Control of Servo Motors

Text book :
T.J.E. Miller, Brushless Permanent-Magnet and Reluctance Motor Drives,
Clarendon Press Oxford, 1989.
J.F. Gieras, and M.Wing Permanent Magnet Motor Technology Design
and Applications : 2nd edition , Marces Dekker Inc., 2002.
Contents :

Structure of servo motor drive system

Permanent magnet materials and circuit
BLDC (Brushless DC )
- Structure, Operation, Torque and EMF equations, Control loop
PMSM (Permanent Magnet Synchronous Motor)
- Structure, Operation, Torque and voltage equations, Control loop, Simulation results
Implementation method for servo motor drive system
- Detection for position, speed, voltage, and current
- Design for DSP interface circuit
Servo motor :Control the position or speed very fast and accurately.
Structure of servo motor drive system
Control of Servo Motors
Control
Power
Semicoductor
Circuit
Servo Motor
Load
- Microprocessor
- Miconcontroller
- DSP
- Power Transistor
- Power FET
- IGBT or IPM
- BLDC
- PMSM
Structure of servo motor drive system
(1) Speed control
Closed control loop
Control of Servo Motors
- Type of closed control : Position or speed or torque controls
*
e
r
e
r
Inverter
Servo
Motor
(2) Position control
*
e
r
e
r
*
ue
ue
p
Inverter
Servo
Motor
(3) Torque control
*
T
e
Inverter
Servo
Motor
T
e
Calculate
Torque
I
s
(1) Analog circuit : OP amp.
Closed control loop
Control of Servo Motors
- Implementation of closed loop
(2) Digital circuit : Microcontroller, DSP, FPGA
DSP : CPU, Memory, Timer/Counter, PWM output, A/D Converter, I/O Port, Serial port, CAN
Structure of DSP TMS320LF2407A
32Kw
Flash
h
2.5Kw
RAM
EVM A
EVM B
10Bit ADC
GPIO
CAN
SCI
SPI
40-MIPS 16Bit DSP
Multiplier
h
16BIT 16 ALU
h
16Bit
File
Register
h
JTAG
h
Time
Real
DC-to-DC converter : Fixed DC voltage Variable DC voltage
Inverter : DC voltage AC voltage
Power Semiconductor circuit & Switching devices
Control of Servo Motors
Power Semiconductor circuit
(1) Power Transistor
(darlington connection)
Switching devices
V
CE
+
-
I
C
I
B
IB
"on" state "off" state
t
* Current controlled device
(2) Power FET
(N-channel MOSFET)
V
GS
I
G
=0
I
D
V
GS
"on" state "off" state
t
* Voltage controlled device
(3) IGBT (Insulated Gate Bipolar Transistor)
V
CE
+
-
I
C
+
-
V
GE
V
GE
"on" state "off" state
t
* Input : Power FET
* Output : Power BJT
(1) Turn-off time t
off
Power Semiconductor circuit & Switching devices
Control of Servo Motors

Parameters for switching device

IB
t
IC
t
on
t
off t
on
on off
t t >>
The switching frequency of device
is dependent on the turn-off time
(2) Forward voltage drop V
F
The semiconductor switching device is not an ideal switch.
Forward voltage drop at the conduction state
V
CE
+
-
I
C
V
F
+
-
I
C
Equivalent circuit
at conducting state
Power dissipation :
C F D
I V P = Heat
Effects of P
D
-Lower efficiency
- Requirement of cooling system
- Decrease of output voltage
(3) Power capacity
Power Semiconductor circuit & Switching devices
Control of Servo Motors
Maximum current and voltage of switching device
- Series connection of device
for increasing the voltage capacity
-Parallel connection of device
for increasing the current capacity
(4) Driver circuit
Current controlled device : complex
Voltage controlled device : simple
Power Semiconductor circuit & Switching devices
Control of Servo Motors
The performance of switching devices
6-7 IGBTs & driver circuits & protection circuit
Modules for IGBT
IPM

