Motion control and servo systems

(MET 437)
Lecture 4
Issues and stability of servo
system

Dr. Mohamed Saber Sokar

Objective of the lecture

 After finishing the lecture, the student will be able to
Recognize the following
Types of servo system
Issues in Mechatronic DC Servo Systems
1.Modeling of a mechatronic servo system.
2.Performance of one axis in a mechatronic servo system.
3.Performance of multiple axes in a mechatronic servo system.
4.Command to servo system (velocity or displacement)
Control structure of the servo systems
Issues in Mechatronic DC Servo Systems
 Stability analysis of a DC Servo Motor System

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 Introduction
 Servo Motors are basically DC Motors with addition
circuit (driver) that support in achieving precise
position of the servo motor.
In order to manage the rotation of the servo motor’s shaft,
you require a special signal called Pulse Width Modulation
PWM signal.
Depending on the width of the pulse, the position of the
servo motor differs. There are various ways in which you
can create the PWM Signal to control a Servo Motor. The
normal way is to use fully analog circuits like the Timer IC
and using a potentiometer to manage the width of the pulse.

Dr. Mohamed Saber Sokar 3 Session 04

Types of Servo Motor

Types of servo motors

AC servo Dc
motors Servomotors

Two phase Three-phase

AC AC
Servomotors servomotors
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 Zero order hold
 The zero-order hold is a method which is widely used to
reconstruct the signals in real time.
 In the zero-order hold, the continuous signal is reconstructed
from its samples by holding the given sample for an interval until
the next sample is received. Therefore, the zero-order hold
generates the step approximations as shown in Fig.

The transfer function of the zero-order hold is given by,

h s
Dr. Mohamed Saber Sokar 5 Session 04

Issues in Mechatronic DC
Servo Systems
 Issues in Mechatronic Servo Systems

1. Modeling of a mechatronic servo system.

2. Performance of one axis in a mechatronic servo system.
3. Performance of multiple axes in a mechatronic servo
system.
4. Command to servo system (velocity or displacement)

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 Issues in Mechatronic DC
Servo Systems
 1. Modeling of a mechatronic servo system.

Modeling of servo system

Model considering servo Model the overall

system and the load but mechatronic servo system
neglect mechanism combining the mechanism
structure structure and servo system

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Issues in Mechatronic DC
Servo Systems
 The parameter representing the industrial
mechanism/ machine can be expressed by Kp.

 The value of Kp is high in huge rigid machines.

Kp rages from 35–40 s-1 in rotation plate, machine
center, etc.,
Kp is 15 s-1 in an industrial robot.

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 Issues in Mechatronic DC
Servo Systems
 2. Performance of one axis in a mechatronic servo
system.
 Discrete time interval
There are two problems on discrete time interval.
(A-) The first discrete time intervals is the data renewal
time interval of control system used in the software of a
mechatronic servo system which is determined by
sampling frequency.
Whereas there exist some delay time and 0th order hold with
this time interval for mechatronic servo system, this time
interval greatly affects the performance characteristic of
closed-loop control system.
Dr. Mohamed Saber Sokar 9 Session 04

Issues in Mechatronic DC
Servo Systems
 Proper Sampling Frequency:
Digital signal processor (DSP) or Microprocessor are
installed into closed-loop of servo system.
The eigenvalue of position control servo system based on
the realized software from the analogue velocity of a control
device cannot be over 1/30 sampling frequency.
In general, in a software of the servo system, the maximal
sampling frequency is selected under the constrain of
hardware cost.

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 Issues in Mechatronic DC
Servo Systems
(B-) The second discrete time intervals coming from the
upper controller, i.e., the computer using for internal
trajectory calculation of the controller, which is
performed by the time interval of the input command to
the servo system.
Where, the overall servo system performance can be
determined from the relation between time interval
providing the command and output performance of the
control system.
From this point of view, the value of these discrete time
intervals are very important for analyzing the performance
of a mechatronic servo system.
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Issues in Mechatronic DC
Servo Systems
 Reference Input Time Interval:
 It is the input command data to the controller of the servo system
given in a designated period; it is also called the (controller
system clock).
 The reference input time interval is discrete width, within this 
interval, the command function of each axis is calculated. This 
calculated value is obtained in the servo system with the state 
of zero order hold. From this, the motion of a servo system 
generates velocity periodic variation depends on this time 
interval and trajectory deterioration.
 In newly developed controller, the reference input time interval 
value has the trend to be minimal.  

