Agenda

ROBO 247 – Robotic Applications

Week #12
 DC Motor Control cont’d…
 Time Controlled Acceleration
 Dynamic Breaking
 Reversing with time delay

Brushless DC Motor
ABB & Fanuc Robot’s Maintenance
Work cell Support Systems
Test#3 Preview

Lab Test – week 14

Test#3 – week 14
Definite time controller
 Definite time controller

Closing the start button completes the control circuit from line 1 to point 5,
energizing relay coils M and TR1. This starts the motor turning by connecting
the armature, through the two series resistor, to the line. Note that the field
coil is connected directly to the line and is not affected by the series resistors
R1 and R2.

Meanwhile, the timing relay TR1 pulls the plunger up into the coil at a rate
determined by its time escape mechanism. After a predetermined time the
plunger is pulled up as far as possible, closing the normally open contacts of
TR1. This action simultaneously energizes acceleration relay A1 and timing
coil TR2. As a result Resistor R1 is cut out of the circuit, allowing the motor to
accelerate. After a further time delay, TR2 times out and energizes the
second acceleration relay A2.
 Dynamic Braking

The purpose of dynamic braking is to bring a motor to a quicker stop. To

do this there must be a method to quickly use the mechanical energy
stored in the momentum of the armature after the main switch is opened.

One method is to change the function of the motor to that of a generator.

(A generator converts mechanical energy into electrical energy.) At the
instant the motor is disconnected from the line, a resistor is connected
across the motor armature. The resistor loads the motor as a generator,
dissipates the mechanical energy, and slows the motor quickly.
CEMF Motor Controller
with Dynamic Breaking
 Dynamic Braking cont’d…

• The dynamic braking coil (DBM) is designed so that its only function
is to ensure a positive closing of the normally closed dynamic
braking contacts 9—10. If the main coil M is energized, the dynamic
braking contacts 9—10 open and contacts 8—9 of M close,
although the dynamic braking coil is also energized. The dynamic
braking coil is a little weaker than the M coil.

• When the start button is pressed, the control coil M is energized,

contacts 8—9 of M close, and the motor starts and accelerates up
to normal speed. At the instant the M control relay is energized, the
normally closed dynamic braking contacts 9—10 open. As a result,
the dynamic brake resistor connection across the armature is
broken.
 Dynamic Braking cont’d…

Stopping

When the stop button is pressed, relay control coil M is de-

energized, and M contacts 8—9 open the armature circuit and close
the dynamic braking contacts 9—10. These contacts connect the
dynamic brake resistor directly across the armature. Since the
shunt field is still connected across the line and receiving full
excitation, the high CEMF generated in the armature causes a high
load current through the dynamic brake resistor. The heavy load
current dissipates the stored mechanical energy in the armature
with the result that the motor slows to a stop. File braking action
decreases as the armature speed decreases.
 Field Discharge Resistor

When using the CEMF controller and dynamic braking, a field

discharge resistor must be added. When the shunt field is
disconnected from the supply voltage and its magnetic field begins
to collapse. The quick collapse of the magnetic field produces a
very large “inductive kick” voltage—thousands of volts: If it does not
have a discharge path, the high voltage actually begins to break
down the field winding insulation. Normally the discharge path is
through the armature, which allows a slower collapse and keeps the
voltage small. A field discharge resistor is a thyristor-type device
that conducts when the voltage across it's high enough, but has a
high resistance to normal line voltage. The collapsing magnetic
field’s voltage can discharge through the FDR (field discharge
resistor) without damaging the field windage.
Thermal Overload Relay
 Jogging or Inching

Jogging is moving the motor in small increments through repeated starting

and stopping, such as moving a crane to a particular location.
 Reversing DC Motor with Time
Delay

If the motor has been running in the forward direction, both M1 and TD1 will have been energized.
This being the case, the normally-closed, timed-closed contact of TD1 between wires 8 and 5 will
have immediately opened the moment TD1 was energized. When the stop button is pressed,
contact TD1 waits for the specified amount of time before returning to its normally-closed state, thus
holding the reverse pushbutton circuit open for the duration so M2 can't be energized. When
TD1 times out, the contact will close and the circuit will allow M2 to be energized, if the reverse
pushbutton is pressed. In like manner, TD2 will prevent the "Forward" pushbutton from energizing
M1 until the prescribed time delay after M2 (and TD2) have been de-energized.
 Reversing cont’d…

The time-interlocking functions of TD1 and TD2 render the M1 and M2 interlocking contacts
redundant. We can get rid of auxiliary contacts M1 and M2 for interlocks and just use TD1 and
TD2's contacts, since they immediately open when their respective relay coils are energized,
thus "locking out" one contactor if the other is energized. Each time delay relay will serve a dual
purpose: preventing the other contactor from energizing while the motor is running, and
preventing the same contactor from energizing until a prescribed time after motor shutdown.
The resulting circuit has the advantage of being simpler than the previous example:
 Brushless DC motor

• The motor consists of a stator with windings placed in its slots, a rotor, which is the
moving part, constructed of permanent magnet material and Hall effect sensors that
are used to give feedback of the rotor position to a microcontroller.

• The commutation of a BLDC motor is controlled electronically with the stator

windings being energized in a sequence that is determined on the position of the rotor
4-pole BLDC Motor
 4-pole BLDC Motor cont’d…

 There are 6 electromagnets since there are 2 for each phase on

opposite sides of the rotor so there is a complete magnetic field
passing through the center of the motor in 3 directions at 120 degrees
to each other.

