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Servo Plant Compensation Techniques: 11.1 Dead-Zone Nonlinearity
Servo Plant Compensation Techniques: 11.1 Dead-Zone Nonlinearity
Servo compensation usually implies that some type of filter network such as
lead/lag circuits or proportional, integral, or differential (PID) algorithms
will be used to stabilize the servo drive. However, there are other types of
compensation that can be used external to the servo drive to compensate for
other things in the servo plant (machine) that can, for example, be structural
resonances or nonlinearities such as lost motion or stiction. These machine
compensation techniques are shown in Figure 1 and are valid for either
hydraulic or electric servo drives.
had some success in overcoming a null hunt problem. However the dead
zone must be very small (e.g., 0.001 in.); otherwise, the servo drive will have
an instability from too much lost motion. A simple analog dead-zone
nonlinear circuit is shown in Figure 2. The same function can be provided
with a digital algorithm in computer control of machines.
From Newton’s second law of motion, the classical equations for this servo
plant (industrial machine system) can be written. In most industrial
machines it can be assumed that the damping BL is zero. Therefore the
T M ¼ J M s2 yM þ KðyM yL Þ (11.3-1)
0 ¼ J L s yL þ KðyL yM Þ (11.3-2)
ðJ M s2 þ KÞyM ¼ T M þ yL (11.3-3)
TM þ KyL
yM ¼ (11.3-4)
JM s 2 þ K
and
TM þ KðKyM =JL s2 þ KÞ
yM ¼ (11.3-7)
JM s 2 þ K
TM ðJL s þ KÞ þ K 2 yM
2
yM ¼ (11.3-8)
ðJM s2 þ KÞðJL s2 þ KÞ
TM ðJL s2 þ KÞ K 2 yM
yM ¼ þ (11.3-9)
ðJM s þ KÞðJL s þ KÞ ðJM s þ KÞðJL s2 þ KÞ
2 2 2
K 2 yM TM ðJL s2 þ KÞ
yM ¼ (11.3-10)
ðJM s þ KÞðJL s þ KÞ ðJM s2 þ KÞðJL s2 þ KÞ
2 2
Let:
J ¼ JM þ JL
J P ¼ J M J L =ðJ M þ J L Þ
TM ðJL s2 þ KÞ
yM ¼ (11.3-16)
s2 Jðs2 JP þ 1Þ
Also:
KyM
yL ¼ (11.3-17)
JL s 2 þ K
From a practical point of view industrial machines and their servo drives
(hydraulic and electric) are to this day still subject to resonant frequency
stability problems. Most industrial servo drives use an inner velocity servo
inside a position servo loop. Hydraulic servo drives have the added variable
of hydraulic fluid resonance, which can be a limiting factor of stability. The
hydraulic resonance or can be observed as a typical second order response
in the Bode frequency response of Figure 6. For hydraulic drives having a
low damping factor dh , the resonant peak may be higher than 0 dB gain,
which will result in a resonant oscillation. There are a number of methods to
compensate for this resonant oscillation. First, a small cross-port damping
hole of about 0.002 in. can be used across the motor ports. Secondly, the
velocity loop differential compensation can be varied, which quite often
eliminates the oscillation. Lastly, the velocity loop gain could be lowered,
which can also lower the velocity servo bandwidth. As an index of
performance (I.P.) the hydraulic resonance should by proper sizing be above
200 Hz, and the separation between the velocity servo loop bandwidth oc
and the hydraulic resonance oh should be three to one or greater. Brushless
DC electric drives do not usually have velocity loop resonance problems
unless a more compliant coupling is used internally in the motor to couple a
position transducer to the motor shaft.
Both hydraulic and brushless DC electric drives can have resonance
(stability) problems if the machine is included in the position servo loop.
