MODULE – 5 – Motion Profiles, Controllers and Applications

Motion profiles – position and velocity controls – Inner and Cascaded

loops – Pulse Width Modulation for DC motors, Servo Systems -
Motion modes – linear, circular and contour moves – motion
programming – single axis motion – multi axis motion – master slave
motion – industrial applications – case studies.
Self-Study:
1. Study of Basic control structures and loops of a motion control system
2. Study of AC servo and Induction motor Model

MHB4321-SMC-HITS-RMKP-2021 2
Unit/ Topic Learning Outcomes
CO- 3 - Design a simple motion control system for mechatronic applications

Discuss various motion profiles used for Load movement in a system

Discuss the various control loops used to implement motion profiles

Comprehend various motion modes used to implement the motion profiles

Comprehend Single axis and Multi axis motions such as Jogging, Homing and
Coordinated Motions
MHB4321-SMC-HITS-RMKP-2021 3
 Motion Profiles and Loops

Motion Modes, Single and

Multi Axes Motions

Contents
PWM Control for DC and Servo
Motor

Motion control design for

Hoist, Conveyor etc. Case stuies

MHB4321-SMC-HITS-RMKP-2021 4
Motion Profiles
• Defines how the motor should behave – in
terms of position, velocity, and acceleration –
during the move w.r.t time.
• Motion:
• Moving along a tool from point A to B in a
straight line or Circular or complex paths.
• Complex paths are called Trajectories or
Motion Profile

Motion controller generates the motion profile at

regular intervals to create velocity and position
commands for the servo control system of each
motor.

MHB4321-SMC-HITS-RMKP-2021 5
Motion Profiles - Concepts
𝒔 = න 𝒗 𝒕 𝒕 − (𝟏)
• Common Motion Profiles are
• Trapezoidal
• Triangular
• S- Shaped – Sigmoidal 𝒗 = න 𝒂 𝒕 𝒕 − (𝟐)
• Kinematics of the system is used for motion profile calculations
• Governs the relationship between time, position, velocity and
acceleration
• Consider and Axis moving from “A” to “B”
• 𝑺 𝒕 = 𝑷𝒐𝒔𝒊𝒕𝒊𝒐𝒏 𝒂𝒍𝒐𝒏𝒈 𝒕𝒉𝒆 𝒕𝒓𝒂𝒋𝒆𝒄𝒕𝒐𝒓𝒚
𝒅𝒔
• 𝒗 𝒕 = = 𝑽𝒆𝒍𝒐𝒄𝒊𝒕𝒚 = Change of position 𝑺 𝒕 at a given
𝒅𝒕
time interval
𝒅𝒗
• 𝒂 𝒕 = = Acceleration = Change of Velocity 𝒗 𝒕 at a given
𝒅𝒕 Basic relationships between position, velocity,
time interval and acceleration
MHB4321-SMC-HITS-RMKP-2021 6
Motion Profiles - Concepts
𝒔 = න 𝒗 𝒕 𝒕 − (𝟏)
Geometric Rules for Motion Profile
• Position at time t is equal to the area under the velocity curve
up to time t
• Acceleration is the slope of the velocity curve 𝒗 = න 𝒂 𝒕 𝒕 − (𝟐)

From equation (1) and (2)

Where, 𝑡0 is the initial time, 𝑣0 is the initial velocity, and 𝑆0 is the

initial position. The acceleration “a” is constant.

MHB4321-SMC-HITS-RMKP-2021 7
Activity - 1
Given the velocity profile in the figure, find the position and
acceleration at t = 5 s.

Solution
Slope of the velocity profile is the acceleration
10
𝑎= = 𝟐 𝐢𝐧/𝒔𝟐
5
Area under the velocity curve is the position reached at t = 5 s
𝟏
𝑺= ∗𝐛∗𝐡
𝟐
𝟏
= ∗ 𝟓 ∗ 𝟏𝟎 = 𝟐𝟓 𝐢𝐧
𝟐

MHB4321-SMC-HITS-RMKP-2021 8
Activity - 2
An axis is traveling at a speed of 10 in/s. At t = 5 s it starts to slow
down as given by the velocity profile in Figure 2.3. What is the axis
position when it stops? Assume that the axis starts decelerating at
25 in

