INFORMACIÓN TÉCNICA

 Y DOCUMENTACIÓN
 

 QUE ES UN SERVOMOTOR AC?

Es un motor electrico de corriente altera, con el que se puede lograr

posicionamientos muy precisos, rápidos y repetibles, ya que cuenta con
una retroalimentación permanente de posión por medio del ecoder.  Este
es un sistema de lazo de conrol cerrado muy utilizado para generar
posicionamientos especificos y controlados.

Para conformar un sevo-sistema básico se debe contar con:

       - Servomotor

       - Amplificador (Driver, Servopack, Servoamplificador)

COMPARACIÓN ENTRE SISTEMA SERVO Y SISTEMA DE

VARIADOR
Ambos sistemas son utilizados en soluciones de automatización en
muchos sectores de la industria.  Algunas de las diferencias entre estos
sistemas son:

1.  El servo-sistema opera con un control de lazo cerrado que

permanentemente está vigilado a la posición del eje de salida mediante la
lectura de pulsos de su encoder, lo que garantiza precisión en su
funcionamiento.

2.  En los servo-sistemas, el torque nominal del servomotor YASKAWA

puede ser mantenido desde 0 RPM hasa la velocidad nominal, a
diferencia de los sitemas con variadores donde el torque nominal solo
puede ser usado en un rango limitado de las velocidades.

3.  El torque máximo de un motor con variador pude llegar a ser de un

a150%.  En un servomotor se puede lograr un torque máximo de 300%.

4. Un servomotor puede acelerar de 0 a 300 RPM en menos de 30 ms.

5. Los sistemas con variadores no pueden mantener su máximo torque a

velocidad cero, mientras que el servo-sistema mantiene su torque máximo
a esta velocidad.

6. Los servo-sistemas asegurar precisión y repetibilidad a alta velocidad,

lo que para el sistema de variador es imposible.  Esto hace al servo-
sistema capaz de realizar posicionamientos muy precisos y diminutos con
la capacidad de repetir cada movimiento.

7. Un sistema con variador se usa para aplicaciones de velocidad variable

como bandas transportadoras, ejes de herramientas, ventiladores, etc., y
arranques continuos, posicionamiento o indexado, como dosificadores,
arrastres a medida, brazos robóticos, mesas posicionadoras, tablas
rotativas, corte al vuelo, precorte de material, etc.

COMPARACIÓN SISTEMA SERVO Y SISTEMA CON MOTOR A

PASO

1. El torque que puede entregar el motor a paso, disminuye a medida que

la velocidad aumenta.  Por el contrario el servomotor puede entregar el
torque nominal a cualquier velocidad.

2. El servomotor puede entregar hasta un 300% de su torque nominal en

situaciones donde se requiera una alta aceleración o una corrección
inmediata de pocisión ante una perturbación, mientras que el motor a
paso pierde el paso al encontrar un torque de oposición.

3. Los sistemas de motor a paso pueden alcanzar una resolución en el eje

de salida de 51.200 micropasos por revolución.  Es decir 360º/51200 =
0.00703125º.  En los servo-sistemas se puede encontrar una resolución de
131.072 pulsos por revolución, es decir: 360º/131072=0.00274º.  La
precisión entonces del servo es casi cuatro veces mayor.

A. Servosistemas estándar CDM

1. Arrastre a medida para maquina selladora de bolsas

plásticas
2. Control de tornillo para maquina dosificadora de
polvos

3. Sistema de arrastre vertical a medida

4. Control de medida en maquinas Flow-Pack horizontal

y vertical

5. Control de corte a medida en maquinas convertidoras

de papel

6. Posicionamiento exacto en mesas rotativas

7. Control de posición en dispositivos XYZ

B. Proyectos especiales
Control de Movimiento Ltda. cuenta con la capacidad y
experiencia técnica necesaria para el desarrollo de
nuevas aplicaciones que se ajusten a las situaciones
especificas de su negocio. Para esto contamos con una
estructura organizacional conformada por un grupo
profesional de alto desempeño, dedicado a la
administración de proyectos, cuya misión es entregarle a
su organización los proyectos debidamente operativos
en total concordancia con los compromisos adquiridos
en la negociación.
Además de disponer del mejor equipo humano, Control
de Movimiento Ltda.  ha estandarizado una metodología
de manejo de proyectos orientada a satisfacer los
exigentes requisitos propios del sector industrial.
            C. Reemplazo de servos Yaskawa y de otras marcas en
cualquier tipo de aplicación, garantizando que el nuevo
equipo funcionara de la misma forma en que lo hacia el
anterior.
           
