PCIM'2001 Conference Nrnberg June 19-21, 2001

HIGH PERFORMANCE SERVO DRIVE DESIGN FOR DISTRIBUTED MOTION CONTROL

D. JOUVE & D. BUI INFRANOR S.A., Avenue Jean Moulin, BP 142, F-65104 Lourdes cedex, FRANCE Phone: +33 5 62 94 10 67 Fax: +33 5 62 42 18 69 E-mail: d.jouve@infranor.fr, d.bui@infranor.fr ABSTRACT This paper presents a high performance servo drive designed for distributed control in the machine automation area. The entire servo drive control task is based on Digital Signal Processing (DSP) technology. The current controller is using an optimal space vector modulation technique in order to improve the servo motor torque production at high speed. The speed and position servo controller performances are optimized according to the mechanical load characteristics thanks to the automatic tuning procedure performed on line on the machine. The axis motion control functionalities are also integrated inside the servo drive, bringing it to be a real stand alone and programmable single axis controller. The PROFIBUS communication port allows to easily integrate this servo drive as an intelligent peripheral component for the host machine controller. Consequently, this solution is best suited for automation applications with a high number of axes to be controlled. The paper focuses on the servo controller design and the motion controller operation and programmation. The design criteria and the resulting performances are discussed in the paper. 1) INTRODUCTION Today, the last servo drive generation is becoming more intelligent because the Digital Signal Processing (DSP) technology has increased the ability to process more complex control tasks inside. Furthermore, the increasing fieldbusses communication in the machine automation area now allows flexible and modular control design based on distributed control architectures to be implemented (1). This results in wiring cost saving and machine simplification. The intelligent CD1p servo drive described in this paper is a stand alone single axis controller including: control sequences programmation, trajectory calculation, position, speed and current servo loops and, of course, the power conversion into the same device as described on figure 1. The communication between the host machine controller and each servo drive is based on the PROFIBUS DP standard. This solution allows to easily build complex applications with a high number of axes to be controlled in a modular way with a high degree of reusability (7). Because of the fieldbusses communication facilities, the complete control system can be easily re-parameter set for a new product without any hardware modifications. The process can also be easily modified by adding or removing control components (servo drives, I/O modules, ...) without major modifications in the control system. The flexibility of this solution is a decisive advantage in the automatized production processes in order to sustain a long term competitive position : the machines can be easily modified or upgraded in response to the decreasing product and technology life cycles. The servo performances are also greatly improved because the digital current, speed and position servo loops are all inside the servo drive. 2) SERVO CONTROLLER DESIGN The cascade control structure is best suited for high performance servo drives. The inner current control loop is performing the motor torque control. The dynamic performances of the outer speed and position control loops directly depend on the inner current loop behaviour.

SERVO DRIVE #1 HOST CONTROLLER

PROFIBUS DP

fieldbus
Sequences selector

Sequences buffer

Trajectory generator

Servo loops

Power stage

SERVO MOTOR

Other devices : Servo drives, I/Os, ... Figure 1 : Intelligent servo drive for distributed motion control

Motion & Automation : High performance servo drive design for distributed motion control

1/6

PCIM'2001 Conference Nrnberg June 19-21, 2001

2-1) Current controller design A brushless servo drive consist of a permanent magnet synchronous motor (PMSM) equipped with a position sensor mounted on the motor shaft. The power conversion from the constant DC power voltage to the three phases AC of the motor is exclusively performed in switched mode (PWM). The power DC voltage of constant magnitude is obtained from the AC main power supply through rectification. To control the torque of a PMSM, it is necessary to control both stator currents amplitude and stator currents phase values : the current amplitude is proportionnal to the desired torque and the current phase is tied to the rotor position. The stator currents can be either controlled in the stator reference frame or in the rotor reference frame. When the current control is performed in the stator reference frame, the traditional control structure includes two or three independent phase current regulating loops which reference has the desired phase current waveforms. The current control in the rotor reference frame is based on the PMSM mathematical model presented on figure 2.
Vd 1 R+Ld.s Ld Lq Vq Tm 1 R+Lq.s Iq Ke Kt TL 1 f+J.s Wm 1 s Pm

