Designing a Motion Control System
Agenda
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Elements of a motion control system Motion Control Software Motion Controllers Motor Drives Motors Feedback devices Example Application
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Motion Control System
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Motion control involves precise and repeatable control of movement by means of torque, speed and position control. There are three categories of motion controla. Point to Point Control(Indexing) b. Tension/Torque c. Speed
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Categories of Motion Control
a. Point to Point Control (Indexing)
b. Tension/Torque
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Categories of Motion Control
Speed Control
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Actuators
a. Linear Motion
a. Rotatory Motion
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Elements of a Motion System
Position App Software
Voltage
Current
Motion Controller
Amp/Drive
Motor
Mechanical
Feedback Device
Position Feedback
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Application Software
App Software
Motion Controller
Amp/Drive
Motor
Mechanical
Feedback Device
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Software Overview
Configuration
Prototype
Application Development Environment
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Motion Controllers
App Software
Motion Controller
Amp/Drive
Motor
Mechanical
Feedback Device
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Motion Controllers
A command Input device is a device that provides position, speed, and torque command to the servo amplifier to produce desired motion. A command Input device, therefore is a motion controller. There are three type of command input devices: PLC,PC and stand-alone
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Motion Controllers
Characteristics of a PLC as a Motion Controller: A PLC is designed for Industrial Environments. A PLC is designed to control any numbers of axes. A PLC can manage a lots of I/o. A PLC has a modular design, making for easy replacement. A PLC is easily reprogrammable.
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Motion Controllers
A command Input device is a device that provides position, speed, and torque command to the servo amplifier to produce desired motion. A command Input device, therefore is a motion controller. There are three type of command input devices: PLC,PC and stand-alone
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Motion Controllers
A command Input device is a device that provides position, speed, and torque command to the servo amplifier to produce desired motion. A command Input device, therefore is a motion controller. There are three type of command input devices: PLC,PC and stand-alone
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Purpose of the Motion Controller :
Calculate the trajectories for each commanded move on the board to prevent host computer interference Provide the torque commands to the motor drive or amplifier Monitor limits and emergency stops for supervisory control Close the PID loop
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A Motion controller can be either single or multi axis
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Features of a Simple Motion Trajectory
Target velocity
Velocity
Starting position
Time
Target position
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Typical Motion Profiles Options
Simple single axis point-to-point motion Requires an axis target position
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Typical Motion Profile Options : :
Vector point-to-point motion Requires X position and Y position
X Axis
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Typical Motion Profile Options : :
Blended motion Requires two vector moves and a blend factor
Blended Path Y Axis
Original Path X Axis
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Servo Amplifier/Drives
Servo Amplifier
An Amplifier consists of an electronics circuit that converts commercial AC power Supply into variable frequency AC power suitable for any specific motor
An Amplifier is comprised of a converter section, a smoothing circuit section, an inverter section, inverter section, and a control circuit section. A servo includes an encoder section.
Commercial AC power Supply
Converter
DC Bus
Inverter
Reference I/P
Control Circuit Section
Encoder Feedback
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Servo Amplifier
Commercial AC power Supply
Converter
DC Bus
Inverter
Command Unit
Position Control
Speed Control
Torque current control
Current Feedback
Encoder Feedback
A Servo has a encoder attached to the servo motor(SM), which sends feedback pulses to the position loop controller and the speed loop controller of the control circuit section.
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Servo Amplifier
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An Amplifier is comprised of : A converter section, that changes commercial AC into DC A Smoothing circuit section, which smoothes out ripples in the DC An Inverter section, which changes the DC into Variable Frequency AC, A Control circuit section, which controls the inverter section A servo Motor includes an encoder section.
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Encoders Feedback devices
Typical Industrial System
Input Controller
Operation (Application)
Output
Feedback
Sensor
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Encoders within a Control System
Feedback
Sensor
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Encoder Definitions
What is an encoder?
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An encoder is a device which converts a mechanical information of a shaft or position into an electrical signal
Encoder
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Encoder Definitions
How is this accomplished?
