Industrial Motion Control E-Book

Hakan Gurocak

• Herausgeber: John Wiley & Sons
• Kategorie: Fachliteratur
• Sprache: Englisch

Seitenzahl: 451

Veröffentlichungsjahr: 2016

Beschreibung

Motion control is widely used in all types of industries including packaging, assembly, textile, paper, printing, food processing, wood products, machinery, electronics and semiconductor manufacturing. Industrial motion control applications use specialized equipment and require system design and integration.  To design such systems, engineers need to be familiar with industrial motion control products; be able to bring together control theory, kinematics, dynamics, electronics, simulation, programming and machine design; apply interdisciplinary knowledge; and deal with practical application issues.

The book is intended to be an introduction to the topic for senior level undergraduate mechanical and electrical engineering students. It should also be resource for system design engineers, mechanical engineers, electrical engineers, project managers, industrial engineers, manufacturing engineers, product managers, field engineers, and programmers in industry.

Leseprobe

Table of Contents

Cover

Title Page

Copyright

Preface

Chapter 1: Introduction

1.1 Components of a Motion Control System

References

Chapter 2: Motion Profile

2.1 Kinematics: Basic Concepts

2.2 Common Motion Profiles

2.3 Multiaxis Motion

Problems

References

Chapter 3: Drive-Train Design

3.1 Inertia and Torque Reflection

3.2 Inertia Ratio

3.3 Transmission Mechanisms

3.4 Torque Required for the Motion

3.5 Motor Torque–Speed Curves

3.6 Motor Sizing Process

3.7 Motor Selection for Direct Drive

3.8 Motor and Transmission Selection

3.9 Gearboxes

3.10 Servo Motor and Gearhead Selection

3.11 AC Induction Motor and Gearbox Selection

3.12 Motor, Gearbox, and Transmission Mechanism Selection

Problems

References

Chapter 4: Electric Motors

4.1 Underlying Concepts

4.2 Rotating Magnetic Field

4.3 AC Servo Motors

4.4 AC Induction Motors

4.5 Mathematical Models

Problems

References

Chapter 5: Sensors and Control Devices

5.1 Optical Encoders

5.2 Detection Sensors

5.3 Pilot Control Devices

5.4 Control Devices for AC Induction Motors

Problems

References

Chapter 6: AC Drives

6.1 Drive Electronics

6.2 Basic Control Structures

6.3 Inner Loop

6.4 Simulation Models of Controllers

6.5 Tuning

Problems

References

Chapter 7: Motion Controller Programming and Applications

7.1 Move Modes

7.2 Programming

7.3 Single-Axis Motion

7.4 Multiaxis Motion

Problems

References

Appendix A: Overview of Control Theory

A.1 System Configurations

A.2 Analysis Tools

A.3 Transient Response

A.4 Steady-State Errors

References

Index

End User License Agreement

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Guide

Cover

Table of Contents

Preface

Begin Reading

List of Illustrations

Chapter 1: Introduction

Figure 1.1 Complex machines with multiple axes are made possible with the ability of the controller to precisely coordinate motion of all axes. (a) Foil and wire winding machine (Reproduced by permission of Broomfield, Inc. [3]). (b) Pressure sensitive labeling machine

Figure 1.2 Multiaxis coordination

Figure 1.3 Components of a motion control system

Figure 1.4 Human–machine interfaces (operator panels) are used to operate the machine. (a) Hardware-based control panel [7]. (b) Software-based control panel with touch screen

Figure 1.5 Motion controllers can have the various form factors. (a) Integrated form factor

Figure 1.6 Drives are used to provide high voltage and current levels necessary to operate motors. (a) Digital servo drive

Figure 1.7 AC servo and induction motors are used in motion control applications as actuators. (a) AC servo motors

Figure 1.8 Gearboxes are used in motion control applications to help achieve speed and torque requirements. (a) In line gearhead for servo motors (Reproduced by permission of DieQua Corp. [6]). (b) Right-angle worm gear reducer for AC induction motors

Figure 1.9 Encoders are used in motion control applications as feedback devices. (a) Rotary encoder

Figure 1.10 Photoelectric sensors are used for detection of presence of an object [11]