Figure 3 : Torque/speed curve of the servo drive

Tm Rated torque Rotor reference frame

Stator reference frame 0

Max speed

Wm

3a) Influence of the current control method

Tm Rated torque

Symmetrical triangle modulation

SVM

Id

Max speed

Wm

3b) Influence of the modulation method The three inverter PWM commands can be calculated either by the symmetrical triangle modulation method or the space vector modulation (SVM) method. In the symmetrical triangle modulation method, the PWM switching times are defined by the intersection points of a symmetrical high frequency triangle waveform (the carrier) and the sinusoidal voltage reference waveform, as shown on figure 4a. In the SVM method, the PWM switching sequences are obtained from the vectorial decomposition of the Park vector by using the eight possible voltage states of the inverter (2) as shown on figure 4b. The SVM method is giving the highest speed range of the servomotor (15% more) with regard to the symmetrical triangle modulation method, as shown on figure 3b. This is due to the additional third harmonic waveform inherent to the SVM method (3). The third harmonic distorsion on the SVM commands is presented on figure 5b; this allows to use the full output voltage range of the converter with sinusoidal phase to phase voltages. As shown on figure 5a, on the symmetrical triangle modulation method, the three phase commands sum is equal to zero. Consequently, the output voltage range of the converter is reduced of 15%.

Figure 2 : PMSM mathematical model in the rotor reference frame The direct and quadrature currents values (Id and Iq) are obtained by the phase current Park transform calculation. The Id and Iq regulating loops are giving the direct and quadrature voltage values (Vd and Vq). The three phases PWM commands are then calculated from the Vd and Vq values by using the inverse Park transform. The better torque control performances over the entire speed range are obtained when the current control is performed in the rotor reference frame as can be shown on figure 3a. The reason is that in the stator reference frame, the three phase current loops reference are sinusoidal, so the evolution of the torque control performances with speed depends on the loop bandwidth, whereas, in the rotor reference frame, Id and Iq references are DC variables because of the Park transform (4). For this reason the current control in the rotor reference frame is preferred for the CD1p servo drive.

Motion & Automation : High performance servo drive design for distributed motion control

2/6

PCIM'2001 Conference Nrnberg June 19-21, 2001

Figure 4 : PWM switching sequences calculation

Symmetrical triangle carrier

U phase command

V phase command W phase command U phase switching pulse V phase switching pulse W phase switching pulse Ts Ts Ts = 62.5 s

5b) Space vector modulation commands

2-2) Position controller design The speed and position servo loop adjustment must be optimized according to the mechanical load characteristics in order to achieve a stable and fast response. The position servo controller design is based on the RST polynomial controller structure and the pole placement tuning method. The RST polynomial controller structure is the most general controller stucture and well suited for parametric tuning method.

4a) Symmetrical triangle modulation method

V3

V2 Park vector V0 V7 Linear modulation range

V4

V1

Figure 6 : RST position controller structure

Td X ref Hmd

V5

V6

+ -

I Iref

1 R S
X mes

Hmc

V0,V1,V2,V3,V4,V5,V6,V7 = Voltage states

4b) Space vector modulation method

RST controller

Drive model

Figure 5 : PWM commands at the maximum speed

6a) Servo loop structure

Td Hsd X ref Hsr Servo transfer function + X mes Regulation transfer function

6b) Closed loop transfer functions

5a) Symmetrical triangle modulation commands

Motion & Automation : High performance servo drive design for distributed motion control

3/6

PCIM'2001 Conference Nrnberg June 19-21, 2001

It is assumed that the drive can be described by the model transfer functions Hmc and Hmd as shown on figure 6a. The servo controller consists of 3 polynomials R, S and T acting respectively on the servo loop error signal, the servo loop feedback signal and the servo loop reference signal. The closed loop output / reference and output / disturbance transfer function are respectively noted as Hsr and Hsd on figure 6b. The controller tuning process consists of pole and zero placement of the Hsr and Hsd transfer functions in order to obtain the desired output / reference and output / disturbance behaviour for the position servo loop. Therefore, the servo loop regulation and tracking behaviour can be fully decoupled. The Hmc and Hmd transfer functions are derived from the mechanical plant model. The plant tranfer function is obtained by an identification procedure executed on the machine under the rated Figure 7 : RST position controller

