Tolomatic presentation understanding motion control technology

MOTION CONTROL TECHNOLOGY

Microstepping Systems Brushed DC Systems Brushless Servo Systems

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ELECTROMATE
Toll Free Phone (877) SERVO98
Toll Free Fax (877) SERV099
www.electromate.com
sales@electromate.com

ENCODER FEEDBACK

Open Loop System
– Gives a commanded position but has no feedback to ensure
the actual position was reached.
• Controller commands a signal to the drive
• Drive converts and amplifies the signal to the motor
• Motor moves commanded number of steps

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ELECTROMATE
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ENCODER FEEDBACK

Open Loop Example

Supply

Command Dimmer Lamp

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ELECTROMATE
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ENCODER FEEDBACK

Closed Loop

– Monitors the commanded position versus the actual position
and adjusts to insure the commanded position is reached

• Command signal responds to eliminate error based on
feedback

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ELECTROMATE
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ENCODER FEEDBACK
Closed Loop Example

65o Current Temp.

72o Command 7o Error
T Furnace

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ELECTROMATE
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ENCODER FEEDBACK
Servo Motor Control Example

COMMAND ERROR
Position 10” Move 1” Power
+ Amplifier Motor
-

FEEDBACK Sold & Serviced By:

ELECTROMATE
9” Machine Motion Toll Free Phone (877) SERVO98
www.electromate.com

FEEDBACK DEVICES
Tell the control system where the tool or work piece is located

– Analog(ex. tachometer)

• Directly represent some physical quantity

• Continually varied

– Digital (ex. encoder)

• Incremental

• Absolute Sold & Serviced By:

ELECTROMATE
www.electromate.com

FEEDBACK DEVICES
Incremental Encoder
– Counts the segments on a disc to determine
position
– Uses a clock to determine velocity
– Has one single mark called an indexer to
eliminate error and allow finer positioning on
homing routine
– 1000 Counts
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ELECTROMATE
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FEEDBACK DEVICES
Quadrature Encoder

– Has two segment patterns that
allow for finer positioning

– Reads 4x the physical line count

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ELECTROMATE
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MOTION CONTROL SYSTEMS

Microstepping

Brushed DC

Brushless Servo

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ELECTROMATE
www.electromate.com

WHY A MICROSTEPPING SYSTEM?

Lowest cost for precision motion

Feedback device not needed

Low RPM applications

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ELECTROMATE
www.electromate.com

STEPPER MOTORS

Windings are on the stator and the
magnets are on the rotor

Current switched electronically
to windings Half Step Full Step

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ELECTROMATE
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STEPPER MOTORS

200 physical steps on the
rotor assembly

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ELECTROMATE
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ADVANTAGES OF STEPPER MOTORS
• Lowest cost for precision motion
• High resolution and positioning precision
• Easy angle and speed control
• Large holding torque
• Good for simple indexing
• High torque at lower speeds

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ELECTROMATE
www.electromate.com

LIMITATIONS OF STEPPER MOTORS
• Torque decreases as velocity increases
• If the load torque exceeds the motor’s available
torque it can stall or lose position
• Speeds typically limited to less than 2000 RPM
• Motion is not as smooth as servos

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ELECTROMATE
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STEPPER VS SERVO TORQUE CURVE

35
MRS31
30 MRV31-Continuous
25 MRV31-Peak
Torque (lb-in)

20

15
10
5
0 Sold & Serviced By:
3000
3600
4200
4800
5400
6000
0

1200
1800
2400
600

ELECTROMATE
www.electromate.com

MICROSTEPPING SYSTEM SUMMARY

• Lowest cost for precision motion
• High resolution
• Large holding torque
• Good for simple indexing
• High torque at lower speeds
• Torque decreases as velocity increases
• Open loop system, no encoder feedback
• Motion is not as smooth as servos Sold & Serviced By:

ELECTROMATE
www.electromate.com

WHY A BRUSHED DC SYSTEM?

• Low to medium cost
• Smooth and quiet operation
• Simple control (switch to switch)
• Higher torque and speed than Stepper

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ELECTROMATE
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BRUSHED DC MOTORS

1. Magnets are on the stator and the windings
are on rotor

2. Current is switched mechanically to the
windings through the brushes

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ELECTROMATE
www.electromate.com

ADVANTAGES OF BRUSHED MOTORS

Easily defined speed and torque output
– Volts/RPM
– Torque/Amp

Simple design keeps the cost down

Better torque roll off compared to steppers

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ELECTROMATE
www.electromate.com

LIMITATIONS OF BRUSHED MOTORS

Current switched mechanically
– Brush wear

Thermally inefficient
– Heat has to dissipate through the magnets
• Can reduce performance and life
• Larger size

Without encoder feedback limited in positioning capability
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ELECTROMATE
www.electromate.com

BRUSHED DC SUMMARY
• Low to medium cost
• Smooth and quiet operation
• Typically switch to switch operation
• Thermal inefficiencies can reduce performance and life
• Brush wear

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ELECTROMATE
www.electromate.com

BRUSHLESS SERVO SYSTEM

Closed Loop

– Monitors the commanded position versus the actual position
and adjusts to insure the commanded position is reached

• Command signal responds to eliminate error based on
feedback

Sold & Serviced By:

ELECTROMATE
www.electromate.com

WHY A BRUSHLESS SERVO SYSTEM?
• Extremely smooth and quiet operation
• Torque, velocity, or position control
• Accurate position and high output torque at high speeds
• Higher performance than Stepper and Brushed DC
• Maintenance free

Sold & Serviced By:

ELECTROMATE
www.electromate.com

BRUSHLESS SERVO MOTORS

1. Windings are on the stator and
the magnets are on the rotor

2. Current is switched electrically

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ELECTROMATE
www.electromate.com

ADVANTAGES OF BRUSHLESS MOTORS

• High continuous and peak torque
• High speeds (up to 6,000 RPM)
• Motor thermal protection
• Metal shell plug and turn connectors
• IP65 options

Sold & Serviced By:

ELECTROMATE
www.electromate.com

LIMITATIONS OF BRUSHLESS MOTORS
• Increased cost
• Increased weight
• Higher control complexity due to encoder feedback

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ELECTROMATE
www.electromate.com

BRUSHLESS SERVO SUMMARY
• Accurate position and high output torque at high speeds
• Excellent heat dissipation allows for higher continuous torque
• No mechanical brushes reduce speed torque ripple
• Higher performance than Stepper and Brushed Servo
• Increased cost

Sold & Serviced By:

ELECTROMATE
www.electromate.com

Applying Motion Control Systems…..
Use Micro-steppers when….
– You identify low speed applications where cost outweighs feedback for
velocity or torque

Use Brushed DC when….
– You run into low to midrange speed and torque applications that that need
simple point to point positioning without high accuracy

Use Brushless Servo when….
– You see high speed and high torque applications that need accurate
feedback for position, velocity, or torque…or
– You see applications that need high performance
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ELECTROMATE
www.electromate.com

QUESTIONS???

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Tolomatic presentation understanding motion control technology

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Tolomatic presentation understanding motion control technology