Drive

System

L12-05-06 01
Servo System

EN. MUHAMAD NABIL

BIN MANSOR
introduction

Definition of “Servo”
servomechanism is defined as a control system
designed to track a target that changes unpredictably,
with the position, bearing, orientation, etc., of a
physical object as the control quantity. When the
target value (position, speed, etc.) is input to the
servomechanism from the command section, the
servomechanism detects the current value, and
continually executes control to reduce the difference
between the current value and target value.
introduction

The configuration of servomechanism

introduction

It has three main advantages:

The motor have a wide speed control range
It maintains a constant output torque from high
speeds (the rated speed) to low speeds (the stalling
speed).
It has a high maximum torque.

Note: Since the motor’s maximum torque is high but its moment of inertia is low, it
is capable of sudden acceleration and deceleration
introduction

Main Servomotor Characteristics

Application of AC servomotors
Machines that require positioning
 Using the AC servomechanism in combination with specialized
positioning controller (see chapter 6) enables accurate
positioning with good reproducibility.
 A general purpose AC servomechanism is capable of a
positioning resolution of 120000 to 4000 divisions per motor
axis revolution, which is sufficient to achieve positioning in
units of 1um with machine travel in the range 24 to 8 m/min.
Example application:
 Machine tools, wood working machines, conveyors, packaging
machines, inserter/mounters, feeder, cutters and specialized
machinery.
Application of AC servomotors
Machines that requires a wide range of speed variation
 The AC servomotor has a speed control range of 1:1000, and
features highly accurate speed control, with a coefficient of
speed fluctuation of no greater than 0.03%. It also features
constant output torque, a characteristics not featured by other
variable speed motors. Because of these characteristics, it is
used for control of production lines and other applications
where highly accurate variable speed drive is required.
Example Applications:
 Printing presses, paper processing machines, film
manufacturing line, wire making machines, winding machines,
feed mechanisms of specialized machines, conveyors, main
shafts of winding/unwinding machines, and wood working
machines.
Application of AC servomotors
High frequency positioning
Positioning is performed as explained in (a) on the previous
page. The maximum torque of the AC servomotor is 300% of the
rate torque and a motor, when it is unloaded, can follow the
acceleration and deceleration from the stopped state to the
rated speed in a mere several tens of milliseconds, which means
it can drive positioning operations at frequencies of 100 times
per minutes and higher. Another important characteristic of the
AC servomotor is that it has no parts that make mechanical
contact, in contrast to other positioning mechanism (clutch,
brake, DC motors, etc.); this makes it maintenance-free and
means that it is not greatly influenced by the ambient
temperature.
Application of AC servomotors

Example applications:
 Press feeder, bad-making machine, sheet cutting machine,
loader/unloaders, filling machine, packaging machines,
conveyors.
Application of AC servomotors

Torque control
 Since recent digital servomotors feature torque control in
addition to conventional functions such as speed control and
position control, they can be used for applications that involve
tension control, such as winding/unwinding machines.
FUNDAMENTALS OF AC SERVO CONTROL

Block Diagram of AC Servomotor

FUNDAMENTALS OF AC SERVO CONTROL

Main Circuit
The basic function of the main circuit is to rectify and smooth a
commercial power supply (3-phase, 200 to 230 VAC,
50/60Hz) by means of a converter (diode bridge, capacitor),
and supply a 3-phase current of any voltage and frequency
that is subjected to sine wave PWM control by the inverter
(power transistor module)- to the motor to control its speed
and torque.
FUNDAMENTALS OF AC SERVO CONTROL

Converter, smoothing capacitor

The commercial power supply is rectified by a diode bridge
and then has its ripple reduced by a smoothing capacitor to
generate a low-ripple DC power supply.
FUNDAMENTALS OF AC SERVO CONTROL

Inverter
The inverter generates, from the DC power supply created by
the converter and smoothing capacitor, a current matched to
the frequency and load torque at the motor’s rotational speed.

