Automation & Control

Motion library for induction motors

by Warren Scott, Abacus Automation; Lance Benn and Bruce Burton, Exigo Motion Control Laboratory
When a unique solution, developed in South Africa, resulted in a number of award- winning projects, Siemens Germany commissioned Abacus Automation together with their joint venture development partner Exigo, to develop the concept into a standard product for them.

Many motion control tasks are often overengineered and use complex equipment and software to perform tasks. Now medium to high performance single axis positioning tasks can be easily done using standard, readily-available micro PLCs, VSDs and induction motors. Siemens has launched free motion control library blocks designed for use on their micro automation PLCs. These blocks empower the micro PLC users to perform a wide scope of medium to high performance motion control tasks with a minimum of drive or motion control knowledge and the most basic of hardware components. The current library of blocks can do single axis motion closed-loop motion control tasks for linear (horizontal or vertical) or rotational axes as well as a variety of advanced functions to assist with implementing and commissioning the users application. These tasks not only include accurate point to point positioning, but also speed controlled jog functions with torque limiting functionality. Future blocks currently undergoing final development and testing at this stage include on-the-fly profiling for more complex positioning, traction control for slipping product and the ability to control two axes from one Micro PLC. Research and development The solution has at its core, optimum torque control algorithms which were developed over a number of years by Exigo Motion Control Laboratories. These algorithms were developed to run on high-end platforms such as digital signal processors (DSPs) and intelligent variable speed drives (VSDs) using complex induction motor models and real time data processing. Using this core technology as a springboard, purpose-adapted algorithms capable of running on lower end platforms like PLCs were developed. This stage of development took place over a two-year period. Finally, the algorithms were incorporated into a user-friendly library for Siemens Germany in

Fig. 1: MAP_Ind Block diagram.

a joint venture project between Siemens Micro Automation, Siemens Small Drives, Abacus Automation and Exigo. The solution was launched under the banner of Micro Automation Set 1 (MAS1), incorporating the library micro automation positioning for induction motors (MAP_Ind) at the SPS/IPC Drives show which took place in Nrnburg, Germany during November 2007. Application examples The micro automation solution allows for single axis applications like: pushing - cut to length, positioning - board cutting, packing, palletising etc; roller feeding systems cut to length, stamping, bending - pipe, sheeting etc.; pick and place - press feeding, palletising, manufacturing; continuous motion profiles vertical/horizontal spraying; conveyor machine feeding, warehousing rack welding, box sorting/storage; belt feeds vertical bagging machines; screwfeeds, actions table/tool positioning, scissor jacks etc; positive displacement pumping - bottle filling, dosing etc.; brake and clutch (high maintenance) replacement presses, cutters etc.

Most stand-alone single axis positioning tasks can be undertaken with this solution. However, some features and limitations need to be considered: induction motors of most sizes and pole pairs are supported, even very large motors and drives; motor speeds of up to 2 600 rpm with a four-pole motor are possible; the transmission system should allow 40 axis length units per motor revolution to position it to better than a single unit. Typically, performance is much better than a single unit in most applications; Induction motors have a low power density and the application should have space for the motor frame size. Beneficial features This solution can replace conventional complex motion control equipment in many tasks as well as open up new applications for motion control. The functionality and advantages it offers to the user include: motion control on small and large induction motor installations; cost savings over conventional solutions; simple to install; easy to use PLC blocks to integrate into an existing program; simple commission to produce high performance
July 2008 - EngineerIT

22

of the system. These can be calculated using basic mechanical formulae as documented in the manual, or optimised in the basic commissioning procedure. Optimal motion is a term widely promised but rarely delivered; in order to achieve this full torque must be used for acceleration to full speed and again for deceleration from full speed to zero landing on the mark without overshoot, regardless of the move size and robust to changing conditions. This ideal move would result in a triangular speed profile as seen in Fig. 2(a). In practice the move size could be too short to reach the maximum speed, resulting in a smaller speed triangle, or too large, resulting in a flattop in the speed profile as seen in Fig. 2(b). These figures help us to understand how the MAP_Ind library blocks position without the need of a control expert. Simplified implementation and commissioning Easy-to-use PLC blocks for professional commissioning to achieve high performance results was previously mentioned as one of the advantages of using the micro automation solutions. We now look at how easy it is to apply a solution using MAP_Ind. The initial requirement comprises an induction motor fitted with a 1 024 pulse A/B phase incremental encoder, a standard drive (Sinamics G110 with analogue input, micromaster, etc) and an S7-200 CPU 224XP PLC with programming software micro/WIN V4.0 SP6. The manuals and library blocks are downloadable from the Siemens Automation

(a)

(b)

Fig. 2: Optimised positioning profiles with and without speed limit reached.