Chapter 2: Motion Profile

Figure 2.1 Basic relationships between position, velocity, and acceleration

Figure 2.2 Velocity profile for acceleration

Figure 2.3 Velocity profile for deceleration

Figure 2.4 Trapezoidal velocity profile and associated position, acceleration, and jerk profiles to move an axis from 0 to position L

Figure 2.5 Trapezoidal velocity profile for the

X

-axis

Figure 2.6 Trapezoidal velocity for Example 2.2.2

Figure 2.7 Triangular velocity profile for Example 2.2.4

Figure 2.8 S-curve velocity profile and the associated position, acceleration, and jerk profiles

Figure 2.9 Pure S-curve velocity profile

Figure 2.10 Pure S-curve velocity and acceleration profiles in Example 2.2.5

Figure 2.11 S-curve velocity profile for Example 2.2.6

Figure 2.12 Multiaxis machine for Example 2.3.1 (top view)

Figure 2.13 Problem 3

Figure 2.14 Problem 6

Figure 2.15 Problem 7. (a) Flying shear machine to cut continuous material into fixed lengths. (b) Velocity profile for the shear (Adapted by permission of ABB Corp.) [1]

Figure 2.16 Problem 8

Figure 2.17 Problem 9

Figure 2.18 Problem 11

Chapter 3: Drive-Train Design

Figure 3.1 Iterative drive-train design process

Figure 3.2 Gear mesh

Figure 3.3 Inertia reflection. (a) Load directly coupled to motor. (b) Load coupled to motor through gears

Figure 3.4 Inertia reflection through gears and the equivalent system

Figure 3.5 Another schematic for the system in Figure 3.4

Figure 3.6 Inertia reflection through a gearbox

Figure 3.7 Schematic of a typical drive with a transmission mechanism

Figure 3.8 External forces or torques on the load are reflected by the transmission as a torque demand on the motor

Figure 3.9 Pulley-and-belt transmission using timing belt and sprockets

Figure 3.10 Pulley-and-belt drive

Figure 3.11 Belt-and-pulley transmission. (a) Top view. (b) Schematic

Figure 3.12 ACME screw and ball-screw used in lead screw transmission

Figure 3.13 Lead (ball) screw transmission. (a) Schematic. (b) Electric slide with ball screw

Figure 3.14 Forces on a lead screw transmission at an angle with the horizontal

Figure 3.15 Rack-and-pinion drive converts rotational motion into linear motion

Figure 3.16 Schematic for rack-and-pinion transmission

Figure 3.17 Belt-drive for linear motion converts rotational motion of the motor into linear motion of the load. (a) Electric linear axis

Figure 3.18 Schematic for belt-drive for linear motion

Figure 3.19 Conveyor

Figure 3.20 Schematic for conveyor

Figure 3.21 Torques on the motor shaft

Figure 3.22 Phases of the motion profile and torque in each phase

Figure 3.23 Cyclical motion profile with dwell period

Figure 3.24 Gantry machine with two parallel linear tracks for -axis

Figure 3.25 Generic torque–speed curves for an AC servo motor under closed-loop control of an electric drive. (a) AC servo motors (Reproduced by permission of Emerson Industrial Automation) [12]. (b) Torque-speed curves for a generic motor

Figure 3.26 Generic torque–speed curves for a vector-duty induction motor with vector-control drive. (a) Vector-duty AC induction motor (Reproduced by permission of Marathon

TM

Motors, A Regal Brand) [21]. (b) Torque-speed curves for a

generic

motor

Figure 3.27 Torque–speed curve for a 5 HP motor and drive combination

Figure 3.28 Both RMS and peak torque requirements of the motion must be within the capabilities of the motor at the desired motor speed for proper operation

Figure 3.29 Direct drive where motor is directly coupled to the load

Figure 3.30 Servo gearheads (Reproduced by permission of Apex Dynamics USA). (a) Inline gearhead [3]. (b) Right-angle gearhead [4]

Figure 3.31 Worm gear speed reducer. (a) Right-angle worm gear reducer for AC induction motors (Reproduced by permission of Cone Drive Operations, Inc.) [9]. (b) Overhung load

