Design Problem: Fast Tool Servo Control

Fiona Grant, Lab Tues. 2-5pm

2.14: Analysis & Design of Feedback Control Systems
Massachusetts Institute of Technology
May 12th, 2016
1. Overview
2. Current Control
The plant transfer function when considering back emf from the motion of the mass is

2 +( + )+2

is

+ +

. The plant transfer function when assuming this back emf is negligible

(please see attached paper calculations). At high frequencies, the back emf

induced by the velocity of the mass will have a negligible effect on the current input. This is
because the dynamics of the current control loop will be much faster than those of the
mechanical system.

Figure 1: The bode diagrams of the transfer functions from Va to Ic, with and without the back emf from
the motion of the mass considered. At high frequencies, these plots are equal. On this basis, the back emf
can be neglected in the calculation.

The values of the resistors and capacitors were calculated to be: 2 = 600 , 3 = 27.2 ,
1 = 0.196 , 2 = 0.0152 (please see paper calculations for detail).

Figure 2: The plant, controller, and loop return ratio for the current control loop are plotted. The loop was
designed to have a -0.6 A/V DC gain, a crossover frequency of 7 105
5.3106 + 1

and a phase margin of 60.

The corresponding controller is () = 5 1.521011 (5.3106 + 1)+1.961010 .

3. Actuator Model
4. Mechanical Plant Model
A dynamic model of the plant was determined first by using the low frequency dynamics to

discover: 1 = 12700 , 1 = 0.5

full dynamic model is:

, and 1 = 0.0147 (please see paper calculations). The

 ()
5

1.510
0.0146 2 + 0.5 + 12700
2
2 0.0618
2
2 0.177
2
2 0.182
(
+
+ 1) (
+
+ 1) (
+
+ 1)
5.98 104
(5.98 104 )2
(1.30 105 )2
1.30 105
(2.30 105 )2
2.30 105

2
2 0.046
2
2 0.0195
2
2 0.0144
(
+
+ 1) (
+
+ 1) (
+
+ 1)
8.01 104
2.10 104
(8.01 104 )2
(2.10 104 )2
(1.60 105 )2
1.60 105
=

(a)

(b)

Figure 3: (a) The first-order mechanical plant model along with a time delay (green) fit to the
plant data (blue). (b) A higher order plant model with the same time delay (green) fit to the plant
data (blue).

Figure 4: The pole zero plot of the dynamic model of the mechanical system determined above.

5. Controller Design
A controller was designed using a variety of methods to minimize tracking error and error due to
noise of the mechanical system (please see paper calcualtions). The loop has a phase margin of
21.3 degrees at 1.46*104 rad/s. The full controller contians proportional control, lead-lag control,
and a low pass filter (please see paper calculations):

+ 1
1
, () = (1 + ) (
)(
)

+ 1
1 + 1
Here, = 0.26, = 10, = 10, = 1.581 105 , and 1 = 2.5 105 . For this
controller the loop is stable, the sensitivity is below the required limit of 10dB, the error to
reference is approximatley 15%, and the error to noise is approximately 11%.

Figure 5: The mechanical plant, dynamic model, controller C, and loop return ratio L.

Figure 6: The Nyquist plot shows that the above controller is stable.

Figure 7: The stability plot shows that the error to reference is always below 10dB.

Figure 8: The sinusoidal reference position, servo tool position, and error.

Figure 9: The error due to a sinusoidal sensor noise voltage.