results in only minutes without requiring motion control expertise; serviceability is the biggest advantage an easy to follow solution using standard components and control signals, with simple-to-interpret fault signals; robust solution, both in hardware and in performance delivery, even under varying motion requirements and machine conditions; powerful motion recording and graphical display. The PLC engineering softwares status chart function allows display of speed, torque and position. This allows even basic users to diagnose and fine-tune motions when high-end performance is required; easy interfacing to human machine interface (HMI) for control signals, fault diagnostics, status info and graphical display of variables like position, speed and torque. Robust and optimal performance The advanced nature of the algorithms which were developed for robustness and optimal performance is why the solution can be implemented with minimal motion control knowledge. In implementing a motion control task for optimal performance, the engineer will want to make best use of the available torque, speed and power in the motor and drive provided. Additionally, the performance should remain as optimal as possible, under changing conditions, which will influence the motion control. These conditions could include: fluctuating drive supply voltage; changing operating parameters (maximum speed and torque, acceleration time); varying load inertia (moving mass); different move sizes (short: triangle profile, long: tabletop profile); insufficient torque to maintain acceleration/deceleration ramp; mechanical noise (belt stretch, etc); noisy speed feedback (some drives exhibit this behaviour); gravity influence on vertical/inclined axes (differs with direction); mechanical wear and tear (stiction, friction, play, etc); motor temperature (motor performance changes with temp); machine workload (cold: components, hot: bearings, grease, etc).
24

Achieving optimal motion control under these changing conditions would be a challenging task for even the most competent engineers specialising in the field of motion control. The library and the algorithms within the library were designed to be robust enough to withstand these changing conditions and deliver as optimal a performance as possible. The algorithms use complex model based nonlinear observers that continually adjust controller gains for changing conditions. By so doing, the flux in the airgap of the motor is controlled and hence the torque. This robust torque controller then forms the basis for the accurate and equally robust position control scheme seen in Fig. 1 that is capable of performing the most challenging of tasks. The commissioning of the system requires the user to enter the motor data (found on the nameplate) as well as some basic mechanical data, such as the gear ratio and the moment of inertia

Fig. 3: Data capture and display tools assist with analysis of the move.

July 2008 - EngineerIT

and Drives website for micro automation Set 1 (MAS1) under the startup code link go to www.automation.siemens.com/microset/ html_76/solutions/mas01.htm Commissioning is as simple as doing moves with the maximum load mass while adjusting one parameter, the inertia set-point [J] until the move is optimised. By visually observing the move at its end, it can be seen if further adjustment is needed due to overshoot or excessive creep. To further fine-tune or diagnose the move a data logging block is provided. This block allows the commissioning engineer to graphically view the speed, torque (see Fig. 3) or position data of the move using the status trend function of Micro/WIN. The manual explains the correct interpretation of these graphs. This is an extremely powerful function which equips the user with high-speed storage scope functionality. This data can also be displayed on a touch panel or PC running WinCC Flexible. Field implementation examples As awareness increases internationally the variety and quantity of applications where this

solution has been implemented successfully is growing fast. Applications include appliance spray painting, pallet marking, board cutting, log cutting, press feeding, pipe cutting, wire fence cutting, metal sheet cutting, automobile carpet press feed, carpet cutting, palletising, rack welding, pipe bending, window frame forming and cutting, conveyor positioning, dipping of products into multiple chemical baths and product sorting. A recent application was the replacement of non-repairable, obsolete servo drives and motors which had failed without warning and simultaneous upgrade of the redundant S5 100U PLC on a serpentine pipe bender. The machine pulled piping from four feed drums through straightening rollers and positioned the pipes to exact lengths on hydraulic benders. The pipes are fed and bent several times, resulting in the manufacture of the serpentine pipe found on the back of fridges and freezers. An easily-sourced induction motor, drive and gearbox combination was matched to the speed and torque performance of the existing servo motor, drive and gearbox. Then the S5 100U PLC was replaced with a S7200 224XP

micro PLC and the machine was up and running with increased speed and accuracy in record time. The increased performance of the machine was as a result of the ease with which optimal, robust positioning is obtained across a wide range of pipe sizes and bending profiles. Conclusion An international joint venture, emanating from a South African companys innovation, has lead to the development of a technology that empowers basic PLC users to implement medium to high performance, manageable, serviceable, affordable and robust motion control tasks. A simple building block approach, downloadable from the web, puts motion control back into the engineers hands without having to first acquire expert knowledge in the field. These blocks allow single axis basic positioning tasks for horizontal, vertical and rotational axes to be done with easy implementation and commissioning. Warren Scott, Abacus Automation, Tel 031 702-576, warren@abacus-automation.co.za

EngineerIT - July 2008

25