10
𝑎=− = − 𝟏 𝐢𝐧/𝒔𝟐
15 − 5

𝟏
𝑺= ∗ 𝐛 ∗ 𝐡 = 𝟎. 𝟓 ∗ 𝟏𝟓 − 𝟓 ∗ 𝟏𝟎
𝟐
= 𝟓𝟎 𝐢𝐧

MHB4321-SMC-HITS-RMKP-2021 9
Trapezoidal velocity profile
• Area under the curve is the total distance moved
• Slope of the initial and final ramp are the maximum acceleration and
deceleration
• Top level of the trapezoid is the maximum velocity
• Continuous acceleration, but there will be a jerk (third order
derivative) at the four sharp corners
• Three distinct phases in the motion
• Acceleration
• Constant Velocity (Zero Acceleration)
• Deceleration
• Desired motion parameters to move an axis of the machine are
• Move velocity 𝒗𝒎
• Acceleration 𝒂
• Distance 𝒔 to be travelled by the axis Trapezoidal velocity profile and associated
MHB4321-SMC-HITS-RMKP-2021 position, acceleration, and jerk profiles
10 to move
an axis from 0 to position L
Geometric Approach
• Goal is to determine move time 𝑡𝑚
• W.k.t acceleration a is the slope of the velocity curve
𝒗𝒎
𝒂 = (1)
𝒕𝒂
𝒗𝒎
• 𝒕𝒂 = 𝒕𝒅 = 𝒂
(2)
• The total motion time is as follows
𝒕𝒕𝒐𝒕𝒂𝒍 = 𝒕𝒂 + 𝒕𝒎 + 𝒕𝒅 (3)
• Total distance travelled by the axis is found by
𝒕 𝒗 𝒕𝒅 𝒗𝒎
𝑳 = 𝒂 𝒎 + 𝒕𝒎 𝒗𝒎 + (4)
𝟐 𝟐
When 𝒕𝒂 = 𝒕𝒅
𝑳 = 𝒗𝒎 (𝒕𝒂 + 𝒕𝒎 )

𝑳 Analytical
𝒕𝒎 = − 𝒕𝒂
𝒗𝒎 Approach ? Trapezoidal velocity profile and associated
MHB4321-SMC-HITS-RMKP-2021 position, acceleration, and jerk profiles
11 to move
an axis from 0 to position L
Activity - 3
The X-axis of a gantry robot is to move for 10 in. The maximum acceleration allowed for this axis is 1 in∕s2. If
the axis needs to move at a desired maximum velocity of 2 in/s, how long will it take to complete this motion?
Given:
S = 10 inch ; a = 1 in/s2 , Vm = 2 in/s

Solution
𝒗𝒎 𝟐
• 𝒕𝒂 = 𝒕𝒅 = = = 𝟐𝒔
𝒂 𝟏

𝑳 𝟏𝟎
• 𝒕𝒎 = − 𝒕𝒂 = −𝟐 = 𝟑𝐬
𝒗𝒎 𝟐

•  𝒕𝒕𝒐𝒕𝒂𝒍 = 𝒕𝒂 + 𝒕𝒎 + 𝒕𝒅
• 𝒕𝒕𝒐𝒕𝒂𝒍 = 2 + 3 + 2 = 7s

MHB4321-SMC-HITS-RMKP-2021 12
Activity - 4
Consider the given motion and velocity profile. Determine the position SA, SB, SC
for the gantry robot whose X – axis must reach the above positions using
a. Geometric Approach
b. Analytical Approach

Ans:
SA = 1 in
SB = 21 in
SC = 22 in

MHB4321-SMC-HITS-RMKP-2021 13
Triangular velocity profile
• Characterized by equal acceleration and deceleration times
(distance travelled)
• Acceleration period
• Deceleration period
• Provides fastest movements between two points
• Applications that don’t require a period of constant velocity
• Height of the triangle represents the maximum velocity
• Acceleration is half the move time

MHB4321-SMC-HITS-RMKP-2021 14
S - Curve velocity profile
• Smoothing the beginning and end of the acceleration and
deceleration phases of motion
• limits the rate of change of acceleration and deceleration (jerk)
• Second order Polynomial functions are used to generate the
rounded corners
• two pieces of quadratic curves designated as “A” and “B”

where C0,C1, and C2 are coefficients

S-curve velocity profile and the associated position,

acceleration, and jerk profiles

MHB4321-SMC-HITS-RMKP-2021 15
S - Curve velocity profile

S-curve velocity profile and the associated position,

acceleration, and jerk profiles

MHB4321-SMC-HITS-RMKP-2021 16
Multi Axes Motion
• Systems having motion in more than one axis
• Requires coordination of the individual axis to complete the task
• Example – CNC milling machines, Gantry Robots

• Coordination approaches in moving the axis of the machines are

• Move one axis at a time
• Start moving all axis at the same time – Slew Motion
• Adjust the motion of the axes so that they all start and finish
at the same time – Interpolated Motion

MHB4321-SMC-HITS-RMKP-2021 17
MULTI AXIS: LINEAR MOTOR DRIVEN POSITIONING STAGE

Motion profiles
(speed, acceleration,
deceleration, position, PID etc.)