            D. Accesorios y Suministros:
                           I.    Interfaces hombre – maquina

                         II.    Reactancias de línea

                       III.    Fuentes de voltaje

                     IV.    Resistencias de regeneración

                      V.    Encoders de línea

What is AC motor drive?
It is an equipment used to control the speed and torque of an induct motor. The DC
voltage can become a variable voltage and variable frequency of alternating current
by the inverter after using the converter to rectify 1-phase or 3-phase AC power to
direct current. For general-purpose AC motor drives, the voltage will be changed
with frequency changes. Therefore, the AC motor drive is called VVVF(Variable
Voltage Variable Frequency) for short.
 
What is the difference between PWM and PAM?
PWM is the abbreviation of “Pulse Width Modulation”. It is a way to adjust output
and waveform by changing the pulse width regularly. PAM is the abbreviation of
“Pulse Amplitude Modulation”. It is a way to adjust output and waveform by
changing the pulse amplitude regularly.
 
Why must the voltage and current of drives change in proportion?
The torque of asynchronous motor is generated by interaction between magnetic
flux of motor and current in rotor. In rated frequency of motors, using constant
voltage with reduced frequency, it will result in over-magnetic flux, magnetic
saturation, and even cause motor damage. Therefore, frequency and voltage have to
be changed in proportion. In other words, the output voltage should be changed
with frequency. To fix the magnetic flux of motor, it can avoid weaken flux and
magnetic saturation. This control method is usually used in energy-saving drives for
fan and pump.
 
If it is driven by the commercial power, the current will be increased when the
voltage is decreased. If it is driven by the AC motor drive, will the current be increased
when the frequency and voltage are decreased?
When the frequency is decreased, the current will be increased with the same output
power. However, the current will be almost the same for the constant torque.
 
How will the start current and start torque be when a motor is driven by the AC
motor drive?
Normally, it will generate 6 to 7 times start current when the commercial power is
applied directly and causes electric inrush.
The motor can be started smoothly when driving by the AC motor drive and the
frequency and voltage will be increased with acceleration. The start current should
be below 150% (125%~200% for the different models), and the start torque is from
70% to 120% rated torque. For the drive with auto-enhanced torque and the start
torque is over 100%, it can be started with full load.
 
How will the motor’s torque be when V and f are changed in proportion?
The voltage will be reduced with frequency in proportion. The torque is also
decreased in low speed because the reduced AC resistance and the constant DC
resistance. Therefore, it can get higher start torque by increasing output voltage in
the low frequency. Many methods can be used to get it, such as auto torque
compensation, high start torque V/f curve and potentiometer adjustment.
 
 In general, the frequency can be set to 6-60Hz (1:10). If the power still outputs when
the frequency is below 6Hz?
It still outputs power when the frequency is below 6Hz. According to the setting of
motor temperature rise and start torque, it can output rated torque without overheat
problem when the frequency is 6Hz.
 
What is V/f mode?
The voltage will be reduced with frequency as described in question 4. The ratio of
V to f is decided in advance by motor characteristics.
 
If users can use the constant torque when the frequency exceeds 60Hz?
For general applications, the constant torque can’t be used for the frequency above
60Hz. Because the voltage and power are usually constant when the frequency is
above 60Hz. When you need to have constant torque in high speed, please pay
attention for choosing motors and drives.
 
What is closed-loop/open-loop control?
For closed-loop control, the motor is used with encoder and sends the actual speed
to the AC motor drive via PG card. For the open-loop control, it is used without
encoder.
 
How should I do when the actual speed is different from the desired speed?
When the AC motor drive is controlled by the open loop, the motor speed will be
varied within ±5% X rated slip. You can use the AC motor drive with the PG
feedback function when the accurate speed is required.
 
If the speed precision will be increased when using PG feedback control?
Normally, it will. But the improvement will depend on the resolution of encoder
and output frequency.
 