Input : Power FET
Output : Power BJT
IGBT

Voltage Controlled
device
Power FET

Current Controlled
device
Power Tr.
Driver
circuit
Capacity
Forward
voltage drop
Turn-off
time
Characteristics
Switching
device
Servo Motors & Load
Control of Servo Motors
Classification of Motor
Servo Motor
DC brush Brushless
AC motors
SRM
Permanent Magnet Induction
BLDC PMSM
[DC Motor ]
<Reluctance Torque>
<Torque
by 3-phase ac current>
Rotor Flux
< Current induced
at rotor conductor>
<Permanent Magnet >
[Induction Motor]
Servo motors : BLDC (BrushLess DC Motor) PMSM (Permanent Magnet Synchronous Motor)
SRM (Switched Reluctance Motor)
Load : CNC, Robot, Electric Vehicle, Hybrid Car, Linear actuator
General application check-list for adjustable speed drives
Control of Servo Motors
[1] Maximum continuous power or torque requirement (Load)
[2] Overload rating and duration
- Power capacities of both the servo motor and switching device in the inverter.
[3] Forward /Reverse operation
- Four quadrant operation power converter
Te
e
r
Forwrad Rotation
Te
Reverse Rotation
Te
Regenerative Braking
Te
Regenerative Braking
Te
e
r
e
r
e
r
e
r

General application check-list for adjustable speed drives
Control of Servo Motors
(1) Regenerative braking
- AC source Motor (Mechanical energy)
[4] Dynamic braking or Regenerative braking
- Mechanical energy at motor speed e
r
:
:
2
2
1
r
Je
- When the motor speed is decreased from e
r1
to e
r2
:
The difference of mechanical energy :
2
2
2
1
2
1
2
1
r r
J J e e
Inverter
Servo
Motor
Converter 3u
ac
Mechanical Energy
(2) Dynamic braking
- Resistance loss Motor (Mechanical energy)
Br
Inverter
Servo
Motor
R
b
Converter 3u
ac
Mechanical Energy
General application check-list for adjustable speed drives
Control of Servo Motors
[5] Supply voltage (AC or DC)
(2) AC supply voltage
- The dc input voltage is too small
* Inverter : DC voltage AC voltage
(1) DC supply voltage
Inverter
Servo
Motor
DC boost converter is required
Inverter
Servo
Motor
DC
Boost
Inverter
Servo
Motor
3u
ac
Diode rectifier Capacitor filter Inverter
General application check-list for adjustable speed drives
Control of Servo Motors
[6] Type of control
- Precision of detector, measurement accuracy, the control algorithm for position and speed
* Speed control, Position control, Torque control
[7] Precision required at controlled position and position.
[8] Programmability : Start/Stop ramp, Speed and/or position profile
Start ramp
t
e
r
*
u
-
or
Profile of reference speed
t
e
r
*
e
r
*
General application check-list for adjustable speed drives
Control of Servo Motors
[9] Dynamic requirement : Transient response for speed or position, convergency time
(1) Moment of inertia of rotor the sharp and mass of rotor in the servo motor
Mechanical equation
L r
r
e
T B
dt
d
J T + + = e
e
,where T
e
: motor torque, T
L
: load torque, J : Moment of inertia, B : Friction coefficient
Neglecting the term Be
r
J
T T
dt
d
L e r

=
e
- The variation of motor speed is inversely proportional to the moment of inertia
Moment of inertia J
m
D
J
4
2
=
D
m : mass
Rotor
General application check-list for adjustable speed drives
Control of Servo Motors
(1) Gear box
[10] Gear box is used or Direct Drive (DD)
(2) Type of controller
- PI controller, PID controller, IP controller, H- control, adaptive control, optimal control
(3) Gains of controller
Servo
Motor
Gear
Box
Load
- Gear ratio | Torque | Speed |
Optimal gear ratio
(2) Direct Drive (DD) : without gear box
[11] Protection arrangement
- Over current protection, Over/Under voltage protection, Over temperature protection, Over load protection
- Protection method, abnormal operation indicates
General application check-list for adjustable speed drives
Control of Servo Motors
(1) Serial communication
[12] Maximum level of acoustic noise
[13] Maximum level of EMI (Conducted EMI or Radiated EMI)
[14] Maximum level of harmonics in the ac supply and motor
[15] Interfaces with control system and host computer
Control
System
RS232C Host
Computer
(2) Network (CAN, Ethernet, DeviceNet, Profibus, LonWorks )
Control
System
Host
Computer
Network
Software tools for simulations of servo motor control system
- Matlab, Pspice, PSIM, Saver, Simplore, MultiSim.