Industrial Motion Control: Motor Selection, Drives, Controller Tuning, Applications

317 Pages·2015·2.96 MB·English

by  Hakan Gürocak

INDUSTRIAL MOTION
CONTROL

INDUSTRIAL MOTION
CONTROL
MOTOR SELECTION, DRIVES,
CONTROLLER TUNING,
APPLICATIONS
HakanGürocak
WashingtonStateUniversity
Vancouver,USA
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Contents
Preface ix
1 Introduction 1
1.1 ComponentsofaMotionControlSystem 3
1.1.1 Human–MachineInterface 3
1.1.2 MotionController 4
1.1.3 Drives 6
1.1.4 Actuators 7
1.1.5 TransmissionMechanisms 7
1.1.6 Feedback 7
References 9
2 MotionProfile 11
2.1 Kinematics:BasicConcepts 11
2.2 CommonMotionProfiles 15
2.2.1 TrapezoidalVelocityProfile 15
2.2.2 S-curveVelocityProfile 21
2.3 MultiaxisMotion 28
2.3.1 SlewMotion 28
2.3.2 InterpolatedMotion 29
Problems 30
References 34
3 Drive-TrainDesign 35
3.1 InertiaandTorqueReflection 36
3.1.1 GearboxRatio 36
3.1.2 ReflectedInertia 38
3.1.3 ReflectedTorque 39
3.1.4 Efficiency 39
3.1.5 TotalInertia 40
3.2 InertiaRatio 41
3.2.1 TargetedPracticalInertiaRatio 43
3.3 TransmissionMechanisms 43
vi Contents
3.3.1 LoadandInertiaReflectionthroughTransmissionMechanisms 44
3.3.2 Pulley-and-Belt 45
3.3.3 LeadScrew 47
3.3.4 Rack-and-PinionDrive 52
3.3.5 Belt-DriveforLinearMotion 53
3.3.6 Conveyor 54
3.4 TorqueRequiredfortheMotion 56
3.4.1 Acceleration(Peak)Torque 57
3.4.2 RunningTorque 57
3.4.3 DecelerationTorque 58
3.4.4 Continuous(RMS)Torque 58
3.5 MotorTorque–SpeedCurves 62
3.5.1 Torque–SpeedCurvesforACServomotors 63
3.5.2 Torque–SpeedCurvesforACInductionMotors 64
3.6 MotorSizingProcess 67
3.7 MotorSelectionforDirectDrive 68
3.8 MotorandTransmissionSelection 69
3.9 Gearboxes 72
3.9.1 PlanetaryServoGearheads 72
3.9.2 WormGearSpeedReducers 73
3.10 ServoMotorandGearheadSelection 75
3.11 ACInductionMotorandGearboxSelection 89
3.12 Motor,Gearbox,andTransmissionMechanismSelection 96
Problems 100
References 105
4 ElectricMotors 107
4.1 UnderlyingConcepts 107
4.1.1 ElectricalandMechanicalCycles 109
4.1.2 Three-PhaseWindings 110
4.2 RotatingMagneticField 110
4.2.1 HallSensors 110
4.2.2 Six-StepCommutation 111
4.3 ACServoMotors 114
4.3.1 Rotor 114
4.3.2 Stator 115
4.3.3 SinusoidalCommutation 119
4.3.4 TorqueGenerationwithSinusoidalCommutation 123
4.3.5 Six-StepCommutationofACServoMotors 124
4.3.6 MotorPhasingwithEncodersandHallSensors 125
4.4 ACInductionMotors 126
4.4.1 Stator 126
4.4.2 Rotor 127
4.4.3 MotorOperation 128
4.4.4 ConstantSpeedOperationDirectlyAcross-the-Line 129
4.4.5 VariableSpeedOperationwithaVFD 131
Contents vii
4.5 MathematicalModels 132
4.5.1 ACServoMotorModel 134
4.5.2 ACInductionMotorModel 140
Problems 145
References 146
5 SensorsandControlDevices 148
5.1 OpticalEncoders 148
5.1.1 IncrementalEncoder 149
5.1.2 SinCosEncoders 152
5.1.3 AbsoluteEncoder 154
5.1.4 SerialEncoderCommunications 157
5.1.5 VelocityEstimation 160
5.2 DetectionSensors 162
5.2.1 LimitSwitches 162
5.2.2 ProximitySensors 162
5.2.3 PhotoelectricSensors 163
5.2.4 UltrasonicSensors 164
5.2.5 TheConceptofSinkingandSourcing 165
5.2.6 Three-WireSensors 167
5.3 PilotControlDevices 168
5.3.1 PushButtons 169
5.3.2 SelectorSwitches 170
5.3.3 IndicatorLights 170
5.4 ControlDevicesforACInductionMotors 171
5.4.1 MotorControlCircuit 172
Problems 174
References 175
6 ACDrives 177
6.1 DriveElectronics 177
6.1.1 ConverterandDCLink 178
6.1.2 Inverter 180
6.2 BasicControlStructures 188
6.2.1 CascadedVelocityandPositionLoops 188
6.2.2 Single-LoopPIDPositionControl 192
6.2.3 CascadedLoopswithFeedforwardControl 201
6.3 InnerLoop 207
6.3.1 InnerLoopforACInductionMotors 209
6.3.2 InnerLoopforACServoMotors 210
6.4 SimulationModelsofControllers 210
6.4.1 SimulationModelforVectorControlofanACInductionMotor 211
6.4.2 SimulationModelforVectorControlofanACServoMotor 215
6.5 Tuning 215
6.5.1 TuningaPIController 219
6.5.2 TuningaPIDPositionController 223
viii Contents
6.5.3 TuningaCascadedVelocity/PositionController
withFeedforwardGains 232
Problems 242
References 245
7 MotionControllerProgrammingandApplications 247
7.1 MoveModes 247
7.1.1 LinearMoves 248
7.1.2 CircularMoves 248
7.1.3 ContourMoves 248
7.2 Programming 249
7.2.1 MotionPrograms 250
7.2.2 PLCFunctionality 250
7.3 Single-AxisMotion 253
7.3.1 Jogging 254
7.3.2 Homing 254
7.4 MultiaxisMotion 256
7.4.1 MultipleMotorsDrivingOneAxis 256
7.4.2 CoordinatedMotionofTwoorMoreAxes 257
7.4.3 FollowingUsingMaster/SlaveSynchronization 258
7.4.4 TensionControl 273
7.4.5 Kinematics 278
Problems 284
References 288
AppendixA OverviewofControlTheory 289
A.1 SystemConfigurations 289
A.2 AnalysisTools 289
A.2.1 TransferFunctions 291
A.2.2 BlockDiagrams 292
A.3 TransientResponse 293
A.3.1 First-OrderSystemResponse 293
A.3.2 Second-OrderSystemResponse 293
A.4 Steady-StateErrors 297
References 298
Index 299