What is stall prevention？
When the accel./decel. time is too short and the change of output frequency is faster
than the motor speed, the AC motor drive will stop due to over-current. This
situation is called stall. To have normal motor operation, it needs to control
frequency by the output current. Therefore, the accel. rate should be decreased
when the output current is too large. That is stall prevention
 
What's difference between the same accel./decel. time setting and the different
accel./decel. time setting for the application?
It needs to set the different accel. time and decel. time for the strict time
requirement applications. But in the fan and drive applications, the accel./decel.
time can be set the same due to longer accel./decel. time requirement.
 
How should I do to enhance the brake performance?
Normally, the brake of the AC motor drive is 10%~20% of rated torque. But it can
be increased when using with brake unit.
 
What are the inverter components?
They are SCR, GTO, BJT and IGBT. By 1970, SCR is the only one component.
After that, they are GTO->BJT->IGBT.
 
What is Auto Tuning?
Auto Tuning is to measure the motor parameters automatically, including no-load
current, stator resistance, rotor resistance, stator inductive reactance, rotor inductive
reactance, etc. These parameters are used to calculate the torque estimation and slip
compensation. With auto tuning, it can get accurate speed without encoder.
 
What are the advantages when using without encoder?
I.Simple wiring.
II.Don’t need to care about the influence that RF noise makes to the low-voltage
signal of encoder
III.Don’t need to care about the high malfunction ratio of encoder in the vibration
applications
 
What is vector control?
In the AC motor, rotor generates flux by the current from stator winding induction.
There are two elements in stator current, one affects flux and the other affects the
output torque of motor. The flux vector can control these two elements individually
so that the speed and torque can be controlled.
The SureServo servo systems provide the highest possible level of performance
for precise control of position, velocity, and torque. As compared to lower cost
stepping systems, the SureServo servo products provide:

 More torque at higher speeds (up to 5,000 rpm)

 Broader range of & higher power (up to 3 kW)
 Higher response with closed-loop control
(high hit rate without stalling or lost position

The SureServo drive closes the loop on current, velocity, and position
(depending on control mode selection). Proportional gain, integral gain, feed
forward compensation, command low pass filter, and notch filter for
resonance suppression are available.

There are three tuning modes:

 Manual Mode
for user-defined adjustments

 Easy Mode
for default settings over a wide range of programmed inertia with 10 response
levels
 Auto Mode
for automatic adjustment using an estimated (or measured) value of inertia

While the SureServo drives can accept traditional commands from outside host
controls, the drives also have the ability to provide for their own internal motion
control. For example, up to eight index moves can be pre-defined and stored in
the drive and then selected and executed using discrete inputs.

The pre-defined index profiles can also be changed using the serial communication
protocol. The motion can be incremental or absolute (homing routines are available
in the drive) and acceleration can be linear or S-curve.

Multiple drives can be daisy-chained and addressed separately using the

RS-485/RS422 capability of the drive's serial port. This allows for very simple yet
powerful control of multi-axis processes that do not need precise path control but
only precise starting and stopping points. Applications include press feeds, auger
fillers, rotary tables, robots for pick and place, test or assembly operations,
oring, drilling, cutting, tapping, and similar applications using simple index moves
for single or multi-axis motion.

 
The primary purpose of the AC servo system is to precisely control the motion
of the load. The most fundamental considerations in selecting the servo system
are "reflected" load inertia, servo system maximum speed requirement, servo
system continuous torque requirement, and servo system peak torque requirement.

In a retrofit application, select the largest torque SureServo™ system that most
closely matches these parameters for the system being replaced.

In a new application, these parameters should be determined through calculation

and/or measurement. The following considerations should be followed in order to
select the proper SureServo™ system:

The inertia of everything attached to the servo motor driveshaft needs to be

considered and the total "reflected" inertia needs to be determined. This means
that all elements of any mechanical transmission and load inertia need to be
translated into an equivalent inertia as if attached directly to the motor
driveshaft. The ratio of "reflected" load inertia to motor inertia needs to be
carefully considered when selecting the servo system.

