10/30/2013 (C) 2001, Ernest L.

Hall, University of Cincinnati 1

Manufacturing
Controls
FALL 2001
Lecture 7
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 2
Syllabus
DATE TOPIC NOTES
1. Sep. 20 Mechatronics Design Process Ch. 1
2. Sep. 25 System Modeling and Simulation Ch. 2
3. Sep. 27 Laplace Transforms and Transfer Functions Ch. 2
4. Oct. 2 Electrical Examples Ch.2, Notes
5. Oct. 4 Mechanical Examples Ch.2, Notes
6. Oct. 9 More Examples, Thermal and Fluid Examples, QUIZ 1 (Take Home)
7. Oct. 11 Sensors and Transducers Ch. 3
8. Oct. 16 Advanced MATLAB
9. Oct. 18 Analog and Digital Sensing Ch. 3,
Notes
10. Oct. 23 Actuating Devices Ch. 4

11. Oct. 25 DC Motor Model Ch. 4,
Notes
12. Oct. 30 Boolean Logic Ch. 5
13. Nov. 1 Programmable Logic Controllers Ch. 5, Notes
14. Nov. 6 Stability and Compensators, P, PI and PD Ch. 6
15. Nov. 8 PID Controllers Ch. 7
16. Nov. 13 QUIZ 2 (In Class - Open Book)
17. Nov. 15 Practical and Optimal Compensator Design Ch. 8
18. Nov. 20 Frequency Response Methods Ch. 9, Notes
19. Nov. 22 THANKSGIVING HOLIDAY Ch. 9, Notes
20. Nov. 27 Optimal Design of a Motion Control System Ch. 9, Notes
21. Nov. 29 QUIZ 3 (In Class - Closed Book)
22. Dec. FINAL EXAM (In Class - Closed Book) Comprehensive
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 3
Todays objective
To continue the introduction
to systems theory by
expanding the use of
sensors for the feedback
example of the motorized
arm.
By the end of this class you
will be able to describe the
advantage of using sensors
and transducers to measure
the response of a system
and see who the
measurements can to used
to control the system.
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 4
Review of the Motorized Robot
Arm
Motor which drives the rigid link pendulum
arm.
Figure 10. Fixed Field DC motor (a) circuit diagram; (b) block diagram
(From Nice)
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 5
A DC motor with armature control and a
fixed field is assumed.
The armature voltage, e
a
(t) is the voltage supplied by an amplifier to control
the motor.
The motor has a resistance R
a
, inductance L
a
and back electromotive force
constant, K
b
.
The back emf voltage, v
b
(t) is induced by the rotation of the armature
windings in the fixed magnetic field.
The counter emf is proportional to the speed of the motor with the field
strength fixed.
Figure 10. Fixed Field DC motor (a) circuit diagram; (b) block diagram
(From Nice)
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 6
The counter emf is proportional to
the speed of the motor
dt
d
K t v
b b
u
= ) (
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 7
Taking the Laplace transform
gives:
V
b
(s)= sK
b
O(s)
for
dt
d
K t v
b b
u
= ) (
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 8
Kirchoffs voltage law
The circuit equation for the
electrical portion of the motor
is:
E
a
(s)= R
a
I
a
(s)+ L
a
sI
a
(s)+V
b
(s)
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 9
This may also be written as:

E
a
(s)= R
a
I
a
(s)+ L
a
sI
a
(s)+V
b
(s)

a a
b a
a
R s L
s s K s E
s I
+
O
=
) ( ) (
) (
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 10
The torque developed by the motor is proportional
to the armature current.
T
m
(s) = K
t
I
a
(s)
This torque moves the armature and load.
Balancing the torques at the motor shaft
gives the torque relation to the angle that
may be expressed as follows
dt
d
D +
dt
d
J = T(t)
m
2
m
2
u u
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 11
Newtons Second Law




where
dt
d
D +
dt
d
J = T(t)
m
2
m
2
u u
u
m
= the motor shaft angle position,
J = all inertia connected to the motor shaft
D= all friction (air friction, bearing friction, etc.) connected to the motor shaft
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 12
Taking the Laplace transform
gives:




T
m
(s)= Js
2
O
m
(s)+ D sO
m
(s)
dt
d
D +
dt
d
J = T(t)
m
2
m
2
u u
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 13
Solving for the shaft angle
gives
Ds Js
s T
s
m
m
+
=
2
) (
) ( u
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 14
Gear train
If there is a gear train between the motor and
load, then the angle moved by the load is
different from the angle moved by the motor.
The angles are related by the gear ratio
relationship, which may be derived by noting
that an equal arc length, S, is traveled by two
meshing gears.
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 15
Equal distances traveled
S = R
m
u
m
= R
L
u
L
.
http://sofengsvc.com/
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 16
Gear ratio
The gear circumference of the motor's gear is
2tR
m
that has N
m
teeth
The gear circumference of the load's gear is
2tR
L
that has N
L
teeth
The ratio of circumferences is equal to the
ratio of radii and the ratio of number of teeth
so that
N
L
u
L
= N
m
u
m


10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 17
Gear ratio
N
L
u
L
= N
m
u
m


n
N
N
L
m
m
L
= =
u
u
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 18
Load reflection
The gear ratio may also be used to reflect
quantities on the load side of a gear train
back to the motor side so that a torque
balance can be done at the motor side.
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 19
Assuming a lossless gear train
It can be shown by equating mechanical
power, Te, and electrical power, EI,
that the quantities such as inertia, J, viscous
damping D, and torsional springs with
constants K may be reflected back to the
motor side of a gear by dividing by the gear
ratio squared.
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 20
Motor side
Equivalent quantities
2
n
J
J
L
mL
=
2
n
D
D
L
L
m
=
2
n
K
K
L
mL
=
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 21
Combining
We can develop a block diagram of the
armature-controlled DC motor as shown
below.
Armature-Controlled DC Motor Block Diagram

T(s) I
a
(s)
s O
m
O
m

1
Out1
1
L
a
.s+R
a

K
t

Torque Constant
Sum1
K
b

Shaft angle velocity feedback



Gear ratio
s
1
Integrator1
1
Js+D

E
a
(s) O
L

n
H
1
= K
b


10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 22

By simplifying the block diagram shown, we can get the
Armature-Controlled motor transfer function as:

| |
| |
t b a a a a
t
t b a a
t L
K K DR s DL JR s JL s
n K
s G
K K R s L D Js s
n K
s E
s
s G
+ + + +
=
+ + +
=
O
=
) ( (
) (
) )( ( ) (
) (
) (
2
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 23
Order of system
As we can see, this model is of the third order
However, in the servomotor case, the
inductance of the armature L
a
could usually
be ignored
Thus this model could be reduced to a
second order system.
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 24
Example
Suppose a DC motor is used to drive a robot
arm horizontally as shown in Figure 12.

Mg
x
y
L
Figure 12. A single joint robot arm driven by an armature-controlled DC motor
horizontally
z
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 25
Parameters
The link has a mass, M=5Kg, length L=1 m,
and viscous damping factor D = 0.1.
Assume the system input is a voltage signal
with a range of 0-10 volts.
This input signal is used to provide the
control voltage and current to the motor.
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 26
Goal- Specifications
The goal is to design a compensation
strategy so that an input voltage of 0 to 10
volts corresponds linearly of an angle of 0 to
an angle of 90.

10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 27
The motor parameters are
J
a
= 0.001 kg-m2/ s2
D
a
= 0.01 N-m s/rad
R
a
= 1 Ohm
L
a
= 0 H
K
b
= 1 V-s/rad
K
t
= 1 N-m/A


n = 1
2
2 2
. 4167 . 0
12
1 5
12
m kg
ML
J
L
=

= =
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 28
Impedence reflection to motor
side
According to the impedance reflection model
established before, the total inertia J and total
damping factor D are:
J = J
a
+ J
L
= 0.001+0.4167 = 0.4177 Kg.m2
D= D
a
+ D
L
= 0.01+0.1=0.11
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 29
Transfer function
Substituting the known
values gives

| | 1 1 ) 0 1 )( 11 . 0 4177 . 0 (
1
) (
) (
) (
+ + +
=
O
=
s s s s E
s
s G
L
) 11 . 1 4177 . 0 (
1
) (
+
=
s s
s G
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 30
Matlab m-file for motor only
D=0.1+0.01;
Num=Kt*n;
Den=[J*La J*Ra+La*D D*Ra+Kt*Kb 0];
step(Num, Den);
title(Step Response of the Motorized Robot
Arm);
End;
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 31
Response

