Servo Drives

State of the Art and Modern Developments

Prof. Dr.-Ing. J. M. Pacas, Institut fr Leistungselektronik und Elektrische Antriebe, Univer sitt Siegen Prof. Dr.-Ing. R. M. Kennel, Lehrstuhl fr elektr ische Maschinen und Antriebe, Bergische Un iversitt Wuppertal

Outline
General Requirements, State of the Art, Structure and Components of Servo Drives Drive Control with Position/Speed Encoder Motion Control Drive Control without Position/Speed Encoder Data Exchange (Communication)
Prof. Dr. -Ing. J. M. Pacas, University of Siegen Prof. Dr. -Ing. R. M. Kennel, Wuppertal University

Page 1

Typical Machine Tool

feed drives control the position between working piece and working tool

main drives provide processing power

Prof. Dr. -Ing. J. M. Pacas, University of Siegen Prof. Dr. -Ing. R. M. Kennel, Wuppertal University

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Parallel Kinematics

TriCenter DMT 100

(Deckel Maho)

Prof. Dr. -Ing. J. M. Pacas, University of Siegen Prof. Dr. -Ing. R. M. Kennel, Wuppertal University

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Characteristics of Servo Drives

feed high maximum torque

high efficiency
drives

constant maximum torque speed range < 10.000 rpm rated power < 20 kW

small size
axis

Spindle

smooth operation at low speeds

drives

high rated/continuous torque

constant maximum power

4 quadrant operation

speed range < 20.000 rpm rated power < 100 kW

main

Prof. Dr. -Ing. J. M. Pacas, University of Siegen Prof. Dr. -Ing. R. M. Kennel, Wuppertal University

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Hystory of Motor Types in Servo Drives

ASM
asynchronous motor

ASM

?
DC
SM
synchronous motor

SM

SM

EC
brushless DC

1970 ff.

1980 ff.

1990 ff.

Prof. Dr. -Ing. J. M. Pacas, University of Siegen Prof. Dr. -Ing. R. M. Kennel, Wuppertal University

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State of the Art: AC Servos

High Speed Spindle (Siemens) High Torque Motor (Baumller)

DSD Servo (Baumller) Spindle Motor (Franz Kessler)

Prof. Dr. -Ing. J. M. Pacas, University of Siegen Prof. Dr. -Ing. R. M. Kennel, Wuppertal University

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Inverters for Servo Drive Applications

Prof. Dr. -Ing. J. M. Pacas, University of Siegen Prof. Dr. -Ing. R. M. Kennel, Wuppertal University

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Encoders
Advantages
low cost high accuracy
(e. g. by gear ratio)

Disadvantages
elastic effects and back lash
source : ERN-Geber, Heidenhain

Prof. Dr. -Ing. J. M. Pacas, University of Siegen Prof. Dr. -Ing. R. M. Kennel, Wuppertal University

Page 8

Encoder Technologies
technology
Mebereich measuring area measuring area Auflsung resolution resolution Robustheit robustness robustness Massenproduktion mass production mass production

magnetic magnetisch magnetic

Resolver: circular tooth wheel: point

low
(multipole resolver: 20 Bit)

good

bad

problematic

very good
(photographic production)

optisch optical optical

point

high
(CCD: > 30 Bit)

(sensitive to temperature and shock)

kapazitive capacitive capacitive

Too less experience to make knowledge-based statements. circular high good good

Prof. Dr. -Ing. J. M. Pacas, University of Siegen Prof. Dr. -Ing. R. M. Kennel, Wuppertal University

Page 9

AC Servo Drive Control

speed M-Regler controller
n* * Feldschwchung
field weakening

current Stromcontrollers Regler

i*q i*d -

M 3~

Feld-Regler field controller

Mamachine schinenmodell model

e
for asynchronous machines

-j

i
Encoder

e-j

for synchronous machines

Prof. Dr. -Ing. J. M. Pacas, University of Siegen Prof. Dr. -Ing. R. M. Kennel, Wuppertal University

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Motion Control (e. g. Electronic Gear)

Virtual Virtueller Master master
S ynchronisierte Synchronized Kommunikation communication

Hauptantrieb main drive

Prof. Dr. -Ing. J. M. Pacas, University of Siegen Prof. Dr. -Ing. R. M. Kennel, Wuppertal University

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Sensorless Control Categories

fundamental models models based on anisotropies

emf-model, Observer

flux modulation

...

dq-inductance

rotor slotting effect

main field saturation

...

Prof. Dr. -Ing. J. M. Pacas, University of Siegen Prof. Dr. -Ing. R. M. Kennel, Wuppertal University

Page 12

Industrial Drives with Sensorless Control

since several years / decades sensorless control is investigated and published on conferences and magazines - acceptance in industry, however, is rather low

Why ?
new ideas and concepts are interesting for industry, only if they do not result in higher cost or higher effort!!!

What does that mean

for industrial drives with sensorless control ?
no additional or more powerful processors / controllers no additional hardware or additional sensors (e. g. voltage sensors) no increased installation effort with respect to parameter adjustments

Prof. Dr. -Ing. J. M. Pacas, University of Siegen Prof. Dr. -Ing. R. M. Kennel, Wuppertal University

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Drives with Diagnostic Features

Prof. Dr. -Ing. J. M. Pacas, University of Siegen Prof. Dr. -Ing. R. M. Kennel, Wuppertal University

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Distributed/Decentralized Control

Prof. Dr. -Ing. J. M. Pacas, University of Siegen Prof. Dr. -Ing. R. M. Kennel, Wuppertal University

Page 15

SERCOS interface
MDT
MST AT 1 AT 2 AT m AT M MST

t1.1

t1.2
t1.m t1.M t2 tScyc
t1.x t2 tScyc AT transmission starting time MDT transmission starting time SERCOS cycle time

Prof. Dr. -Ing. J. M. Pacas, University of Siegen Prof. Dr. -Ing. R. M. Kennel, Wuppertal University

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Future Developments
Motors (Actors)
synchronous motors with surface mounted permanent magnets as a standard - different solutions in special applications only (for cost reasons)

Signal Processing
further developments on speed/position encoders to be expected sensorless/encoderless control only, if no additional hardware effort (processors and/or sensors) no parameter dependencies during operation

Data Exchange/Communication
synchronized communication systems are demanded for multi axis servo drive systems for high requirements
Prof. Dr. -Ing. J. M. Pacas, University of Siegen Prof. Dr. -Ing. R. M. Kennel, Wuppertal University

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