Servos

Doug Bristow

December 6, 2001 Alleyne Research Group 1

 Outline

Introduction
DC Brush motors
Stepper motors
Servo motors
Low tech vs. High tech servo
systems
Conclusions
December 6, 2001 Alleyne Research Group 2
 Introduction
Servos are used whenever precision control of very
small to very large loads is required.
Applications:
CNC machines
Laser and water-jet cutting
Winders
Pipe bending
Pick and place tables
Robotics
Cappers
Fillers
Al Gore
Wafer handling
Ion Implanting
Pattern Sewing
Fabric Cutting

December 6, 2001 Alleyne Research Group 3

 DC Brush Motors

F IB

Simple 2 Pole DC Brush Motor

December 6, 2001 Alleyne Research Group 4

 DC Brush Motors

2 Pole DC Brush Motor 4 Pole DC Brush Motor

December 6, 2001 Alleyne Research Group 5

 DC Brush Motors

December 6, 2001 Alleyne Research Group 6

 Stepper Motors

Stepper motors are brushless

December 6, 2001 Alleyne Research Group 7

 Stepper Motors

Benefits Disadvantages
Low Cost Run hot
Reliable Inefficient
Safe Noisy
Open-loop control Cannot achieve high
speeds

December 6, 2001 Alleyne Research Group 8

 Servo Motors

2 Pole Single Phase DC Servo

December 6, 2001 Alleyne Research Group 9

 Servo Motors

2 Pole Single Phase DC Servo Position-Torque Characteristic

December 6, 2001 Alleyne Research Group 10

 Servo Motors
Hall Effect

Hall Effect
IC

2 Pole Three Phase Servo

December 6, 2001 Alleyne Research Group 11

 Encoders

Incremental Encoder Absolute Encoder

December 6, 2001 Alleyne Research Group 12

 Servo System

Amplifier
Motor

December 6, 2001 Alleyne Research Group 13

 Four-Quadrant Control
The servo motors that
weve describe are 4-
quadrant because they
can accelerate and
provide braking torque in
both directions.

A simple variable-speed
drive capable of running
in one direction with
uncontrolled deceleration
would be single-quadrant.

December 6, 2001 Alleyne Research Group 14

 Regenerative Power
When decelerating the servomotor
to a stop or when a load is applied to a
vertical axis, the servomotor acts as a
generator returning regenerative power
to the amp. The power is dissipated by
charging the smoothing capacitor.
When the capacitor limit is reached,
power must be dissipated through a
regenerative resistor.
Regenerative Resistor

December 6, 2001 Alleyne Research Group 15

 Holding Brake
Servomotors generally
have an optional holding
brake. THIS BRAKE IS NOT Encoder
FOR DECELERATION! It Brake
works by engaging a Motor Windings
powerful electromagnetic
brake that clamps down on a
disc that is attached to the
shaft (like disc brakes on a
car). It is meant primarily for
holding a load on a vertical
axis.
Encoder
Brake
Motor Windings

December 6, 2001 Alleyne Research Group 16

 The Low Tech Servo System
Aerotech motors used
in this lab
BA series amplifier
BM/BMS series
servomotor
2 modes of operation:
Torque
Velocity
Gain and other
variables set by
potentiometers

December 6, 2001 Alleyne Research Group 17

 The High Tech Servo System

Yaskawa Sigma II
Servos and Amps
Key Improvements
Fully Digital Amp
Segmented Stator
Sinwave Amp (or
AC Servo)
Computer Interface

December 6, 2001 Alleyne Research Group 18

 Fully Digital Amplifier
The new, high tech amps are fully digital even driving the
motor phases using pulse width modulation (PWM).
Gains are set digitally no change over time.
No analog interference in internal (digital) signals.
Internal processor opens a whole new world in flexibility and
customizability with a couple hundred settings.
Gain switching for inertia changes.
Max velocity/torque settings.
Electronic Gear.
Position control loop in addition to velocity and torque control.
Can be used as a stepper through position control with as
many steps as resolution of encoder (8192-131072 steps/rev)
Fault and emergency stop routines.
Auto-tuning.

December 6, 2001 Alleyne Research Group 19

 Segmented Stator Servomotor
Traditional solid stators look like The segmented is made up of
the drawing shown earlier: individual segments wrapped like
spools of wire and then assembled.

Typically yields 35-40% packing 75%+ packing factor yields 33-

factor. 50% more torque.

December 6, 2001 Alleyne Research Group 20

 Sinwave Amplifier (AC Servo)
Recall that the old tech servo drive
approach is to divide the motor into
6 sections. While the rotor occupies
any point in a particular section, 2
corresponding phases are excited
with the same DC current. This
creates a torque ripple.

December 6, 2001 Alleyne Research Group 21

 Sinwave Amplifier (AC Servo)
Ideally, we would like to have the
stator field 90 out of phase with
the stator to create a maximum,
constant torque.

It turns out that we can create an

equivalent field with the 3 phases
by driving the current in each phase
as a sinusoidal function of the rotor
position with different offsets for
each phase.
Using sinwave amplification, the Sigma II
Using this approach requires that achieves constant torque 2%
the amplifier know the rotors exact
position. i.e. An absolute encoder
is required.

December 6, 2001 Alleyne Research Group 22

 Linear Servomotor

A linear servomotor is
essentially an unwrapped
rotary servomotor. The
stator becomes the forcer
and the rotor becomes the
magnet track.

December 6, 2001 Alleyne Research Group 23

 Dynamic Braking

A digital servo amplifier can be set up

to use dynamic braking to stop the
servo quickly, reliably, and safely in an
emergency. This can be done by
shorting the motor phases and using
their relative offsets to create a large
resistance.

December 6, 2001 Alleyne Research Group 24

 Conclusions
Servos are everywhere in industry.
Steppers are open-loop, servos are closed-loop.
Sinwave commutation will improve performance
more than any other characteristic of an amplifier.
Digital amplifiers eliminate noise and offer a lot in
terms of flexibility
If motor clearance is a problem, more torque can be
achieved if the servo motor uses a segmented
stator.

December 6, 2001 Alleyne Research Group 25

 Questions?

December 6, 2001 Alleyne Research Group 26