Configuration of the inverter section

FUNDAMENTALS OF AC SERVO CONTROL

Inverter output current

FUNDAMENTALS OF AC SERVO CONTROL

the direction of rotation and the rotational speed (frequency)

of the motor are determined by the direction of the current
and the width of turn on time in each direction, which depend
on the ON/ OFF switching of the transistors in the inverter
section. This type of the control, in which the size of the
current is controlled by the width of turn on time, is called
PWM control (pulse width control).

Current Control Using the PWM Method

FUNDAMENTALS OF AC SERVO CONTROL
Regenerative brake

 Regenerative brake circuit

The regenerative brake operates when the actual rotational

speed of the motor is higher than the speed reference- e.g.
during deceleration, during descent on a vertical axis, or when
a braking force is applied to an unwinding shaft – to achieve a
braking effect by absorbing (consuming) the rotational energy
of the motor and load in the servo amplifier.
FUNDAMENTALS OF AC SERVO CONTROL

This kind of operation is called ‘ regenerative ’, and

servo amplifiers normally incorporate a regenerative
circuit. This regenerative circuit acts as a load on the
motor, and its rate of energy consumption determines
the regenerative braking force. The amount of
rotational energy consumed varies according to the
operating condition. When a large amount of energy
has to be consumed, a circuit capable of consuming
this energy is provided outside the servo amplifier.
FUNDAMENTALS OF AC SERVO CONTROL

Types of regenerative brake circuit

• Where a small braking capacity is required (the

amount of rotational energy to be consumed is
small ), braking is achieved by using the energy to
temporarily charge the smoothing capacitor
mentioned previously. This is called the condenser
regenerative method and can be used for
applications up to about 0.4kW.
FUNDAMENTALS OF AC SERVO CONTROL

Types of regenerative brake circuit

• In case where a medium braking capacity is

required, a method in which current is passed
through resistors and the energy consumed as
heat is adopted; this is called the resistor
regenerative methods. The problems associated
with this method include the need to use large
resistors if the amount of energy to be consumed
is large, and adverse effects on surrounding parts
due to heat radiating from the resistors.
FUNDAMENTALS OF AC SERVO CONTROL

Types of regenerative brake circuit

• In case where a large braking capacity is required,

a method in which energy is returned to the power
supply has recently been adopted in order to
avoid the deficiencies of the resistor regenerative
method. This is called the power supply
regenerative method and it can be use when the
amount of energy involved exceeds 11kW.
FUNDAMENTALS OF AC SERVO CONTROL

Types of regenerative brake circuit

• In case where a large braking capacity is required,

a method in which energy is returned to the power
supply has recently been adopted in order to
avoid the deficiencies of the resistor regenerative
method. This is called the power supply
regenerative method and it can be use when the
amount of energy involved exceeds 11kW.
FUNDAMENTALS OF AC SERVO CONTROL

Dynamic brake

When it stops with the output of inverter parts, such

as the time of power cut off and alarm generating, (
base interception ), a motor serves as a free run, and
time long to a stop may be required, the long overrun
may become large, and it may serve as fault of
colliding with a stroke end.
FUNDAMENTALS OF AC SERVO CONTROL

Dynamic brake

A dynamic brake functions to stop the motor quickly

in the event of a base circuit cut-off by short circuiting
the servomotor terminals through an appropriate
resistor and consuming the rotational energy as heat.
a dynamic brake is usually installed separately from
the motor and amplifier, but it is incorporated into
some models of servo amplifier. Since a dynamic
brake has no holding power when a mechanical
brake if the motor drive motion on a vertical axis.
FUNDAMENTALS OF AC SERVO CONTROL

Dynamic brake
FUNDAMENTALS OF AC SERVO CONTROL

Due to the delay in the control circuit, the motor will

rotate with delay on input of the command pulse to
the position control section. The pulses that
accumulate during this delay are held at the deviation
counter; these pulses are called droop pulse. The
droop pulses are output to the speed control section
as speed commands.
FUNDAMENTALS OF AC SERVO CONTROL