Figure 3.32 Motor coupled to the load via a gearhead

Figure 3.33 Motion profile for output shaft of gearhead

Figure 3.34 Motor and gearbox selection for a converting machine. (a) Sheet aluminum converting machine. (b) Rewind axis schematic

Figure 3.35 First page of

Excel

spreadsheet for cyclical operation calculations for part (a) in Example 3.10.1. Gear ratio 20:1 with AKM23D-BN servomotor

Figure 3.36 Second page of the

Excel

spreadsheet for servomotor selection for part (a) in Example 3.10.1. Gear ratio 20:1, with AKM23D-BN servomotor

Figure 3.37 Induction motor coupled to the load via a gearbox

Figure 3.38 Core capping machine

Figure 3.39 Motor coupled to the load via a gearbox and transmission mechanism

Figure 3.40 Problem 1. (a) Simple gearbox. (b) Gear train

Figure 3.41 Pulley geometry for Problem 3

Figure 3.42 Conveyor for Problem 4

Figure 3.43 Box pusher for Problem 7

Figure 3.44 Rewind axis of winding machine for Problem 8. (a) Hardwound paper towels. (b) Axis and motor. Reproduced by permission of Georgia — Pacific LLC [18]

Figure 3.45 Pallet dispenser for Problem 11

Chapter 4: Electric Motors

Figure 4.1 Magnetic polarity of an electromagnet can be changed by changing the current direction

Figure 4.2 One-phase stator. (a) One phase winding made with two coils. (b) Bar magnet rotor

Figure 4.3 Winding of one phase for a four-pole motor

Figure 4.4 Electrical and mechanical cycles. (a) Two pole rotor. (b) Four pole rotor

Figure 4.5 Three-phase stator and WYE-connected phases

Figure 4.6 Three Hall sensors create six segments for the course measurement of the absolute position of the rotor field. Each segment is identified by a unique three-digit code formed by combining the signals from the sensors. Here it was assumed that the sensor gives a high signal (indicated by “1”) when it is triggered by the North Pole of the rotor

Figure 4.7 Six-step commutation algorithm. Stator and rotor field orientations and active phase windings in each step to rotate the rotor CW

Figure 4.8 AC servo motors

Figure 4.9 Four-pole rotor with (a) surface-mounted, and (b) inset-mounted magnets

Figure 4.10 Stator for distributed windings. (a) Stator with slots and a coil for phase winding. (b) Phase windings in stator slots

Figure 4.11 Distributed phase A winding for a three-phase four-pole motor

Figure 4.12 Winding terminology. (a) Coil pitch and pole pitch. (b) Full-pitch winding. Coil pitch is equal to pole pitch. (c) Fractional-pitch winding. Coil pitch is shorter than pole pitch

Figure 4.13 Flux linkage in one phase coil as the rotor of a four-pole full-coil pitch motor rotates

Figure 4.14 Back emf voltage in each phase winding of a three-phase stator

Figure 4.15 Back emf waveforms in one phase winding of an integral slot motor and a fractional slot motor. (a) Integral slot motor. All coil back emf voltages are in phase with each other. Hence, the overall phase winding back emf has the same shape as coil voltages but the amplitude is the sum of all coil voltages. (b) Fractional slot motor. Individual coil back emf voltages are shifted in phase. The overall phase winding back emf voltage is approximately sinusoidal

Figure 4.16 Sinusoidal phase currents and pulsating magnetic field in phase A. (a) Sinusoidal phase currents shifted by 120. (b) Pulsating magnetic field in phase A. Its magnitude varies and its direction changes back and forth along the magnetic axis of the winding

Figure 4.17 Rotating magnetic field as a result of sinusoidal phase currents

Figure 4.18 Torque generated when an AC servo motor is coupled to a six-step drive

Figure 4.19 Vector-duty AC induction motor

Figure 4.20 AC induction motor stator. (a) Stator windings in slots

Figure 4.21 Squirrel cage rotor of an AC induction motor

Figure 4.22 Induced rotor currents and resulting magnetic fields

Figure 4.23 Torque–speed curve of a NEMA B type AC induction motor and various operating points [25]

