Open and Close Loop

System
Prepared By
Nagendra Kushwaha
Open Loop Positioning System
•  Uses Stepper Motor
• Driven by Series of Electrical Pulses (Generated in MCU)
• Each Pulse causes fraction of one revolution = step angle

• Step Angle α = Eq.(1) [ ns an integer]

•  The angle through which the motor shaft rotates, Am = np α Eq.(2)
• The motor shaft is generally connected to the screw through a gear box which
reduces the angular rotation of the screw.
• The Angle of the screw rotation, As = = Eq.(3)

• Gear ratio, rg = = Eq.(4)

• Liner movement of the worktable is given by the number of full and partial
rotations of the screw multiplied by its pitch,
x= Eq.(5)
• Number of pulses req. to achieve x –position increment,
= Eq. (6)
•  Control Pulses are transmitted from the pulse generator at a certain
freq., which drives the worktable at a corresponding velocity or feed
rate in the direction of the screw axis.
• Rotational Speed of the screw depends on the freq. of the pulse train
as: Ns = in rpm. Eq. (7)
• For two axis table with continuous path control, the relative velocities
of the axes are coordinated to achieve the desired travel direction.
• The table travel speed, vt = fr = Ns p Eq. (8)

• The req. pulse train freq. to drive the table at a specified linear travel
rate, [from Eq. (7) and Eq. (8)
• fp = = = Eq. (9)
Example
(A) One axis of the worktable in a CNC positioning
system is driven by a ball screw with a 6-mm
pitch. The screw is powered by a stepper motor
which has 180 step angles using a 2:1 gear
reduction (two turns of the motor for each turn of
the ball screw). The worktable is programmed to
move a distance of 200 mm from its present
position at a travel speed of 600 mm/ min. (a)
How many pulses are required to move the table
the specified distance? (b) What is the required
motor rotational speed and (c) pulse rate to
achieve the desired table speed?
(B) One axis of an open-loop positioning system is driven
by a stepper motor, which is connected to a ball screw
with a gear reduction of 3:1 (three turns of the motor for
each turn of the screw). The ball screw drives the
positioning table. Step angle of the motor is 1.80 , and
pitch of the ball screw is 7.5 mm. The table is required to
move along this axis a distance of 300 mm from its
current position in exactly 20 sec. Determine (a) the
number of pulses required to move the specified
distance, (b) pulse frequency, and (c) rotational speed of
the motor to make the move.
(C) A stepper motor with 60 step angles is coupled to a
leadscrew through a gear reduction of 3:1 (three
rotations of the motor for each rotation of the leadscrew).
The leadscrew has 2.5 threads/cm. The worktable driven
by the leadscrew must move a distance 80.0 cm at a
feed rate 100 cm/min. Determine (a) the number of
pulses required to move the table. (b) required motor
speed, and (c) pulse rate to achieve the desired table
speed.
Optical Encoder
To Learn More watch video here
https://youtu.be/CHE1imH9tdg
Close Loop Positioning System
• The
  angle between slots in the disk must satisfy the following relation:
Eq. (10)
where α = angle between slots, /slot and ns = number of slots in the disk
• For a certain angular rotation of the encoder shaft, the number of pulses
sensed by the encoder,
= Eq. (11)
Where np = pulse count emitted by the encoder,
As = Angle of rotation of the encoder shaft
•  The pulse count can be used to determine the distance moved by the
worktable along the x- axis (or y – axis),
= Eq. (12) [ From Eq. (11)]

[From Eq. (10)]

• The velocity of the worktable, also the feed rate in machining
operation,
vt = fr = Ns p = Eq. (13)
• The Pulse frequency emitted by the encoder,
Eq. (14)
Q. An NC worktable operates by closed-loop positioning. The system
consists of a servomotor, ball screw, and optical encoder. The screw has
a pitch of 6.0 mm and is coupled to the motor shaft with a gear ratio of
5:1 (five turns of the drive motor for each turn of the screw). The
optical encoder generates 48 pulses/ rev of its output shaft. The table
has been programmed to move a distance of 250 mm at a feed rate =
500 mm/min. Determine (a) how many pulses should be received by
the control system to verify that the table has moved exactly 250 mm,
(b) the pulse rate of the encoder, and (c) the drive motor speed that
corresponds to the specified feed rate.

Ans: a)2000 pulses b) 66.667 Hz c) 416.667 rpm

Precision in Positioning System
Three measures of precision:
1. Control Resolution
2. Accuracy
3. Repeatability
 1. Control Resolution

• It is the distance separating two adjacent addressable points in the

axis movement.
• Addressable points locations along the axis to which the worktable
can be specifically directed to go.
• Desirable: CR as small as possible.

Locations of addressable points depend on

the limitations imposed by:
1. The Electromechanical components of
the positioning system and/or
2. The number of bits used by the
controller to define the axis coordinate
location
•1.  Electromechanical components: screw pitch, gear ratio, step angle or angle
between slots
For open loop : Eq.(15)
Where CR1 = Control Resolution of Emech. Comp. in mm (in).
2. Number of bits: if B is the number of bits in the storage register for the axis,
Then number of control points into axis can be divided = 2B

Assuming the control points are equally spaced,

Then Eq. (16)

Where CR2 is the control resolution of the computer control system, mm (in).
•  The control Resolution of the positioning system is,
Eq. (17)
• Desirable criteria:
• Current CNC Technology, CR : 0.0025 mm (0.0001 in)
• Exact Location of the table: By given addressable point>> limited by
mechanical errors.
• Mechanical errors: Play, Backlash, and deflection of m/c components.
• Mech. Errors: Assuming unbiased normal statistical distribution about
control points with mean, and st. deviation σ constant over the range.

• Nearly All mechanical Errors (99.73%) are within .

•  Accuracy is defined under worst case condition.
• Maximum Possible error

• Accuracy: The maximum possible

error that can occur between the
Desired target point and the actual
Position taken by the system.
• +3 in mm (or in) Eq. (18)

• Example:
• Repeatability:
  The ability of the positioning system to return to a given
addressable point that has been previously programmed.
• This Capability: in terms of location error
• Location error: Due to mechanical errors
Thus , The repeatability of any given axis of a positioning system is of the
mechanical error distribution associated with the axis.
in mm. Eq. (19)

Example: Suppose the mechanical inaccuracies in the open-loop positioning

system of Example 7.1 are described by a normal distribution with standard
deviation = 0.005 mm. The range of the worktable axis is 1,000 mm, and there are
16 bits in the binary register used by the digital controller to store the programmed
position. Other relevant parameters from Example 7.1 are the following: pitch 6.0
mm, gear ratio between motor shaft and screw = 5.0, and number of step angles in
the stepper motor 48. Determine the (a) control resolution, (b) accuracy, and (c)
repeatability of the positioning system.