The conventional PID controller can be easily implemented on the RST controller structure with the following polynomials : R(s)=R1.s+R2.s2 and T(s)=S(s)=S0+S1.s+S2.s2 (s being the Laplace transform variable). Position loop tracking and regulation performances in this case are presented on figure 7a. The RST controller structure allows to easily modify the servo loop tracking behaviour while maintaining the same regulation performances by changing only the T polynomial. In this case, as shown on fi 7b th l t ki h b Figure 8 : Filtering of the torsional vibrations

8a) Torsional vibrations due to the coupling elasticity

7a) PID type design

8b) Effect of the anti-resonance filter The flexibility of the RST polynomial controller structure allows also to easily include a specific filter design according to the application requirements. When a very large load inertia is reflected to the motor shaft, the coupling elasticity can induce torsional vibrations. The torsional vibrations frequency is calculated according to the plant characteristics. Assuming that : Jm= motor inertia value, Jl= load inertia value, Nr= motor/load coupling ratio, Ks= motor/load coupling stiffness ; the torsional vibration frequency is given by : Wr= (Ks. 1/2 (Nr2.Jm +Jl) / (Nr2.Jm.Jl) ) . The torsional vibration effects can dramatically reduce the servo loop d di h ti b f

7b) RST tracking design

Motion & Automation : High performance servo drive design for distributed motion control

4/6

PCIM'2001 Conference Nrnberg June 19-21, 2001

current consumption, as shown on figure 8a. In this case, the auto-tuning procedure can calculate an anti-resonance filter in order to cancel the torsional servo loop vibrations. The anti-resonance filter effect is shown on figure 8b for this particular application where load/motor inertia ratio is close to 200. 3) MOTION CONTROLLER OPERATION A distributed motion control architecture suitable for multi-axes applications is based on intelligent stand alone servo drives. In this case, the axes motion control tasks are distributed inside each servo drive. Each servo drive can be independently programmed in order to perform a given axis motion control task. The fieldbus communication between the host machine controller and the servo drives is used for the servo drives programmation and the machine process control and monitoring. Up to 128 preprogrammed motion control sequences can be stored in the servo drive EEPROM. There are four types of basic motion sequences to be programmed : - Axis homing sequence is used for the axis index position research after the servo drive power up. - Absolute positioning sequences are used for moving the axis to a given absolute position value with regard to the axis index position. - Relative positioning sequences are used for moving the axis to a given distance from the current position value. - Speed profile sequences are useful for moving the axis with a specific speed profile shape. - Torque set point sequences are useful for applications like grippers were a constant force must be applied to the load. The sequence parameters (acceleration and deceleration time, running speed, time delay, start condition, triggering position, output flag, counter, link,...) allow to define in details the sequence execution. All the sequences can be linked together and a programmable time delay can be introduced into the sequence chaining. The sequence counter also allows to execute many times the same sequence or a group of sequences. The sequences chaining capability allows to define macro-sequences for complex positioning applications as shown on figure 9.
Speed Linked Position sequences Sequence 1: Position=130 Speed = 1500 Tacc = 2000 Tdec = 0 Time = 0 link = 2 Sequence 2: Position=530 Speed = 2000 Tacc = 2000 Tdec = 2000 Time = 1000 link =-1 Time

These functionalities are making the servo drive a very compact motion control solution with regard to the traditional solution based on an external motion control board + the servo drive. 4) PROFIBUS DP COMMUNICATION The servo drives are connected to the PROFIBUS serial link in order to be easily integrated into the host PC or PLC machine controller environment. PROFIBUS DP was chosen because it is an open vendor-independent fieldbus standard for a wide range of applications in manufacturing, process and building automation (8). PROFIBUS DP version is designed especially for communication between automation control systems and distributed I/O at the device level. Via PROFIBUS DP, a host PLC controller can communicate at high speed in a cyclic way with its distributed field devices (I/O, valves, drives, ...). The PROFIBUS DP communication profile between the host PLC and the CD1p servo drive is based on PPO messages exchanges. The CD1p servo drive comunication profile is using PPO1 to PPO4 type of messages. The PLC sends a message by a PPO write and receives a message by a PPO read. The PPO write and PPO read messages are cyclically transferred by the Data Exchange function of the PROFIBUS DP. The parameter area is used by the PLC to read or modify the servo drive parameters. There are two types of operational data to be sent by the PLC to the servo drive : -The Control Word concerns the servo drive operation: Enable, Run, Jog, Home, Move... -The Input Command concerns the number of the sequence to be executed and the sequence starting conditions. There are two types of operational data to be received by the PLC from the servo drive : -The Status concerns the servo drive status: Ready, Stopped, Running, In sequence, Error... -The Feedback concerns the number of the current sequence in progress, the axis position and the motor speed value. This CD1p communication profile was designed in order to integrate the servo drive as a simple I/O device for the host PLC controller. Thanks to this approach, a high level motion control can be performed inside the CD1p servo drive without using the host PLC controller computational resources. We can also note that the bus cycle time value has no effect on the servo drive motion control performances. Consequently, this solution is best suited for positioning applications with a high number of axes to be controlled. The maximum value for the number of axes to be controlled is only limited by the fieldbus performances (up to 125 stations can be connected on the same PROFIBUS DP bus). The PROFIBUS configuration based on device data base file (GSD file) permits a simple plug-and-play integration of the CD1p servo drive. The GSD file can be described as an electronic data sheet of the CD1p servo drive device. An example of CD1p servo

