008

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

 Evaluations
● Document will be uploaded in BKEL weekly. Student could
download and print out when coming to class.
● The overall scores are estimated via
● Homeworks (individual, group)
● Experiments
● Process of studies
● Final exam

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

 Detailed Content

● Chapter I: Overview
● Chapter II: Types of Motion Control System
● Chapter III: Modeling and Simulation
● Chapter IV: Investigation in Motion Control IC
● Chapter V: Hard ware and Software
● Chapter VI: Experimental Application

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

Practical Applications
 Examples of Motion Control System

Conveyor handling system

Five-axis CNC machines

Six-axis Robot
TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn
Examples of Motion Control System

Many devices for motion controls of an aircraft

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn
Examples of Motion Control System

motion controls of a ship

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn
Examples of Motion Control System

motion controls of a camera platform

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More Examples ?

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Motion Control System
 Motion Control Definition

Motion control is a sub-field of automation, encompassing the systems or sub-systems

involved in moving parts of machines in a controlled manner. The main components
involved typically include a motion controller, an energy amplifier, and one or more
prime movers or actuators. Motion control may be open loop or closed loop. In open
loop systems, the controller sends a command through the amplifier to the prime
mover or actuator, and does not know if the desired motion was actually achieved.
Typical systems include stepper motor or fan control. For tighter control with more
precision, a measuring device may be added to the system (usually near the end
motion). When the measurement is converted to a signal that is sent back to the
controller, and the controller compensates for any error, it becomes a Closed loop
System.

Simplified definition: Drive movement of systems that includes

position, velocity, and force

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

 Motion Control Definition

There many “drive” devices such as electric, hydraulic,

pneumatic drives.

- In this course, we just interested in motion control of AC servo

devices

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

Review on Electric Device
Electric Actuator
DC motor Brushless DC motor

Stepper motor AC motor

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

DC Motor

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 DC Motor
F: force on the conductor (in Newton)
The magnitude of the I: current through the conductor (in amperes)
force on the wire: B: magnetic flux density (in gauss)
L: length of the wire (in meters)
: angle between the magnetic field and current

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

 BLDC Motor

Brushless DC motors (BLDC) operate without brushes by taking advantage of modern

electronic switching techniques.

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

 BLDC Motor

Exploded view of a brushless DC motor

with Hall-effect sensor

A magnetic sensor as a rotor position

A resolver as rotor position indicator

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn
BLDC Motor

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

 BLDC Motor
A schematic of a generalized three-phase BLDC

Advantages: extremely reliable, very efficient, and easily controlled.

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

 AC Motor
AC motors work by rotating the stator field. It makes use of the natural alternating
nature of the AC wave to turn the field coils on and off sequentially.

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

 AC Motor
The rotor is always going slower than the rotating field, and this difference is
referred to as slip. Slip is frequently given as a percentage (usually less than
10%) of the stator speed.

Synchronous equation:
Ss: synchronous (stator) speed (in rpm)
Sr: rotor speed (rpm)
f: frequency of the AC line
P: number of field poles per phase

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

 Stepper Motor
A stepper motor is a unique type of DC motor that rotates in
fixed steps of a certain number of degrees. Step size can range
from 0.9 to 90°.

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

 Stepper Motor

Excitation modes for PM stepper motors

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 Stepper Motor

The top electromagnet (1) is

The top electromagnet (1) is turned turned off, and the right
on, attracting the nearest teeth of a electromagnet (2) is energized,
gear-shaped iron rotor. With the teeth pulling the nearest teeth slightly to
aligned to electromagnet 1, they will the right. This results in a rotation
be slightly offset from electromagnet of 3.6° in this example.
2
TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn
Stepper Motor

The left electromagnet (4) is enabled,

rotating again by 3.6°. When the top
The bottom electromagnet (3) is electromagnet (1) is again enabled, the
energized; another 3.6° rotation teeth in the sprocket will have rotated
occurs. by one tooth position; since there are
25 teeth, it will take 100 steps to make
a full rotation in this example.
TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn
Stepper Motor

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

Servo System
 Servo System
What is a servo motor? - A command signal which is issued from the user's interface
panel comes into the servo's "positioning controller". The positioning controller is the
device which stores information about various jobs or tasks. It has been programmed
to activate the motor/load, i.e. change speed/position.

Concept of a servo system

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn
 Diagram of Servo System
electr. energy

PC, set value motion

controller command amplifier
PLC
energy
servo amplifier current
losses
position speed
signal signal motor
position,
sensor speed

load
position,
speed
mech. energy
TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn
 Issues in Motion Control System

▪ Current control = torque control

- Maintaining current (torque) constant
- Mostly included in controller (but not always accessible)
- For fast motor reaction
- No special feedback device needed
▪ Speed control
- Maintaining speed constant
- "speed = 0" does not mean "position is held"
▪ Position control
- Moving from position to position, stop at and maintain a position

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 Control Loop

set value system

 controller  motor
+ deviation +
- -
current-
feedback
actual value sensor

incremental
IxR DC tacho encoder Hall sensor resolver

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 Analog Encoder Speed Control Loop
• Speed control loop with encoder feedback
- Amplification (gain) depends on parameters PID
- Applies also to Hall Sensor feedback with EC motors (6 IMP)
• Current control loop
- Subordinate control loop, enhances system dynamics
- Power amplifier (MOSFET)

speed power
amplifier (PID) amplifier
set value R current current
 E  motor
speed + command +
- -
current-
C
feedback
speed
feedback encoder

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

 Digital Control Loop
• Digital parameters (profile, position, amplification)
• DSP: digital signal processor
• Firmware: software of the controller

power
amplifier
set value
current
speed
command motor
DSP
current feedback
set value
position

path position position feedback

generator decoder
speed feedback encoder

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 Gain/Amplification PID
Amplifier (PID)
set value E current
How the deviation signal E is it amplified to  command
produce a purposeful reaction (current +
command)?
actual value
• P: Proportional (a multiplication = "amplification") system reaction
– Problem: very small deviation lead to small corrections
only. The set value cannot be reached. PI
– Remedy: Combination of P and I
• I: Integration P only
– A persisting deviation is summed up (integrated) and
eventually corrected.
• D: Differentiation PID
– a sudden increasing deviation (e.g. a set value jump),
produces a strong reaction
– for dynamic reaction set value
– overshoot, instability
t

TS. Ngô Hà Quang Thịnh, nhqthinh@hcmut.edu.vn

 How to Measure the Feedback Value

• Open loop
– no feedback system
• Current control
– no special feedback
• Speed control
– feedback devices for DC motors: Encoder, DCTacho, Hall-sensor
• Position control
– feedback devices: Encoder, Hall-Sensor

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Comparisons

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The End

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