Figure 4.24 Torque–speed characteristics of NEMA A, B, C, and D motors

Figure 4.25 Constant torque and constant horsepower operating ranges for an AC induction motor controlled by a variable frequency drive (VFD) (Adapted by permission of Siemens Industry, Inc. [25])

Figure 4.26 Motor conceptual model. (a) Motor converts voltage input into rotor speed. (b) Motor model includes electrical and mechanical components

Figure 4.27 Per-phase circuit model for a motor

Figure 4.28 Mechanical model of a motor

Figure 4.29 Mechanical model block in Simulink®. (a) Top-level Simulink® block for the mechanical model of a motor. (b) Second-level: Details of mechanical motor model block

Figure 4.31

dq

-frame and the hypothetical rotating direct-axis () and quadrature-axis () inductances

Figure 4.30 Expanded AC servo motor conceptual model

Figure 4.32 Top-level Simulink model for a three-phase AC servo motor

Figure 4.33 Second-level Simulink model for a three-phase AC servo motor

Figure 4.34 Electrical and torque generation models for AC servo motor. (a) Electrical model block details. Variables u(1) and u(2) correspond to and , respectively. (b) Torque generation block details

Figure 4.35 Park and inverse-Park transforms in the AC servo motor model. (a) abc-dq block details. (b) dq-abc block details

Figure 4.36 Top-level Simulink model for a three-phase AC induction motor

Figure 4.37 Second-level model: inside the AC induction motor

Figure 4.38 Computation of currents and torque generation in an AC induction motor. (a) Details of the “Flux to current conversion” block. (b) Details of the “Torque Generation” block

Figure 4.39 Fractional pitch coil and the resulting back emf waveform for Problem 8

Chapter 5: Sensors and Control Devices

Figure 5.1 Main components of an optical encoder (signal conditioning circuit not shown)

Figure 5.2 Incremental encoder (Reproduced by permission of US Digital Corp. [28]). (a) Disc with a single track black-and-white pattern. (b) Disc mounted on a hub. (c) Disc and detector assembly

Figure 5.3 Encoder pulses from (a) single track with single detector and (b) single track with two detectors

Figure 5.4 Determination of motion direction with two detectors

Figure 5.5 Quadrature signals

Figure 5.6 Linear encoder (linear scale) (Reproduced by permission of Heidenhain Corp. [10]))

Figure 5.7 Analog sinusoidal encoder signals from a SinCos encoder

Figure 5.8 Complimentary (differential) encoder channels to increase noise immunity

Figure 5.9 Noise immunity with differential line drivers

Figure 5.10 Absolute encoder disks with 3-bit resolution. (a) 3-bit binary code disc [2]. (b) 3-bit gray code disc [12]

Figure 5.11 Gray code disk (9-bits) [16]

Figure 5.12 SSI interface

Figure 5.13 HIPERFACE interface

Figure 5.14 Mechanical limit switch and circuit symbols. (a) Mechanical limit switch with roller-lever operator (Courtesy of

Rockwell Automation, Inc.

) [17]. (b) Circuit symbols for N.O. and N.C. limit switches

Figure 5.15 Inductive proximity sensor and wiring. (a) Inductive proximity sensor (Courtesy of

Rockwell Automation, Inc.

) [18]. (b) Three-wire N.O. proximity sensor wired to a load (input card of a motion controller)

Figure 5.16 Photoelectric sensor detection methods and a diffuse mode industrial sensor. (a) Through-beam. (b) Retroreflective. (c) Diffuse sensing. (d) Diffuse mode infrared industrial photoelectric sensor [13]

Figure 5.17 Ultrasonic sensor (Courtesy of Rockwell Automation, Inc.) [19]

Figure 5.18 Two ways to wire a simple circuit with a switch. (a) Switch before the bulb. Switch is sourcing. (b) Switch after the bulb. Switch is sinking

Figure 5.19 Sinking or sourcing input card. (a) Sinking input card, sourcing field device. (b) Sourcing input card, sinking field device

Figure 5.20 Sinking or sourcing output card. (a) Sourcing output card, sinking field device. (b) Sinking output card, sourcing field device

Figure 5.21 Three-wire sensor wiring. (a) Three-wire sourcing-type sensor (with PNP transistor). (b) Three-wire sinking-type sensor (with NPN transistor)

Figure 5.22 IEC- and NEMA-style push buttons (Courtesy of Rockwell Automation, Inc.). (a) IEC style push button [20]. (b) NEMA style push button [23]

Figure 5.23 Industrial push button operator, contact block and symbols. (a) Operator and contact block Photo: (Courtesy of

Rockwell Automation, Inc.