0 2 4 6 8 10
0
500
1000
1500
Time (Seconds)
Step Response of Motorized Robot Arm
D
e
g
r
e
e

Figure 13. The motorized robot arm with velocity feedback step
response
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 32
Add feedback
Measure corresponding angle change. In this
case, Kp=(10-0)/(90-0)=0.1111 V/degree
The gear ratio is 1.
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 33
Feedback system
G(s)
H(s)=Kp
R(s)
C(s)
-
+
E(s)
F(s)
C(s) = G(s)E(s)
F(s) = H(s)C(s)
E(s) = R(s)-F(s)
C(s) = G(s)(R(s)-F(s)
C(s) = G(s)(R(s)-H(s)C(s))
C(s)=G(s)R(s)-G(s)H(s)C(s)
C(s)(1+G(s)H(s))=G(s)R(s)
C(s)/R(s) = G(s)/(1+G(s)H(s))
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 34

The new transfer function is:
0011 . 0 11 . 1 4177 . 0
1
) ( '
) ( 1
) (
) ( '
2
+ +
=
+
=
s s
s G
K s G
s G
s G
p
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 35
Matlab step response
computation
V=10;
Angle=90;
Kp=V/Angle; %feedback voltage/angle constant
G=tf([1],[0.4177 1.11 0]);
% the transfer function of the velocity loop
sysclose=feedback(G,Kp);
%the closed loop function of position feedback
step(sysclose);
end
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 36
Try this example
Does the response fit specifications.
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 37
Unit step response
Input of 1 volt
Figure 15. Step response of the position feedback uncompensated
system
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 38
Better but still not good
enough
After position feedback, the steady response
tends to be stable as shown in Figure 15.
However, the system response is too slow, to
make it have faster response speed, further
compensation is needed.
The following example describes the outline
of building a compensator for feedback
control system.
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 39
Other criteria
Rise time the time required for the
response to go from 0.1 to 0.9 of its final
value.
Settling time the time required for the
response to reach and stay within 2% of its
final value.
Steady state error difference between the
input and output for a given test input as time
approaches infinity.
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 40
New specification
The required response
could have an
overshoot below 10%
A settling time below
0.2 second
and a steady state error
of zero.
These seem OK.

Figure 15. Step response of the position feedback
uncompensated system
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 41
Rise time
The rise time is about 45 seconds.
So an improved rise time might be the
needed specification for this example.
Lets try a serial compensator.
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 42
Serial compensator
G(s)
H(s)
R(s)
C(s)
-
+
E(s)
F(s)
C(s) = G
c
(s)G(s)E(s)
F(s) = H(s)C(s)
E(s) = R(s)-F(s)
C(s) = G
c
(s)G(s)(R(s)-F(s)
C(s) = G
c
(s)G(s)(R(s)-H(s)C(s))
C(s)=G
c
(s)G(s)R(s)-G
c
(s)G(s)H(s)C(s)
C(s)(1+G
c
(s)G(s)H(s))=G
c
(s)G(s)R(s)
C(s)/R(s) = G
c
(s)G(s)/(1+G
c
(s)G(s)H(s))
G
c
(s)
E(s)
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 43
Compensator added


um(s) s u m (s) Ia(s) T(s)
output
180/t
rad 2 deg1
1/n
gear ratio1
n
gear ratio
compensator 1
La.s+Ra
Kt
Torque Constant
Sum2
Sum1
Kb
Motor angle velocity feedback
Kp
Load angle velocity feedback
s
1 1
Js+D
Input
uL(s)
Motor
Figure 14. Position and velocity feedback model of the motorized
rigid link
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 44
How do we design the
compensator?
Analog system
Digital system
We will explore the use of a digital
compensator using a digital filter in a
computer controller.
10/30/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 45
Any questions?