Tolomatic presentation understanding motion control technology
1. MOTION CONTROL TECHNOLOGY
Microstepping Systems Brushed DC Systems Brushless Servo Systems
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2. ENCODER FEEDBACK
Open Loop System
– Gives a commanded position but has no feedback to ensure
the actual position was reached.
• Controller commands a signal to the drive
• Drive converts and amplifies the signal to the motor
• Motor moves commanded number of steps
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3. ENCODER FEEDBACK
Open Loop Example
Supply
Command Dimmer Lamp
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4. ENCODER FEEDBACK
Closed Loop
– Monitors the commanded position versus the actual position
and adjusts to insure the commanded position is reached
• Command signal responds to eliminate error based on
feedback
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5. ENCODER FEEDBACK
Closed Loop Example
65o Current Temp.
72o Command 7o Error
T Furnace
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6. ENCODER FEEDBACK
Servo Motor Control Example
COMMAND ERROR
Position 10” Move 1” Power
+ Amplifier Motor
-
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7. FEEDBACK DEVICES
Tell the control system where the tool or work piece is located
– Analog(ex. tachometer)
• Directly represent some physical quantity
• Continually varied
– Digital (ex. encoder)
• Incremental
• Absolute Sold & Serviced By:
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8. FEEDBACK DEVICES
Incremental Encoder
– Counts the segments on a disc to determine
position
– Uses a clock to determine velocity
– Has one single mark called an indexer to
eliminate error and allow finer positioning on
homing routine
– 1000 Counts
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9. FEEDBACK DEVICES
Quadrature Encoder
– Has two segment patterns that
allow for finer positioning
– Reads 4x the physical line count
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10. MOTION CONTROL SYSTEMS
Microstepping
Brushed DC
Brushless Servo
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11. WHY A MICROSTEPPING SYSTEM?
Lowest cost for precision motion
Feedback device not needed
Low RPM applications
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12. STEPPER MOTORS
Windings are on the stator and the
magnets are on the rotor
Current switched electronically
to windings Half Step Full Step
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13. STEPPER MOTORS
200 physical steps on the
rotor assembly
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14. ADVANTAGES OF STEPPER MOTORS
• Lowest cost for precision motion
• High resolution and positioning precision
• Easy angle and speed control
• Large holding torque
• Good for simple indexing
• High torque at lower speeds
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15. LIMITATIONS OF STEPPER MOTORS
• Torque decreases as velocity increases
• If the load torque exceeds the motor’s available
torque it can stall or lose position
• Speeds typically limited to less than 2000 RPM
• Motion is not as smooth as servos
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17. MICROSTEPPING SYSTEM SUMMARY
• Lowest cost for precision motion
• High resolution
• Large holding torque
• Good for simple indexing
• High torque at lower speeds
• Torque decreases as velocity increases
• Open loop system, no encoder feedback
• Motion is not as smooth as servos Sold & Serviced By:
ELECTROMATE
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18. MOTION CONTROL SYSTEMS
Microstepping
Brushed DC
Brushless Servo
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19. WHY A BRUSHED DC SYSTEM?
• Low to medium cost
• Smooth and quiet operation
• Simple control (switch to switch)
• Higher torque and speed than Stepper
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20. BRUSHED DC MOTORS
1. Magnets are on the stator and the windings
are on rotor
2. Current is switched mechanically to the
windings through the brushes
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21. ADVANTAGES OF BRUSHED MOTORS
Easily defined speed and torque output
– Volts/RPM
– Torque/Amp
Simple design keeps the cost down
Better torque roll off compared to steppers
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22. LIMITATIONS OF BRUSHED MOTORS
Current switched mechanically
– Brush wear
Thermally inefficient
– Heat has to dissipate through the magnets
• Can reduce performance and life
• Larger size
Without encoder feedback limited in positioning capability
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23. BRUSHED DC SUMMARY
• Low to medium cost
• Smooth and quiet operation
• Typically switch to switch operation
• Thermal inefficiencies can reduce performance and life
• Brush wear
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24. MOTION CONTROL SYSTEMS
Microstepping
Brushed DC
Brushless Servo
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25. BRUSHLESS SERVO SYSTEM
Closed Loop
– Monitors the commanded position versus the actual position
and adjusts to insure the commanded position is reached
• Command signal responds to eliminate error based on
feedback
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26. WHY A BRUSHLESS SERVO SYSTEM?
• Extremely smooth and quiet operation
• Torque, velocity, or position control
• Accurate position and high output torque at high speeds
• Higher performance than Stepper and Brushed DC
• Maintenance free
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27. BRUSHLESS SERVO MOTORS
1. Windings are on the stator and
the magnets are on the rotor
2. Current is switched electrically
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28. ADVANTAGES OF BRUSHLESS MOTORS
• High continuous and peak torque
• High speeds (up to 6,000 RPM)
• Motor thermal protection
• Metal shell plug and turn connectors
• IP65 options
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29. LIMITATIONS OF BRUSHLESS MOTORS
• Increased cost
• Increased weight
• Higher control complexity due to encoder feedback
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30. BRUSHLESS SERVO SUMMARY
• Accurate position and high output torque at high speeds
• Excellent heat dissipation allows for higher continuous torque
• No mechanical brushes reduce speed torque ripple
• Higher performance than Stepper and Brushed Servo
• Increased cost
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31. Applying Motion Control Systems…..
Use Micro-steppers when….
– You identify low speed applications where cost outweighs feedback for
velocity or torque
Use Brushed DC when….
– You run into low to midrange speed and torque applications that that need
simple point to point positioning without high accuracy
Use Brushless Servo when….
– You see high speed and high torque applications that need accurate
feedback for position, velocity, or torque…or
– You see applications that need high performance
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