 The rotor which has a fixed magnet is attached to the output shaft.

 The three phases red, blue and black are each producing an
alternating field and the three together produce a rotating field
which pulls the rotor magnet round as well as the shaft.
 Brushless DC motors (BLDC) -
Electronically Commutated Motors
(ECM)
Powered by a DC electric source via an integrated inverter/switching power
supply, which produces an AC electric signal to drive the motor

Power inverter - an electronic circuitry that changes DC to AC

Brushless motors offer higher efficiency and a lower mechanical wear

More complex expensive control electronics

Rotating permanent magnets and a fixed armature, therefore problems

associated with connecting current to the moving armature is eliminated

An electronic controller replaces the brush/commutator assembly of the

brushed DC motor, which continually switches the phase to the windings to
keep the motor turning. The controller performs similar timed power
distribution by using a solid-state circuit rather than the brush/commutator
system.
 BLDC- Advantages:

Increased reliability, reduced noise, longer lifetime (no brush and commutator
erosion)

Elimination of sparks from the commutator

Stationary windings are not subjected to centrifugal forces, and because they are
supported by the housing, they can be cooled by conduction, requiring no airflow
inside the motor for cooling. Therefore the motor can be entirely enclosed and
protected from dirt.
 BLDC Applications

Applications which need maintenance-free operation, high speeds, and

operation where sparking is hazardous (i.e. explosive environments)

Cost and control complexity is an issue. Nevertheless, widely used in:

computer hard drives and CD/DVD players.
Small cooling fans in electronic equipment
cordless power tools where the increased efficiency of the motor leads to
longer periods of use before the battery needs to be charged.

High power brushless motors are found in electric vehicles and hybrid
vehicles

HVAC and refrigeration industries use these motors because of dramatic

reduction in power required to operate them versus a typical AC motor. Also
the built-in microprocessor allows for programmability.
In manufacturing brushless technology is primarily used for servomotors,
actuators for industrial robots, extruder drive motors and feed drives for CNC
machine tools.
ABB & Fanuc robot’s maintenance
 ABB & Fanuc robot’s maintenance
cont’d…

The robot has several functions to provide efficient diagnostics and error
reports:

• The robot performs a self test when power on is set

• Errors are indicated by a message displayed in plain language. The message
includes the reason for the fault and suggests recovery action
• A board error is indicated by an LED on the faculty unit
• Faults and major events are logged and time-stamped. This makes it
possible to detect error chains and provides the background for any
downtime. The log can be read on the display of the teach pendant, stored in
a file, and can also be printed out
• There are commands and service programs in RAPID(ABB) to test units and
functions
• Fanuc has Karel programs to test and service
 ABB & Fanuc robot’s maintenance
cont’d…

The following maintenance is required:

• Lubricating spring brackets every six months

• Changing filter for the transformer/drive unit cooling every year (ABB)
• Greasing axes 5 & 6 every year (ABB)
• Greasing axes 1,2, & 3 for Fanuc
• Changing the oil for the gearbox for axis 4 (Fanuc)
• Changing the oil for the gearbox for axes 5 & 6 (Fanuc)
• Changing backup batteries every third year (ABB) & annually (Fanuc)

The maintenance intervals depends on the use of the robot. For detailed
information on maintenance procedures, see the robot’s respective manuals
under maintenance section
Product manual (ABB)
Mechanical unit Operator manual (ArcMate 100iC)
 Work-cell support system

In addition to the sensors, solenoids, robot I/O signals and PLC I/O signals,
a variety of other support systems are required for robotic automation cells
Material handling
Material handling systems are responsible for:
Delivering raw material to the automated work cell.
Moving parts between work stations
Removing finished parts from the automated work cell

3 types of transfer mechanisms:

1) Continuous transfer
2) Intermittent or synchronized transfer
3) Asynchronous transfer
 Work-cell support system, cont’d:

1) Continuous transfer

• The parts or material move through the

production sequence at a constant speed

• If the work station includes a robot, then the

robot must perform the work while the part is
moving through the cell
 Examples:
Continuous transfer

In-floor tow system (Car assembly plant.)

Overhead monorail
 Work-cell support system, cont’d:

2) Intermittent or synchronized transfer

• Workstations are fixed in place.

• The transfer device motion is intermittent,
the parts are synchronized and cycle
between being in motion and being
stationary.
• E.g. Rotary index table.
Work-cell support system, cont’d:

Rotary index table

 Work-cell support system, cont’d:

3) Asynchronous transfer

• Not synchronized. Each part moves

independent of other parts

• E.g. Pallet conveyor system. The robot

unloads the parts and the pallet slides on
the belt surface
 Example:
Asynchronous transfer

Pallets conveyor system

 Other support systems
Part feeders

Aside from material handling systems, other support systems are

part feeders
Function – To orient and position parts with sufficient accuracy.
There are 4 types:
1) Gravity feeders
Gravity feeders provide the force to move parts to the pickup point.
2) Tape feeders
• Tape feeders have components trapped between 2 layers of
tape with equal spacing and a fixed orientation.
• E.g. electronic components (Resisters, capacitors, ..etc)
3) Waffle-tray feeders
• A waffle-tray feeder is usually a plastic tray with equally spaced
compartments.
• E.g. The pallet of the ABB robot palletizing program.
 Work-cell support system, cont’d…

4) Vibratory feeders (See text)

– Two types – linear track and bowl.
– Track vibrations are along the length of the track.
– Vibration of the bowl is rotary about the centerline of the
bowl. (The bowl feeder)