This is an ongoing problem with industrial machines, in spite of all the
available technology to minimize stability problems. A typical position
servo Bode frequency response is shown in Figure 7. As a figure of merit the
separation between the velocity loop bandwidth oc and the position-loop
velocity constant K v (gain) should be two to one or greater. The machine
resonance or should be at least three times greater than the velocity servo
bandwidth oc . However in actual practice the machine resonance inside the
position loop is often quite low (such as 15 Hz). The resonant peak in this
case should be above 0 dB gain, resulting in a resonant oscillation. There are
a number of control techniques that can be applied to compensate for
machine structural resonances that are both low in frequency and inside the
position servo loop. The first control technique is to lower the position-loop
gain Kv (velocity constant). Depending on how low the machine resonance
is, the position-loop gain may have to be lowered to about 0.5 ipm/mil (8.33/
sec). This solution has been used in numerous industrial positioning servo
drives. However, such a solution degrades servo performance. For very
large machines this may not be acceptable. The I.P. that the servo loop gain
(velocity constant) should be lower than the velocity servo bandwidth by a
factor of two, will be compromised in these circumstances.
A very useful control technique to compensate for a machine
resonance is the use of notch filters. These notch filters are most effective
when placed in cascade with the input to the velocity servo drive. These
notch filters should have a tunable range from approximately 5 Hz to a
couple of decades higher in frequency. The notch filters are effective to
compensate for fixed structural resonances. If the resonance varies due to
such things as load changes, the notch filter will not be effective. Since most
of these unwanted resonant frequencies are analog sinusoidal voltages, a
notch filter can effectively remove these frequencies.
In digital control the algorithm for the notch filter can be used. A
simple analog notch filter is shown in Figure 8 as it appeared in Electronics
Magazine, December 7, 1978. This filter is equivalent to a twin T-notch filter
but it is an active filter versus passive networks, so there are no signal losses.
The frequency of the notch is set by the selection of resistor R. For a
1-microfarad (mF) capacitor (C), the values for R versus the notch frequency
are shown in Figure 9.
The depth of the notch is adjusted by varying the potentiometer P1 .
Frequency responses of the notch filter for values of R ranging from 40 K
ohms to 200 ohms are shown in Figure 10. A 40-Hz notch filter frequency
response is shown in Figure 11 with a number of potentiometer settings to
show the change in the depth of the notch filter as the potentiometer is
varied.
A few case histories are of interest. In a hydraulic servo valve feed
drive, pump pulsations of 500 Hz traveled through the machine piping to the
servo valve, the hydraulic motor, and finally the feedback tachometer of the
velocity loop. The high sensitivity of the tachometer (100 V/1000 rpm)
sensed the 500-Hz vibration and generated this voltage into the servo drive
electronics, where it was amplified through the entire drive, causing an
undesirable vibration. A 500-Hz notch filter at the tachometer output feed
to the servo amplifier eliminated the vibration problem.
In another case, the switching frequency of a numerical control
(125 Hz) beat with the single-phase, full-wave DC SCR drive frequency
(120 Hz) producing a 5-Hz signal that appeared in the machine servo drive,
causing what appeared to be a 5-Hz instability. Using a notch filter
frequency of the control switching frequency, the 5-Hz beat frequency signal
was eliminated.
In another case history a 45-Hz resonance existed in an air bearing of a
rotary position feedback transducer. Once this resonance was excited it was
amplified through the electronics drive and the machine slide vibrated at
45 Hz.
A 45-Hz notch filter applied at the input to the velocity drive
eliminated the problem. There are numerous possibilities where unwanted
Compensator Operation
The complete control circuit has more complexity than comparing two
position transducer outputs. Figure 12 can be used to discuss the actual
operation of the compensating system. This particular compensating scheme
used an instrument servo to perform the compensating function. A software
based frequency selective feedback system will also be discussed. For this
compensating system, the machine-feed servo drive uses a position
measuring feedback resolver (1) connected electrically in series with a
correction resolver (5). Any correction required during positioning is
introduced into the numerical control feedback circuit with the correction
resolver (5).
The compensator circuit includes the positioning servo-motor position
measuring resolver called a compensator feedback resolver (2), a machine
slide linear position measuring transducer (3), and an instrument type
correction servo drive. The difference between the feed servo-drive motor
position and the machine slide position is measured with the compensator
feedback resolver (2) and the linear resolver (3). However, an additional
correction resolver (4) is included in the circuit. Therefore, the instrument
correction servo error is a function of three resolver positions. This is shown
in the block diagram of Figure 13. The resolver positions are shown as angle
y. The total correction error is shown as a function of the three resolver
positions
yc ¼ ym y c y s : (11.4-1)
ye ¼ ym yc ys ¼ ðym ys Þ yc (11.4-2)
yc ¼ G1 ½ðym ys Þ yc (11.4-3)
ye ¼ ðym ys Þ yc (11.4-2)
Assuming the initial condition at the start of the correction is such that the
The relation between ym and ys is the same but the machine position ys has
moved to the correct position.