Voltage loop ( convert the

parameters into voltages based
on error signals)

Current loop

Desired Motion

Position feedback

MHB4321-SMC-HITS-RMKP-2021 18
Multi Axes Motion – Slew Motion
• All axes start moving with the same speed and at the
same time, but each axis finishes its motion at a
different time.
• Each axis travels at different speeds but start at the
same time
• Usually results in unnecessary wear on the axis and
often leads to unanticipated results in the path taken
by the system.

Consider the machine shown in the above figure. If both

axes are moving at the speed of 4 in/s using trapezoidal
velocity profile with ta = 0.2 s, how long will it take each
axis to complete its move? Will the tool tip follow a straight
line as shown in figure?

MHB4321-SMC-HITS-RMKP-2021 19
Multi Axes Motion – Slew Motion
Solution:

For X – axis For Y – axis

𝒊𝒏 𝒊𝒏
𝒕𝒂 = 𝟎. 𝟐𝒔; L = 16 in; 𝒗𝒙 = 𝟒 𝒕𝒂 = 𝟎. 𝟐𝒔; L = 12 in; 𝒗𝒚 = 𝟒
𝒔 𝒔

W.k.t for trapezoidal velocity profile W.k.t for trapezoidal velocity profile
𝑳 𝟏𝟔 𝑳 𝟏𝟐
Move time 𝒕𝒙𝒎 = − 𝒕𝒂 = − 𝟎. 𝟐 = 𝟑. 𝟖 𝒔 Move time 𝒕𝒙𝒎 = − 𝒕𝒂 = − 𝟎. 𝟐 = 𝟐. 𝟖 𝒔
𝒗𝒎 𝟒 𝒗𝒎 𝟒

Total time taken = 𝒕𝒂 + 𝒕𝒙𝒎 + 𝒕𝒅 = 𝒕𝒙𝒎 + 𝟐𝒕𝒂 Total time taken = 𝒕𝒂 + 𝒕𝒙𝒎 + 𝒕𝒅 = 𝒕𝒙𝒎 + 𝟐𝒕𝒂
Total time = 3.8 s + 2 * 0.2 = 4.2 S Total time = 2.8 s + 2 * 0.2 = 3.2 S

Tool tip will not follow the straight line

MHB4321-SMC-HITS-RMKP-2021 20
Multi Axes Motion – Interpolated Motion
• All joints start, and stop at the same time
• Faster axis are slowed down by the controller such that all axis finish at the same time.
• All the axes are coordinated by the controller
• Two approaches to achieve motions are
✓ Slow down the faster axes while keeping the acceleration time, ta, the same as the axis that
takes the longest time to complete its motion
✓ Slow down the faster axes while keeping the acceleration, a, the same as the axis that takes the
longest time to complete its motion.
• To make the tool tip to follow a straight line in the previous example, the controller will adjust the
velocity of the Y-axis to 3 in/s making both the axis have similar time to complete its motion
𝑳 𝟏𝟐
𝒖𝒚 = = = 𝟑 𝒊𝒏/𝒔
(𝒕𝒎 + 𝒕𝒂 ) 𝟐. 𝟖 + 𝟎. 𝟐
MHB4321-SMC-HITS-RMKP-2021 21
Multi Axes Motion – Interpolated Motion
• Types of Interpolation are
• Linear Interpolation
• Circular Interpolation – move consisting of a straight-line chord
segments
• Contouring - a series of points is provided during programming,
and the motion controller extrapolates a smooth line or curve
from these points.