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As the code disc rotates, it shutters light from the LED and is received and transmitted as square\sine waveforms
Receiver / Sensor
Code disc Lens Transmitter / LED Shaft
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Encoder Selection Process
Type (Rotary, Linear, Incremental, Absolute) Electrical Interface Mechanical Considerations
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Encoder Selection Process
Type (Rotary, Linear, Incremental, Absolute)
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Types of Encoders
Encoder
Rotary Encoder
Linear Encoder
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Types of Encoders
Rotary
Convert Angular Position into Analog or Digital Signal Encoders for rotary motion and measuring angle, speed or velocity
Linear
Convert Linear distance movement to Analog or Digital Signal
Encoders for measuring distance travelled, positioning, location information.
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Types of Encoders
Encoder
Linear Encoder
Wire Draw
Linear with Scale
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Types of Encoders
Wiredraw
Convert pulled wire length distance to feedback With Scale
Absolute and Incremental
Analog, digital or Bus feedback interfaces Distance: up to 50m
Two part devices; Active Head, Passive Scale Absolute Positioning Scale : Magnetic Tape or Elements Hiperface, SSI, Bus Interfaces
Distance: up to 1700m
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Types of Encoders
Encoder
Rotary Encoder
Linear Encoder
Incremental
Absolute
Wire Draw
Linear with Scale
Incremental
Absolute
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Incremental Encoders
Incremental
Produces electrical pulses or increments with linear or rotary motion Signals can be square or sinusoidal waves Signals start over at power up, or after a power failure. In other words, an incremental encoder does not retain position after a power cycle Incremental encoders are typically used for speed or applications that do not require absolute position
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Absolute Encoders
Absolute
Code disc for absolute encoders
Provides a unique value for every shaft or linear position Absolute encoders retain their position after a power cycle Signals typically use SSI, parallel, or field bus interfaces (Ethernet/IP, EtherCAT, Profinet, Devicenet, CANopen, Profibus, etc) Absolute encoders are used in applications were position information is necessary
LED
Lens
Scanning mask Code disc PhotoElements
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Encoder Selection Process
Type (Rotary, Linear, Incremental, Absolute) Electrical Interface
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Types of Encoders
Encoder
Rotary Encoder
Incremental
Absolute
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Incremental Encoders
Output Channels
Incremental encoders
produce electrical pulses or increments (usually as a square wave) with linear or rotary motion of the encoder
Resolution
The number of pulses or increments per channel, per revolution. Also known as Pulses Per Revolution, or PPR
Quadrature:
The standard convention is to output two square wave channels along with their complements Channels A and B are offset by of a cycle using all four channels with this output, we can interpolate 4 positions within one pulse cycle. This is known as quadrature The 1/4th offset also allows us to see which direction the encoder is turning based on what channel is leading. If channel A goes high first followed by channel B, we can determine the direction of rotation, and visa versa.
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Incremental Encoders
Electrical Signals
Output Voltages
Standard output voltages are HTL, TTL or Open Collector. These refer to the amplitude of the square waves
HTL (High Threshold Logic)
Also known as push pull The output voltage will be the same as the supply voltage (e.g if the supply on the encoder is 24V, the output signal will also be ~24V)
TTL (Transistor Transistor Logic)
Also known as a differential line driver or RS422 The output voltage will always be 5V regardless of the supply voltage on the encoder
Open Collector
Instead of outputting a signal of a specific voltage or current, the output signal is applied to the base of an internal NPN transistor whose collector is externalized
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Incremental Encoders
Interface Summary
Incremental Encoder Electronic Interface Summary
Standard Supply voltages are 5VDC, 10-32 VDC, and 8-24VDC Standard outputs are TTL, HTL and Open collector Incremental Electronic Interface
TTL / RS 422 Supply = 5V
TTL / RS 422 Supply = 10 ... 32V
HTL / Push Pull Supply = 10 ... 32V
Open Collector Supply = 8-24 V
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Absolute Encoders
Singleturn vs Multiturn Absolute Encoders
Encoder
Rotary Encoder
Incremental
Absolute
Singleturn
Multiturn
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Singleturn and Multiturn Absolute
Singleturn
Multiturn
Measures the Absolute position within 1 revolution/turn In Addition, measures the number of revolutions as well.