Control Circuit

While carrying out operation processing of the

amount of control (a position, speed, current) at high
speed and with high precision from an instruction
value (target value) and the present value using a
microcomputer and realizing Servo control with high
accuracy by high response, the monitor of the
contents of control and protection of a unit are
performed. The outline of the contents of control is
explained below.
FUNDAMENTALS OF AC SERVO CONTROL

Position
Control

In a pulse
sequence,
control of the
rotation speed
and the direction
of a motor and
highly precise
positioning are
performed.
FUNDAMENTALS OF AC SERVO CONTROL

Speed Control

The output of a position control part deviation

counter is proportional to instruction speed, and this
serves as speed instructions. A speed instruction
part outputs the deviation of speed instructions and
motor speed as current instructions. In addition,
when operating in speed control mode, analog
voltage (0-±10V) is inputted from the exterior as
speed instructions.
FUNDAMENTALS OF AC SERVO CONTROL

Current Control and 3-phase generating circuits

A current control part controls the current of a motor

so that the inverter of the main circuit is controlled
and a motor moves as position instructions or a
speed instruction. In order to achieve this control, the
phases of the 3-phase alternating current are set to
coincide with the magnetic field of the
motor(determined by the positions of the rotor’s
permanent magnets) and a current that corresponds
to the speed deviation is output
FUNDAMENTALS OF AC SERVO CONTROL
FUNDAMENTALS OF AC SERVO CONTROL
When supplying current to a synchronous motor, the position of
the magnetic fields (magnetic pole positions) must be aligned
with the phases.
To achieve this alignment, the motor’s detector detects the
magnetic pole positions and continually feeds back this
information to the servo amplifier. On the basis of this signal,
the servo amplifier generates the reference 3-phase current in
the 3- phase generating circuit. The current control section
multiplies the reference 3-phase current by speed deviation to
generate 3 –phase current commands and controls the PWM
circuit.
Note: Induction type servomotors do not have independent
magnetic fields. Accordingly, magnetic pole position detection is
not necessary when they are used.
FUNDAMENTALS OF AC SERVO CONTROL

A PWM system is a system which several times of switching

pulses is generated in 1 cycle, and the pulse width is changed,
and changes output voltage. The thing of the number of
switching pulses generated in 1 second is called career
frequency. In the case of a PWM system, the motor vibration
and the motor noise of a frequency ingredient proportional to
this career frequency occur.
FUNDAMENTALS OF AC SERVO CONTROL

Principle of PWM Control

FUNDAMENTALS OF AC SERVO CONTROL
Types of servomotor and their characteristics

There are two main type of servomotor – AC

servomotor and DC servomotors- but the category of
AC servomotor is further divided into the
SM type (synchronous motors) and the
IM type (inductance motors). Table 1.2 indicates the
configuration and characteristics of each type of
servomotor.
FUNDAMENTALS OF AC SERVO CONTROL
Types of servomotor and their characteristics
FUNDAMENTALS OF AC SERVO CONTROL
Types of servomotor and their characteristics
FUNDAMENTALS OF AC SERVO CONTROL
Types of servomotor and their characteristics
FUNDAMENTALS OF AC SERVO CONTROL
Principle of operation of encoder

As explained previously, in servo control the actual

value (motor speed, position) is feedback for
comparison with the command value and control is
executed to reduce the deviation between the two.
FUNDAMENTALS OF AC SERVO CONTROL
Construction of encoders

The construction of the most commonly used type of

detectors is shown below.
FUNDAMENTALS OF AC SERVO CONTROL
Function of encoders and the signal types

The three major functions of encoders mounted on

servomotors are:
1) Detection of the motor position
2) Detection of the motor speed
3) Detection of the magnetic pole position of the motor
(does not apply to IM type AC servomotors and DC
servomotors)

A 2-phase pulse output incrementally as the motor

rotates is used for functions 1) and 2).
FUNDAMENTALS OF AC SERVO CONTROL
Encoder Signals
EN. MUHAMAD NABIL
BIN MANSOR