The compensator correction resolver (4) serves the purpose to reduce the
instrument servo error to zero.
As the correction process becomes a continual process, as in normal
machine operation, the resolver (4) will continually be in motion to reduce
the error to zero in the correction loop of the instrument servo. At machine
traverse feeds the correction will not be effective, but this is not important
since there will not be any machining operations at the traverse feeds.
F ðsÞ is a polynomial that represents the dynamics of the servo drive and
servo plant. What is really desired of the servo of Figure 17 is that yi ¼ y0
under all conditions. That is, for any yi ; e ¼ 0. Clearly, this is not possible
for a type 1 servo described by Figure 17.
yoðsÞ GðsÞ
Since ¼ GcðsÞ ¼1 (11.5-2)
yiðsÞ 1 þ GðsÞ
1 þ GðsÞ 1
Thus : GcðsÞ ¼ ¼ þ1 (11.5-3)
GðsÞ GðsÞ
Kv
GðsÞ ¼ for a practical position servo: (11.5-4)
sFðsÞ
sFðsÞ FðsÞ
Note that yiðsÞ ¼ oiðsÞ (11.5-5)
Kv Kv
dyiðtÞ
Where oiðtÞ ¼ (11.5-6)
dt
Furthermore, a well-designed, high-performance servo GðsÞ should have
dynamics described by F ðsÞ sufficiently negligible with respect to the
integration crossover that F ðsÞ need not be synthesized in the forward
compensating path. This assumption is important to the simplicity of the
concept, but it is possible to check if it is valid in any specific application.
Kv C=s2 þ C=s ðs þ Kv ÞC
yoðsÞ ¼ ¼ 2 (11.5-12)
sFðsÞ þ Kv s ðsFðsÞ þ Kv Þ
Applying the final value theorem, the steady-state position error is:
lim C s þ Kv
eð?Þ ¼ lim seðsÞ ¼ 1 (11.5-16)
s?0 s sFðsÞ þ Kv
lim C s þ Kv 1
¼ 1 (11.5-17)
s?0 sFðsÞ þ Kv s
lim C sFðsÞ þ Kv s Kv 1
¼ (11.5-18)
s?0 sFðsÞ þ Kv s
lim C FðsÞ 1
¼ (11.5-19)
s?0 sFðsÞ þ Kv
Kv a=s3 þ a=s2 a s þ Kv
yiðsÞ ¼ ¼ 3 (11.5-22)
sFðsÞ þ Kv s sFðsÞ þ Kv
limseðsÞ a sFðsÞ þ Kv s Kv
And eð?Þ ¼ ¼ 2 (11.5-23)
s?0 s sFðsÞ þ Kv
lim a ðFðsÞ 1Þ
eð?Þ ¼ (11.5-24)
s?0 s ðsFðsÞ þ Kv Þ
alim FðsÞ 1 alim dFðsÞ =ds
eð?Þ ¼ ¼ (11.5-25)
s?0 s2 FðsÞ þ Kv s s?0 ds2 FðsÞ =ds þ Kv
lim dFðsÞ
Then ?finite value (11.5-26)
s?0 ds
limit ds2 FðsÞ
While ?0 (11.5-27)
s?0 ds
1
Thus eð?Þ ¼ (11.5-28)
Kv
The magnitude of the finite position error will depend in this case on the
coefficient of the s term of F(s). If b is this coefficient, then
ab
eð?Þ ¼ (11.5-29)
Kv
The compensator technique described holds excellent potential for provid-
ing an outstanding servo drive for the industrial machine. When properly
executed in a well-designed position servo it should virtually eliminate
velocity lag errors and reduce acceleration lag errors to low levels. The
velocity feedforward approach will eliminate position errors for constant
velocity moves on a machine axis if the machine dynamics represented by
F ðsÞ in the feedforward term F ðsÞ =K v exactly respresents the G(s) term of the
forward position loop. Matching of position-loop gains K v on all axes will
not be required. For the case of acceleration and deceleration the velocity
feedforward approach will not be effective. For these situations commercial
servo-drive manufacturers will use an additional technique of acceleration
feedforward.