Measures the Absolute position within 1 revolution/turn
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Absolute Encoder Interfaces
Absolute Electronic Interface
Parallel
SSI
BUS
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Parallel Output
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Parallel Output
First form of communication for absolute encoders
Connection
Point-to-point communication where each output wire represents a different data bit
Benefits
Direct output to digital inputs Fast (60us typically)
Drawbacks
Complex cabling due to separate bit wires High cost
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Synchronous Serial Interface (SSI)
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Synchronous Serial Interface (SSI)
Very common serial interface standard for industrial applications Developed by Stegmann in 1984 for absolute encoders now in many products
Connection
Point-to-point connection from a master (PLC, microcontroller) to a slave (encoder)
Benefits
Simple cabling, especially compared to parallel outputs Fast communication speeds Low cost
Drawbacks
Point-to-point connection, topology restrictions
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Network Encoders
What do we (or the customer) mean when we say network encoder?
- A network is a collection of products (sensors, HMIs, processes, etc) that are connected to a central controller or share information between parts. - Also known as Field Bus
- Example: an Internet VPN (virtual private network):
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Field Bus Interfaces :
Field Bus
Industrial network system that connects multiple products in a manufacturing plant or on a machine
Benefits
Products are no longer point-to-point which allow multiple products to be connected to one controller Generally does not require as many cables as a point to point configuration, and cables do not need to be as long. This saves on system costs. Typically the controller has more flexibility for configuration and information gathering
Disadvantages
The network topologies are generally more complex Individual components cost more than standalone products (potential system savings, however)
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SICK Absolute Encoder Fieldbus Interfaces
ATM60 Series
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AFx60 Series
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Electrical Interface Summary
Things to know when choosing an encoder
Incremental Encoders
- Resolution (PPR) - Supply Voltage - Output Voltage (HTL, TTL or Open Collector)
Absolute Encoders
- Resolution (singleturn, multiturn) - Output type
Parallel (output voltage needed) SSI Fieldbus
- Programmable Encoders:
DFS60 and DFS2x encoders let you program ALL electrical configurations except an open collector output
- Programmable Encoders
Programmable options for SSI encoders to program the resolution. All field bus encoders are programmable over their respective networks
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Encoder Selection Process
Type (Rotary, Linear, Incremental, Absolute) Electrical Interface Mechanical Considerations
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Mechanical Characteristics
Housings and Connection
Housing Size Cable or Connector
Shafts
Solid, blind hollow, through hollow Sizes, shaft load
Flange
Face mounting flange Servo flange Square Flange Tethers
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Encoder Selection Process
Type (Rotary, Linear, Incremental, Absolute) Electrical Interface
Mechanical Considerations
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Product Overview - Rotary Encoders
Absolute Singleturn Encoders
Absolute Multiturn Encoders
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Product Overview - Linear Encoders
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Key Products in 2013
Choice encoders that will solve most applications
DFS60 with PGT-10-S Programming Tool DFS20/25 Incremental Encoder AFx60 Series With Ethernet BCG Wiredraw with Analog Output
Handheld, battery operated programming tool Easy menu structure for fast setup and flexibility Can be used for diagnostics with the display or as a cloning module
USA sized encoders with SICKs F-Technology: Wide set bearings for even shaft loading
Absolute single- and multiturn encoders with EtherNet/IP, EtherCAT, and Profinet interfaces Device Level Ring (DLR) functionality with the EtherNet/IP version Superior diagnostics for temperature, speed, runtime, and many more
Compact wiredraw encoder for applications in tight spaces Up to 10m of measuring length Analog output scalable directly on the encoder for fast commissioning
Metal code disc for high vibration and temperature
Programmable using the PC-based tool
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Fields of applications
Packaging Print & Paper Wood industry
Machine Tooling
Automotive
Ports & Cranes
Handling
And many more
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Application Examples
OVERHEAD CRANE AFM60 EtherNet/IP used to track position of crane
CONVEYORS DKV60 used to track speed of conveyor
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Application Examples
WIND TURBINE Absolute encoder AFM60 for gandala and blade angle tracking
BOTTLING Absolute encoder AFS60 to track position of fillers
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Application Examples
STADIUM ROOF Position with KH53 Linear Encoder
LIFT APPLICATIONS Height and Width positioning using BGC Wiredraw Encoders
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