Figure 9 : Example of a macro sequence

Motion & Automation : High performance servo drive design for distributed motion control

5/6

PCIM'2001 Conference Nrnberg June 19-21, 2001

drive integration into a SIEMENS PLC based control system is presented on figure 10. The motion sequences parameters are simple variables to be loaded inside the CD1p servo drive via the PROFIBUS parameter area. They can then be stored inside the CD1p servo drive EEPROM. Consequently, a specific programmation language is not required for the motion control sequences setting, and a high level of motion control programmation can be achieved with the standard IEC 1131-3 programming languages (6). CONCLUSION Distributed motion control architecture based on intelligent servo drives is a cost effective and flexible solution with regard to the traditional motion control solution based on a CNC motion controller and analog velocity servo drives. The presented intelligent CD1p servo drive based on DSP technology is performing the complete motion control task for a given axis. This structure allows to increase the servo loops performances. The servo motor torque production at high speed has been improved thanks to the space vector modulation technique. The optimum gains adjustment for the speed and position servo loops has been achieved by the automatic tuning procedure performed on line on the machine. This intelligent servo drive can also be integrated into a PLC environment as a simple I/O device for the host PLC controller thanks to the PROFIBUS DP communication port. This motion control solution is best suited for applications with a high number of axes to be controlled (up to 100). APPENDIX Tested motor data sheet : Rated current = 7Arms, Peak current = 40 Arms Rated torque = 1.8Nm, Peak torque = 10Nm Rated speed = 6000rpm Max. speed = 12000rpm Pole pairs = 4, Torque constant : 0.26 Nm/Arms -3 2 Inertia : 0.05 10 Kgm , Inductance : 1.4mH

REFERENCES 1) T. BULLOCK "Intelligent drives"

MOTION CONTROL magazine March/April 1996 p 44

2) J. HOLTZ "Pulsewidth Modulation for Electronic Power Conversion"

IEEE proceedings Vol 82 N 8 August 94 pp 1194-1214

3) J.T. BOYS, P.G.HANDLEY "Harmonic analysis of space vector modulated PWM waveform "
IEE proceedings 1990, vol 137, pt B, N4, pp 197-204

4) G. CHAMPENOIS, P. MOLLARD, J.P.ROGNON "Effective digital torque control system for permanent magnets converter fed sinusoidal synchronous machines"
IECON88 conference, Singapore, pp 259-265

5) D. JOUVE, J.P. ROGNON, J. SAADI "Autotuning of axis control system for robotic and machine tools"
IECON'91 conference, Kobe, pp 1106-1111

6) T. ZHAO, A. OSSEYRAN "The Benefits of Integrating Motion Control into PLC System"
ICMA98 Conference (TEMPERE) Proceedings pp 29-41

7) D. JOUVE, D. BUI "Intelligent servo drives and fieldbusses communication provides flexible motion control solutions"
PCIM'99 Conference (Nrnberg) Proceedings pp 27-32

8) PROFIBUS Technical description Rev. April 97 PROFIBUS Nutzerorganisation e. V. Haid-und-NeuStr. 7 D-76131 Karlsruhe

Figure 10 : Example of CD1p servo drives integration with the GSD file

Motion & Automation : High performance servo drive design for distributed motion control

6/6