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Servo DrivesState of the Art

and Modern Developments

Prof. Dr.-Ing. J. M. Pacas, Institut fr Leistungselektronik und Elektrische Antriebe,Universitt Siegen

Prof. Dr.-Ing. R. M. Kennel, Lehrstuhl fr elektrische Maschinen und Antriebe,

Bergische Universitt Wuppertal

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Prof. Dr. -Ing. J. M. Pacas, University of Siegen

Prof. Dr. -Ing. R. M. Kennel, Wuppertal University Page 1

General Requirements, State of the Art,

Structure and Components of Servo Drives

Drive Control with Position/Speed Encoder

Motion Control

Drive Control without Position/Speed Encoder

Data Exchange (Communication)

Outline

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Prof. Dr. -Ing. J. M. Pacas, University of Siegen

Prof. Dr. -Ing. R. M. Kennel, Wuppertal University Page 2

feed drives

control the position

between working piece

and working tool

main drives

provide

processing power

Typical Machine Tool

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Prof. Dr. -Ing. J. M. Pacas, University of Siegen

Prof. Dr. -Ing. R. M. Kennel, Wuppertal University Page 3

Parallel Kinematics

TriCenter DMT 100

(Deckel Maho)

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Prof. Dr. -Ing. J. M. Pacas, University of Siegen

Prof. Dr. -Ing. R. M. Kennel, Wuppertal University Page 4

feed

drives

axis

Spindle

drives

main

high efficiency

small size

smooth

operation

at low speeds

4 quadrant

operation

high maximum torque

constant maximum torque

speed range < 10.000 rpm

rated power < 20 kW

Characteristics of Servo Drives

high rated/continuous torque

constant maximum power

speed range < 20.000 rpm

rated power < 100 kW

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Prof. Dr. -Ing. J. M. Pacas, University of Siegen

Prof. Dr. -Ing. R. M. Kennel, Wuppertal University Page 5

ECbrushless

DC

SMsynchronous

motor

ASMasynchronous

motor

SM SM

ASM

?

?

DC

1970 ff. 1980 ff. 1990 ff.

Hystory of Motor Types in Servo Drives

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Prof. Dr. -Ing. J. M. Pacas, University of Siegen

Prof. Dr. -Ing. R. M. Kennel, Wuppertal University Page 6

State of the Art: AC Servos

High Speed Spindle

(Siemens) DSD Servo

(Baumller)

High Torque Motor

(Baumller) Spindle Motor

(Franz Kessler)

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Prof. Dr. -Ing. J. M. Pacas, University of Siegen

Prof. Dr. -Ing. R. M. Kennel, Wuppertal University Page 7

Inverters for Servo Drive Applications

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Prof. Dr. -Ing. J. M. Pacas, University of Siegen

Prof. Dr. -Ing. R. M. Kennel, Wuppertal University Page 8

Encoders

Advantages low cost

high accuracy(e. g. by gear ratio)

Disadvantages elastic effects

and back lash

source : ERN-Geber, Heidenhain

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Prof. Dr. -Ing. J. M. Pacas, University of Siegen

Prof. Dr. -Ing. R. M. Kennel, Wuppertal University Page 9

Encoder Technologies

Mebereich

measuring area

Auflsung

resolution

Robustheit

robustness

Massenproduktion

mass production

magnetisch

magnetic

Resolver:

circular

tooth wheel:

point

low

(multipole resolver: 20

Bit)

good bad

optischoptical point

high

(CCD: > 30 Bit)

problematic

(sensitive totemperature

and shock)

very good

(photographicproduction)

kapazitive

capacitive

circular high good good

Too less experience to make knowledge-based statements.

measuring area resolution robustness mass production

magnetic

optical

capacitive

technology

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Prof. Dr. -Ing. J. M. Pacas, University of Siegen

Prof. Dr. -Ing. R. M. Kennel, Wuppertal University Page 10

-

Feldschwchung

- -

-

M-Regler Strom-Regler

Feld-Regler

Ma-

schinen-

modell

ej

e-j

e-j

M3~

i

u

Encoder

n*

i*q

i*d*

for asynchronous

machines

field weakening field controller

speed

controller

current

controllers

machine

model

for synchronous

machines

AC Servo Drive Control

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Prof. Dr. -Ing. J. M. Pacas, University of Siegen

Prof. Dr. -Ing. R. M. Kennel, Wuppertal University Page 11

Motion Control (e. g. Electronic Gear)

Hauptantrieb

Virtueller

Master

SynchronisierteKommunikation

main drive

Virtual

master Synchronizedcommunication

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Prof. Dr. -Ing. J. M. Pacas, University of Siegen

Prof. Dr. -Ing. R. M. Kennel, Wuppertal University Page 12

Sensorless Control Categories

fundamental models models based on anisotropies

emf-model,

Observer

dq-inductance ...main field

saturation

... rotor slotting

effect

flux

modulation

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Prof. Dr. -Ing. J. M. Pacas, University of Siegen

Prof. Dr. -Ing. R. M. Kennel, Wuppertal University Page 13

Industrial Drives with Sensorless Control

since several years / decades sensorless control is investigated

and published on conferences and magazines

- acceptance in industry, however, is ratherlow

Why ?new ideas and concepts are interesting for industry,

only if they do not result in highercost or highereffort!!!

What does that meanfor industrial drives with sensorless control ?

no additional ormore powerful processors / controllers

no additional hardware oradditional sensors (e. g. voltage sensors) no increased installation effort with respect to parameter adjustments

D i ith Di ti F t

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Prof. Dr. -Ing. J. M. Pacas, University of Siegen

Prof. Dr. -Ing. R. M. Kennel, Wuppertal University Page 14

Drives with Diagnostic Features

Di t ib t d/D t li d C t l

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Prof. Dr. -Ing. J. M. Pacas, University of Siegen

Prof. Dr. -Ing. R. M. Kennel, Wuppertal University Page 15

Distributed/Decentralized Control

SERCOS i t f

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Prof. Dr. -Ing. J. M. Pacas, University of Siegen

Prof. Dr. -Ing. R. M. Kennel, Wuppertal University Page 16

SERCOS interface

AT 2AT MAT mAT 1

t1.1t1.2

t1.Mt2

tScyc

t1.m

MDT

MSTMST

t1.x AT transmission starting time

t2 MDT transmission starting time

tScyc SERCOS cycle time

F t D l t

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Prof. Dr. -Ing. J. M. Pacas, University of Siegen

Prof. Dr. -Ing. R. M. Kennel, Wuppertal University Page 17

Data Exchange/Communication

synchronized communication systems are demanded

for multi axis servo drive systems for high requirements

Future Developments

Motors (Actors)

synchronous motors with surface mounted permanent magnets as a standard

- different solutions in special applications only (for cost reasons

Signal Processing

further developments on speed/position encoders to be expected

sensorless/encoderless control only, if

no additional hardware effort (processors and/or sensors)

no parameter dependencies during operation