Professional Documents
Culture Documents
MotionControlTerminologyPrimerv2 PDF
MotionControlTerminologyPrimerv2 PDF
ELECTROMATE
Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com [email protected]
Motion Controller
A motion controller is the primary intelligence, or brain, within a motion control system. It is responsible for calculating and generating the output commands for a desired motion path or trajectory. Motion controllers vary in complexity; sophisticated motion controllers typically consist of a trajectory generator (path planner), interpolator, and control loop for servo motor control. A step generator block is added when used for stepper motor control.
Fieldbus Based
The trajectory generator calculates the segments, or set points, of a motion path based on the desired target position, maximum velocity, acceleration, deceleration and jerk. It determines how much time is spent in the three primary segments of a move: acceleration, constant velocity and deceleration. Algorithm within the motion controller that calculates nely spaced positions from the set points generated by the trajectory generator. This is typically performed by some form of a cubic spline equation. The results of the interpolator are fed into the control loop. Algorithm within the motion controller that calculates an error signal based on the dierence between the expected and actual position/velocity. Motion controllers typically use a PID (proportional, integral, derivative) algorithm with enhancements for more advanced control capabilities. The gain settings for the PID dictate the responsiveness of the control loop. Algorithm within the motion controller that precisely generates digital step command pulses to meet the desired motion path.
Digital versus Analog Drives Linear Drive Switching Drive Microstepping Drive Servo Drive Intelligent Drive/Smart Drive
ELECTROMATE
Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com [email protected]
Motors
Commutation
Act of precisely switching, or sequencing, current in a motors windings, or phases, to obtain rotation. This function is performed mechanically by a commutator for DC motors. It is performed electrically by the drive for brushless and step motors. Motors that have winding in the rotor and permanent magnets on the stator. Carbon brushes and a mechanical commutator provide a current path through the windings to achieve motor torque. A DC motor will continuously rotate if a DC power source is applied across its terminals. DC motors require simpler drives but require higher maintenance, and are larger in size for the same output power. Motors that have windings in the stator and permanent magnets attached to the rotor. No brushes are used. Motor rotation is achieved by means of electrical commutation performed by the drive. Brushless servo motors provide high acceleration, high torque, and no maintenance. A linear motor provides direct linear motion (rather than rotary). Electromagnetic force is utilized to produce thrust directly, eliminating the need for rotary to linear conversion. Advantages include: high speeds, high precision, fast response, stiness, zero backlash and maintenance free operation. Disadvantages include: higher cost, required higher bandwidth, larger footprint and heat. Types: Iron core, air core, slotless. Motor with windings in the stator and permanent magnets attached to the rotor. It provides xed mechanical increments of motion; these increments are referred to as steps and are generally specied in degrees. A step motor, in conjunction with a stepper drive, rotates in predened angles proportional to the digital input command (stepper) pulses. A typical full-step system achieves 200 steps per revolution, this equates to 1.8 per full step. Step motors provide acceleration torque equal to running torque and require no maintenance. They have limited operation at high speeds, run hot, and can stall with excessive loads. Types of Step Motors - There are three types of step motors: Variable Reluctance: Has teeth on the rotor and stator but no rotor permanent magnet. Permanent Magnet: Has a permanent magnet for a rotor but no soft iron rotor teeth. Hybrid: Combines the magnet from the permanent magnet motor and the rotor and stator teeth from the variable reluctance motor.
Feedback Sensors
A class of devices required for closed loop operation. They provide a signal back to the drive or motion controller to monitor an operation or process and verify that proper operation occurs.
Encoders
An electromechanical device for translating linear or rotary displacement into a corresponding series of digital signals or analog output voltage. A device that generates electrical signals by means of a rotating disk that passes between a light source and photo detectors. Incremental encoders have two output signals, or channels, commonly referred to as A and B. The A and B outputs are nominally 90 out of phase with each other and are interpreted by a motion controller to determine position/velocity information. The lead/lag relationship between the A and B channels provides directional information. It is important to understand that each mechanical position is not uniquely dened. When the incremental encoder is powered on, the position of an incremental encoder is not known, since the output signals are not unique to any singular position. Incremental encoders often provide a third output that pulses once per revolution of the disk. This is typically called the Index, or Z-channel, and is commonly used for homing/reference moves. Absolute encoders have a unique value (voltage, binary count, etc.) for each mechanical position. When an absolute encoder is powered on, the position is known. Absolute encoders most commonly provide digital data in a parallel or serial format to the motion controller which is used to determine position/velocity information. Since they provide absolute position information when powered on they eliminate the need for a homing/reference move in a motion system. A resolver is a feedback device whose construction is similar to a motor (stator and rotor). It uses four wires to carry an encoded angle and produces two alternating voltages whose amplitudes or phases depend on the shaft rotation angle. It provides absolute position information and can be used by the motion controller to determine position/velocity information. A Hall eect sensor is a transducer that varies its output voltage in response to changes in magnetic eld density. Hall sensors are used for proximity switching, positioning, speed detection, and current sensing applications. They are often used on brushless servo motors to provide positioning information for the drive to commutate the motor.
Incremental Encoder
Absolute Encoder
Resolvers
Step Motor
Mechanical System
The part of a motion control system that produces the desired motion. The mechanical system can include actuators, motors and hydraulic devices.
A device that creates physical movement by converting various forms of energy to rotary or linear mechanical motion. A device that converts various forms of energy to linear motion. Screw Actuators: Lead screw actuators: A lead screw actuator with a threaded nut that moves with a screw. It provides both simple construction and lowest cost. Ball screw actuators: A lead screw actuator that uses ball bearings; more expensive but less friction compared with lead screw actuators. Planetary roller screw actuators: A lead screw actuator that uses threaded rollers surrounding the main threaded shaft; the most expensive option but also the most durable.
Belt Actuators: Actuators based on belt drives; often used where speed is important but with limited accuracy. Rod Versus Rodless: Rod type: The thrust element or rod moves out of the end of the actuator as motion takes place; produces more force and highly tolerant of dirty environments but require a structure to carry the load. Rodless type: The actuator housing completely surrounds the screw which provides a load bearing and guidance structure. Rodless actuators are dicult to seal for dirty or wet environments. Integrated Actuators: Integrates the actuator into the motor to eliminate the need for a coupling. Integrated actuators provide lowest size and weight and easier maintenance but are typically higher cost.