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 Issues in Mechatronic DC
Servo Systems
 Quantization Error and Control Performance of
Control System
 In the construction of the control system, high response
performance is generally required from its internal minor-
loop. In the electric servo system, current (torque)
feedback loop is the inner-most loop. How resolution of
current detection is expected for satisfying the required
performance of servo system. It is an important item to
discuss in the stage of designing hardware constructing
servo system.
 The quantization scale of control system internal, i.e.,
resolution is determined based on experience.
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Issues in Mechatronic DC
Servo Systems
 3- Performance of a Multi-Axis Mechatronic Servo System
 3.1 Torque saturation is a basic induced phenomena can
be found in the motion of multi-axis servo systems. But in
the state of one axis, there is almost no problem due to
torque saturation from the servo system performance
point of view.
 Torque saturation will cause a
loss of performance of servo
system.
 Motor saturation occurs when the
current flowing through a motor
exceeds its maximum rated value.
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 Issues in Mechatronic DC
Servo Systems
 Servo motor torque:
The servo motor torque curve, which indicate the amount of
torque a motor can produce over its range of operating speeds, is
one of the most useful tools in servo motor sizing and selection.
Servo motors have two
operating zones: continuous
duty and intermittent (peak)
duty.
When evaluating whether an
application lies within the
continuous duty zone, the
motor’s root mean square
(RMS) torque is used.
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Issues in Mechatronic DC
Servo Systems
 Servo motor torque:
 In actual servo systems, constant coulomb friction from motion
resistance consumes a big part of rated torque when the servo
system is installed into a mechanism. It means that, the opposite
force in operation is regarded as the torque load.
 When clarifying the condition of a mechatronic system
application, it must grasp that in which scale torque
reaches saturation in the state of capable motion of the
mechanism as well as in which degree, control
performance deteriorates due to torque saturation.
 Generally, in mechatronic servo systems of a mechanism,
the ratio of maximal rated torque that can be used with
respect to acceleration/deceleration is about 1:375.
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 Issues in Mechatronic DC
Servo Systems
 What are the potential consequences of motor saturation (and
thus controller instability)?
1. Reduced torque output: This can result in a loss of power and reduced
performance of the system being driven by the motor.
2. Increased heat generation: This can lead to thermal damage and
reduced lifespan of the motor.
3. Controller instability: This occurs when the controller is no longer
able to accurately control the motor due to the high current levels. This
can result in uncontrolled movement or vibration of the system being
driven by the motor.
4. Reduced efficiency: which can result in increased power consumption
and higher operating costs.
Hint: It is important to ensure that the motor is not operated above its
maximum rated current in order to avoid saturation.
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Issues in Mechatronic DC
Servo Systems
 3.2 Master-Slave Synchronous Positioning Control
method
 It is the control method that must satisfy the ratio between the
movement of one axis to another axis.
 Example of this control, is the motion performance required in the
tapping process of a center lathe.
 In the tapping process, the 1st axis
is the master axis.
o This axis is moving as the
control system performing start
and stop stage form driving
installed in the turning
machines.
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 Issues in Mechatronic DC
Servo Systems
 The 2nd axis is the transfer axis that should be traced, namely
synchronized. So, it performs a parallel movement as a position control
part.
 When the tapper is kept as the master axis, if it rotated once, the
transfer axis must be moved correct one pitch of the lath’s screw.