In general, applications that need high response or bandwidth will benefit from
keeping the ratio of load inertia to motor inertia as low as possible and ideally
under 10:1. Systems with ratios as high as 200:1 can be realized but
corresponding lower bandwidth or responsiveness must be accepted. The servo
response including the attached load inertia is determined by the servo tuning.
SureServo™ systems may be tuned manually, adaptively with measurement of the
load inertia, or set with default tuning based on a programmed value of load
inertia.

With knowledge of the motion profile and any mechanical transmission between
the motor and load, calculations can be made to determine the required servo
motor continuous torque, peak torque, and maximum motor speed.

The required amount of continuous torque must fall inside the continuous
operating region of the system torque-speed curve (you can check the continuous
torque at the average speed of the motion profile). The required amount of peak
torque must also fall within the servo system's intermittent operating region of the
system torque-speed curve (you need to check this value at the required
maximum speed).
Servo systems are used to control a load. In order for the servo to do this
properly per the system requirements, it must be appropriately sized. The servo
system needs to be able to provide the required torque, the required speed, and
the required accuracy in order for the entire system to perform as designed.

The type of load, the mechanical transmission, the duty cycle of the system
(how often it starts and stops its operation), how fast the system needs to go
during operation, and how accurate the system needs to be all play a part in
deciding what system should be selected. Generally when replacing an existing
servo system, the same power size can be selected even though the motor may
be a different physical size.

When deciding on a servo system for a new application, sizing software is often
used to help the process. This software contains all the required mathematical
formulas used to determine the inertia of the load which is a critical parameter
used in selecting a servo.

Each of the eight standard systems has a torque-speed curve including the
motor inertia for reference. This is the fundamental information that you need
to select the servo drive and matching motor for your application.

Don't forget the cables and ZIPLink break-out board kit!

Included in the ordering guide are the available connection cables from the
drive to motor in standard lengths from 10 to 60 feet. The break-out board kit
including 0.5 m (19 inch) cable for the CN1 user interface is also listed for your
convenience. We highly recommend all five items per system as a minimum.

All cables are 100% factory tested to make your system installation as easy
and quick as possible. See the Accessories section for regeneration resistors,
AC line filters, fuses, contactors, and RF noise filters.

The SureServo™ motors have keyless shafts that are designed for use with
clamp-on or compression style couplings. Couplings using keys and/or set screws
should NOT be used with SureServo™ motors as they are likely to come loose or
damage the motor shaft. "Servo grade" clamp-on or compression style couplings
are usually the best choice when you consider the stiffness, torque rating, and
inertia.

Higher stiffness (lb-in/radian) is needed for better response but there is a

trade-off between the stiffness and the added inertia of the coupling. Concerning
the torque rating of the coupling, use a safety factor of 1.3 to 1.5 over the
SureServo peak torque requirement of your application.
Common mechanical transmissions include leadscrews, rack & pinion mechanisms,
conveyors, gears, and timing belts. The use of leadscrew, rack & pinion, or
conveyor are common ways to translate the rotary motion of the servo motor
into linear motion of the load.

The use of a speed reducer such as a gearbox or timing belt can be very
beneficial as follows:

1. Reduction of Reflected Load Inertia

As a general rule, it is beneficial to keep the reflected load inertia as low as

possible while using the full range of servo speed. SureServo™ systems can go up
to 5,000 rpm for the low inertia motors and up to 3,000 rpm for the medium
inertia motors.

However, when investigating the effect of different speed reduction ratios DO

NOT forget to include the added inertia of couplings, gearbox, or timing belt
pulleys. These added inertias can be significant and can totally undo any inertia
reduction due to the speed reduction.

2. Low Speed & High Torque Applications

If the application requires low speed and high torque then it is common to
introduce a speed reducer so that the servo system can operate over more of the
available speed range. This could also have the added benefit of reducing the
servo motor torque requirement which could allow you to use a smaller and lower
cost servo system.

Additional benefits are also possible with reduction in reflected inertia, increased
number of motor encoder counts at the load, and increased ability to reject load
disturbances due to mechanical advantage of the speed reducer.

3. Space Limitations and Motor Orientation

Reducers can possibly allow the use of a smaller motor or allow the motor to be
repositioned. For example, some reducers would allow for in-line, right angle, or
parallel mounting of the motor.