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MOTION CONTROL TECHNOLOGY Brushless Servo Systems Brushed DC Systems Microstepping Systems ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com [email protected]

Tolomatic presentation understanding motion control technology

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Page 1: Tolomatic presentation understanding motion control technology

MOTION CONTROL TECHNOLOGY

Brushless Servo Systems Brushed DC SystemsMicrostepping Systems

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Page 2: Tolomatic presentation understanding motion control technology

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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Page 3: Tolomatic presentation understanding motion control technology

ENCODER FEEDBACK

Command Dimmer Lamp

Supply

Open Loop Example

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Page 4: Tolomatic presentation understanding motion control technology

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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Page 5: Tolomatic presentation understanding motion control technology

72o Command

65o Current Temp.

7o ErrorT Furnace

Closed Loop Example

ENCODER FEEDBACK

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Page 6: Tolomatic presentation understanding motion control technology

PowerCOMMANDPosition 10”

ERRORMove 1”

FEEDBACK9” Machine Motion

Amplifier-

+ Motor

Servo Motor Control Example

ENCODER FEEDBACK

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Page 7: Tolomatic presentation understanding motion control technology

FEEDBACK DEVICESTell 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

• AbsoluteELECTROMATE

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Page 8: Tolomatic presentation understanding motion control technology

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

FEEDBACK DEVICES

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Page 9: Tolomatic presentation understanding motion control technology

Quadrature Encoder

– Has two segment patterns that allow for finer positioning

– Reads 4x the physical line count

FEEDBACK DEVICES

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Page 10: Tolomatic presentation understanding motion control technology

MOTION CONTROL SYSTEMS

Microstepping

Brushed DC

Brushless Servo

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Page 11: Tolomatic presentation understanding motion control technology

Lowest cost for precision motion

Feedback device not needed

Low RPM applications

WHY A MICROSTEPPING SYSTEM?

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Page 12: Tolomatic presentation understanding motion control technology

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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Page 13: Tolomatic presentation understanding motion control technology

STEPPER MOTORS

200 physical steps on the rotor assembly

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• 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

ADVANTAGES OF STEPPER MOTORS

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• 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

LIMITATIONS OF STEPPER MOTORS

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Page 16: Tolomatic presentation understanding motion control technology

STEPPER VS SERVO TORQUE CURVE

0

5

10

15

20

25

30

35

0

600

1200

1800

2400

3000

3600

4200

4800

5400

6000

RPM

Torq

ue (l

b-in

)

MRS31MRV31-ContinuousMRV31-Peak

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Page 17: Tolomatic presentation understanding motion control technology

• 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

MICROSTEPPING SYSTEM SUMMARY

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Page 18: Tolomatic presentation understanding motion control technology

MOTION CONTROL SYSTEMS

Microstepping

Brushed DC

Brushless Servo

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Page 19: Tolomatic presentation understanding motion control technology

• Low to medium cost

• Smooth and quiet operation• Simple control (switch to switch)

• Higher torque and speed than Stepper

WHY A BRUSHED DC SYSTEM?

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Page 20: Tolomatic presentation understanding motion control technology

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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Page 21: Tolomatic presentation understanding motion control technology

Easily defined speed and torque output– Volts/RPM– Torque/Amp

Simple design keeps the cost down

Better torque roll off compared to steppers

ADVANTAGES OF BRUSHED MOTORS

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Page 22: Tolomatic presentation understanding motion control technology

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

LIMITATIONS OF BRUSHED MOTORS

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Page 23: Tolomatic presentation understanding motion control technology

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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Page 24: Tolomatic presentation understanding motion control technology

Microstepping

Brushed DC

Brushless Servo

MOTION CONTROL SYSTEMS

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Page 25: Tolomatic presentation understanding motion control technology

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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• 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

WHY A BRUSHLESS SERVO SYSTEM?

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Page 27: Tolomatic presentation understanding motion control technology

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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Page 28: Tolomatic presentation understanding motion control technology

• High continuous and peak torque

• High speeds (up to 6,000 RPM)

• Motor thermal protection

• Metal shell plug and turn connectors

• IP65 options

ADVANTAGES OF BRUSHLESS MOTORS

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Page 29: Tolomatic presentation understanding motion control technology

• Increased cost• Increased weight

• Higher control complexity due to encoder feedback

LIMITATIONS OF BRUSHLESS MOTORS

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Page 30: Tolomatic presentation understanding motion control technology

• 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

BRUSHLESS SERVO SUMMARY

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Page 31: Tolomatic presentation understanding motion control technology

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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Page 32: Tolomatic presentation understanding motion control technology

QUESTIONS???

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