Motion Control Systems - Lec 1

Industrial motion control systems, Chapter 1: Overview
Industrial Motion Control

Systems
© 2017 Quoc Chi Nguyen, Head of Control & Automation Laboratory, nqchi@hcmut.edu.vn 1-1
EXAMPLES OF MOTION CONTROL
Conveyor handling system

Five-axis CNC machines
Six-axis Robot
MORE EXAMPLES?
Many devices for motion controls of an aircraft

MORE EXAMPLES?
motion controls of a ship

MORE EXAMPLES?
motion controls of a camera platform
MOTION CONTROL DEFINITION

Motion control is a sub-field of automation, encompassing the systems or sub-systems
involved in moving parts of machines in a controlled manner. The main components
involved typically include a motion controller, an energy amplifier, and one or more
prime movers or actuators. Motion control may be open loop or closed loop. In open
loop systems, the controller sends a command through the amplifier to the prime
mover or actuator, and does not know if the desired motion was actually achieved.
Typical systems include stepper motor or fan control. For tighter control with more
precision, a measuring device may be added to the system (usually near the end
motion). When the measurement is converted to a signal that is sent back to the
controller, and the controller compensates for any error, it becomes a Closed loop
System.
Simplified definition: Drive movement of systems that includes

position, velocity, and
There many “drive” devices such as electric, hydraulic,

pneumatic drives.
- In this course, we just interested in motion control of AC servo

devices
Review on electric devices
Electric actuators
DC motor Brushless DC motor
Stepper motor AC motor
DC motor
DC motor
F: force on the conductor (in Newton)
The magnitude of the I: current through the conductor (in amperes)
force on the wire: B: magnetic flux density (in gauss)
L: length of the wire (in meters)
θ: angle between the magnetic field and current
Brushless DC motor
Brushless DC motors (BLDC) operate without brushes by taking advantage of modern

electronic switching techniques.
Exploded view of a brushless DC motor

with Hall-effect sensor
A magnetic sensor as a rotor position
A resolver as rotor position indicator
Brushless DC motor
A schematic of a generalized three-phase BLDC
Advantages: extremely reliable, very efficient, and easily controlled.
AC motor
AC motors work by rotating the stator field. It makes use of the natural alternating
nature of the AC wave to turn the field coils on and off sequentially.
AC motor
The rotor is always going slower than the rotating field, and this difference is
referred to as slip. Slip is frequently given as a percentage (usually less than
10%) of the stator speed.
Synchronous equation:
Ss: synchronous (stator) speed (in rpm)
Sr: rotor speed (rpm)
f: frequency of the AC line
P: number of field poles per phase
Stepper motor
A stepper motor is a unique type of DC motor that rotates in
fixed steps of a certain number of degrees. Step size can range
from 0.9 to 90°.
Stepper motor
Excitation modes for PM stepper motors
The top electromagnet (1) is

The top electromagnet (1) is turned turned off, and the right
on, attracting the nearest teeth of a electromagnet (2) is energized,
gear-shaped iron rotor. With the teeth pulling the nearest teeth slightly to
aligned to electromagnet 1, they will the right. This results in a rotation
be slightly offset from electromagnet of 3.6° in this example.
2
The left electromagnet (4) is enabled,

rotating again by 3.6°. When the top
The bottom electromagnet (3) is electromagnet (1) is again enabled, the
energized; another 3.6° rotation teeth in the sprocket will have rotated
occurs. by one tooth position; since there are
25 teeth, it will take 100 steps to make
a full rotation in this example.
Servo system
What is a servo motor? - A command signal which is issued from the user's interface
panel comes into the servo's "positioning controller". The positioning controller is the
device which stores information about various jobs or tasks. It has been programmed
to activate the motor/load, i.e. change speed/position.
Concept of a servo system

Servo system for motion control
electr. energy
PC, set value motion

controller command amplifier
PLC
energy
servo amplifier current
losses
position speed
signal signal motor
position,
sensor speed
load
position,
speed
mech. energy
What to control?
 Current control = torque control
- Maintaining current (torque) constant
- Mostly included in controller (but not always accessible)
- For fast motor reaction
- No special feedback device needed
 Speed control
- Maintaining speed constant
- "speed = 0" does not mean "position is held"
 Position control
- Moving from position to position, stop at and maintain a position
set value system

Σ controller Σ motor
+ deviation +
- -
current-
feedback
actual value sensor
incremental
IxR DC tacho encoder Hall sensor resolver
Analog encoder speed control loop
• Speed control loop with encoder feedback
- Amplification (gain) depends on parameters PID
- Applies also to Hall Sensor feedback with EC motors (6 IMP)
• Current control loop
- Subordinate control loop, enhances system dynamics
- Power amplifier (MOSFET)
speed power
amplifier (PID) amplifier
set value R current current
Σ E Σ motor
speed + command +
- -
current-
C
feedback
speed
feedback encoder
Digital control loop

• Digital parameters (profile, position, amplification)
• DSP: digital signal processor
• Firmware: software of the controller
power
amplifier
set value
current
speed
command motor
DSP
current feedback
set value
position
path position position feedback

generator decoder
speed feedback encoder
Gain, amplification: PID

Amplifier (PID)
set value E current
How the deviation signal E is it amplified to Σ
produce a purposeful reaction (current + command
command)?
actual value
• P: Proportional (a multiplication = "amplification") system reaction
– Problem: very small deviation lead to small corrections
only. The set value cannot be reached. PI
– Remedy: Combination of P and I
• I: Integration P only
– A persisting deviation is summed up (integrated) and
eventually corrected.
• D: Differentiation PID
– a sudden increasing deviation (e.g. a set value jump),
produces a strong reaction
– for dynamic reaction set value
– overshoot, instability
t
How to measure the feedback value?

• Open loop
– no feedback system
• Current control
– no special feedback
• Speed control
– feedback devices for DC motors: Encoder, DCTacho, Hall-sensor
• Position control
– feedback devices: Encoder, Hall-Sensor
Difference between servo motor and stepper motor

Motion Control Systems - Lec 1

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Industrial motion control systems, Chapter 1: Overview

Industrial Motion Control

EXAMPLES OF MOTION CONTROL

Conveyor handling system

Many devices for motion controls of an aircraft

motion controls of a ship

motion controls of a camera platform

MOTION CONTROL DEFINITION

Simplified definition: Drive movement of systems that includes

There many “drive” devices such as electric, hydraulic,

- In this course, we just interested in motion control of AC servo

Review on electric devices

Stepper motor AC motor

Brushless DC motors (BLDC) operate without brushes by taking advantage of modern

Exploded view of a brushless DC motor

A magnetic sensor as a rotor position

A resolver as rotor position indicator

Advantages: extremely reliable, very efficient, and easily controlled.

Excitation modes for PM stepper motors

The top electromagnet (1) is

The left electromagnet (4) is enabled,

Concept of a servo system

Servo system for motion control

PC, set value motion

set value system

Digital control loop

path position position feedback

Gain, amplification: PID

How to measure the feedback value?

Difference between servo motor and stepper motor

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