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Issues in Mechatronic DC
Servo Systems
 4. The Command of Mechatronic Servo Systems
 4.1 Modified Taught Data Method
 The contour control for a three-dimensional curve of
industrial robot, the curve is approximated by a folded line.
 In the contour control, the locus (position) and its motion speed
are the important control parameters.
 As usual, the ramp input with a designated slope for each
axis as its command is introduced.
 In such a kind of robot, when three points and
angles are described by a line trajectory, at the
corner part, the trajectory deviates from the
corner point depending on the velocity.
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 Practical Mechatronic Servo
System
 CNC servo system

Servo Servo Manual 

motor drive Pulse 
Generator
(MPG) 

Input/output board

Servo
Servo drive motor

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Practical Mechatronic Servo

System
 Servo Drive Incremental Absolute Motor Controller
Driver

Short Description:
Power supply: ~220V
Output current: 30A
Output power: 2.3KW
Output torque: 1~15NM
Type: AC servo
Certification: CE
Weight: 2kg

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 Practical Mechatronic Servo
System
 Product Features
1. The motor power adapt 100W-11KW
2. Single channel, two-channels AC servo motor driver controlling system
3. Switch to torque, speed, position, locate with point to point and mixed mode
4. Position control, speed control, servo electrical tool rest and JOG controlling mode
5. With built-in 4 segment locating position could control point to point locate freely
6. Accuracy of locating ±0.01%
7. Input frequency of pulse is less than 500KHZ
8. Analog input: 0~10V or 0~±10V
9. Modified the space vector algorithm, the torque is bigger than the normal SPWM,
the sound is lower
10. Overload capacity 300%
11. The power supply adapt ~220V±20% or ~380V±20%
12. Perfect protection: Overload current, overload voltage, overload heat, short
circuit and fault of encoder
13. Many kinds of display: Rotating speed, current and offset position of motor,
number of pulse, pulse frequency, straight line speed, diagnosis of input and output,
history records of alarm and so on
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Practical Mechatronic Servo

System
 Production line transmission and positioning system
GH AC-servo drive can be widely used in coordinate axis control of CNC milling
machine, lathe, gantry/huge machine tools, which can realize:
◆Coordinate axis back to zero automatically
◆Independent handwheel control of coordinate axis
◆Absolutely independent drive with manual single shaft

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 Mathematical Model of a
Mechatronic Servo System
 4th Order Model of One Axis in a Mechatronic Servo System
 The structure of mechatronic servo systems in industry can be
expressed in high order (i.e., 4th order model) for expressing all
factors. This 4th order model correctly expresses the response
characteristic of one axis of a mechatronic servo system

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Stability a DC Servo Motor

System
 Example:
 Consider the transfer function model of the
servomotor is.
𝜃 s K
𝐸 s 𝑠 (𝜏 𝑠 1
Assume motor time constant 𝜏 0.1 ms & 𝐾 =2

Study the stability of the Servomotor by using Bode plot

method.

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 Stability a DC Servo Motor
System
 Solution
 Let 𝑠 𝑗𝜔
 G 𝑗𝜔
.

 𝐾 2
 𝐾 20 log 2 6 𝑑𝑏
 ∅ ∠ 𝐺 𝑗𝜔 𝐻 𝑗𝜔 90 tan 0.1𝜔

ω 0 0.1 1 5 10 100 1000 ∞

∅ -90 -90.6 -95.7 --116.56 -135 -174.3 -179.43 -180

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Stability a DC Servo Motor

System
 Log magnitude
Element ωc Slope Net slope
1 - -20 -20
𝑠
1 10 -20 -40
0.1 𝑠 1

 From bode plot

Phase margin PM ≅ +58o
Gain margin GM ≅ +∞ db

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 Stability a DC Servo Motor
40
System
20
0
Magnitude (dB)

-20
-40 GM=+ ∞
-60
-80
-100
-120

0
From bode plot
-90 Phase margin PM ≅ +58o
Phase (deg)

Gain margin GM ≅ +∞ db
𝑷𝑴 +58o

-180 Stable system

𝟏𝟎 𝟏 𝟏𝟎𝟎 𝟏𝟎𝟏 𝟏𝟎𝟐 𝟏𝟎𝟑
Frequency (rad/sec)
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