MHB4321-SMC-HITS-RMKP-2021 22
Control Structures
• Needs precise control of velocity and position
• Three basic structures are used
• Cascaded Position and Velocity Loops
• Single – Loop PID position control
• Cascaded Loops with Feedforward control

Cascaded Position and Velocity Loops

MHB4321-SMC-HITS-RMKP-2021 23
Cascaded Position and Velocity Loops

Velocity Loop

Position loop – outer loop

MHB4321-SMC-HITS-RMKP-2021 24
Cascaded Position and Velocity Loops

MHB4321-SMC-HITS-RMKP-2021 25
Inner loop or Current loop

Generic structure of the inner loop (current loop)

MHB4321-SMC-HITS-RMKP-2021 26
Pulse Width Modulation (PWM)

Pulse-width modulation (PWM). (a) Duty cycle in pulse width modulation

(PWM). (b) average voltage output is proportional to the duty cycle

MHB4321-SMC-HITS-RMKP-2021 27
Pulse Width Modulation (PWM)

Duty cycle is defined as the percent ratio of the on-time to the period of the square wave

MHB4321-SMC-HITS-RMKP-2021 28
Motion (Move) Modes
Motion Controller:
• Calculates and controls the mechanical trajectories an actuator must
follow
• Ensure the axis position and move between two points
• Linear
• Circular
• Move Constraints are
• Position / distance
• Velocity Limits
• Acceleration / Deceleration
• Move constraints are used to create the trajectory profile by the
controller

MHB4321-SMC-HITS-RMKP-2021 29
Motion (Move) Modes
Linear Move:
• Rectilinear motion, is one-dimensional motion along a straight line
• Start and End points along with constraints are necessary
• Target positions are specified in two ways
• Absolute – Axis starts at origin as reference
• Incremental – Axis starts with the previous position as reference
∆𝒙 𝑿𝟐 −𝑿𝟏
• 𝒗𝒂𝒗𝒈 = =
∆𝒕 𝒕𝟐 −𝒕𝟏
• Example – given trapezoidal velocity profile with move velocity (𝑣𝑚 ),
• Controller computes the move time (𝑡𝑚 ) and acceleration and
deceleration time (𝑡𝑑 )

MHB4321-SMC-HITS-RMKP-2021 30
Motion (Move) Modes
Circular Moves
• Circular path interms of arc is followed between two points A and B
• 2 D as an arc or 3D as an helix
• Requires multiple axis to be coordinated
• Start Point
• End Point
• Center point of the arc
• Direction of the move I.e. CW or CCW

Circular moves in the XY plane

MHB4321-SMC-HITS-RMKP-2021 31
Motion (Move) Modes
Contour Moves
• Mix of various moves and must when a trajectory
cannot be construction with straight line or an arc
• Sequence of points are connected by means of
splines – cubic splines to generate trajectory
• Smooth motion is ensured by means of blending
between two linear, or two circular or between a
linear and circular segments
• Smooth transition from one velocity to another by
blending the velocity of the first move to the velocity
of the next move
Blended moves. (a) Blending of velocities between two
• End position of each segment may or may not be consecutive moves. (b) Two linear moves (Left) with and (Right)
reached. without blending

MHB4321-SMC-HITS-RMKP-2021 32
Single-Axis Motion
• Moving one axis at a time without any coordination
with any other axes
• Jogging – Moving a single axis with defined speed Linear axis with two limit switches and a home switch

and velocity in both positive and negative direction

• Homing – moving to reference position
• Trapezoidal or S-curve velocity profile is used
• Three modes of operation through
• Terminals
• Host computer (HMI)
• Programming

Homing search based on the move-until-trigger scheme

MHB4321-SMC-HITS-RMKP-2021 33
Multi-Axis Motion
• Multi-axis motion may involve
• Multiple motors driving one axis
• Coordinated motion of two or more axes
• Following using master/follower synchronization
• Tension control, or
• Kinematics. set-point coordinated motion

Gantry machine with set-point coordinated base axis. (a) Gantry machine with two motors
driving the base axis. (b) Same set-point commanded to both motors of the base axis
MHB4321-SMC-HITS-RMKP-2021 34
Multi-Axis Motion
• Coordinated motion of two or more axes
• Each motor is driving a single axis, but all axes move in coordination
• All axis are assigned same coordinate system
• Master/Slave Synchronization
• Master axis and slave axes
• Constant gear ratio called electronic gearing

MHB4321-SMC-HITS-RMKP-2021 35
Algorithm
Structure of a basic motion program

MHB4321-SMC-HITS-RMKP-2021 36
Algorithm
Multi-axis motion: Coordinated linear motion

MHB4321-SMC-HITS-RMKP-2021 37
SCARA Robot - Applications

Four-axis SCARA robot for kinematic analysis.

(a) Four-axis SCARA robot. (b) Top view
MHB4321-SMC-HITS-RMKP-2021 38
This Photo by Unknown Author is licensed
under CC BY-SA

MHB4321-SMC-HITS-RMKP-2021 39