) [23]. (b) Symbols for push button

Figure 5.24 Push/pull emergency stop button (Courtesy of Rockwell Automation, Inc.) [21]

Figure 5.25 Three-position selector switch. (a) Selector switch (Courtesy of

Rockwell Automation, Inc.

) [22]. (b) Truth table

Figure 5.26 Pilot light (Courtesy of Rockwell Automation, Inc.) [24]

Figure 5.27 Contactor and overload relay schematic and commercial modules. (a) Schematic. (b) Commercial contactor unit [6]. (c) Commercial thermal overload relay unit [7]

Figure 5.28 Three-wire motor control circuit

Figure 5.29 Measuring wheel for Problem 8

Chapter 6: AC Drives

Figure 6.1 AC drive with pulse width modulation (PWM) inverter (adapted by permission of Siemens Industry, Inc. [17])

Figure 6.2 Converting AC into DC using diode rectifiers. (a) Diode has the effect of cutting the bottom part of the AC waveform. (b) Full-wave bridge rectifier

Figure 6.3 Three-phase converter circuit and the bridge rectifier as a commercial product. (a) Three-phase converter circuit. (b) Three-phase rectifier bridge.

Figure 6.4 DC link smooths out the resulting DC bus voltage

Figure 6.5 Three-phase inverter circuit and a commercial inverter module. (a) Inverter circuit with six IGBTs (1 through 6) (Adapted by permission of Siemens Industry, Inc.) [17]. (b) Three-phase inverter. (Reproduced by permission of Vishay Intertechnology, Inc.) [2]

Figure 6.6 Simplified inverter with switches replacing the IGBTs

Figure 6.7 Pulse-width modulation (PWM). (a) Duty cycle in pulse width modulation (PWM). (b) Average voltage output is proportional to the duty cycle

Figure 6.8 Triangular carrier signal and sinusoidal reference signal to create a corresponding PWM signal

Figure 6.9 Two-phase sinusoidal reference signals shifted and the corresponding PWM signals

Figure 6.10 PWM signal for the line-to-line voltage

Figure 6.11 Simulation model for the PWM inverter. (a) Top-level model for PWM inverter. (b) Details of the PWM inverter model

Figure 6.13 Velocity loop

Figure 6.14 Position loop

Figure 6.15 Double integrators

Figure 6.16 Simplified theoretical velocity controller block diagram

Figure 6.17 Closed-loop response of the velocity loop for various damping ratios

Figure 6.18 Single-loop PID position control encloses double integrators

Figure 6.19 PID controller has three gains

Figure 6.20 Motion controller with P control connected to a linear axis ()

Figure 6.21 (a) Spring–mass system at rest; (b) displaced through distance due to force ; (c) free-body diagram

Figure 6.22 Motion controller with PD control connected to a linear axis ()

Figure 6.23 (a) Spring–mass–damper system at rest; (b) displaced through distance due to force ; (c) free-body diagram

Figure 6.24 Motion controller with PID control connected to a linear axis ()

Figure 6.25 Motor with vertical load under PID position control

Figure 6.12 Cascaded velocity and position loops of the control system for an axis

Figure 6.26 Control structure with transfer functions for the PID position controller and the system

Figure 6.27 New PID control structure obtained by moving the derivative gain to the feedback loop. (a) Derivative gain on the feedback loop. (b) Same structure drawn in a different way

Figure 6.28 Type-1 system with unity feedback

Figure 6.29 Constant velocity following error in a Type-1 control system

Figure 6.30 Velocity feedforward added to the cascaded velocity/position control structure

Figure 6.31 Acceleration and velocity feedforward added to the cascaded velocity/position control structure

Figure 6.32 Cascaded velocity/position controller with velocity and acceleration feedforward gains

Figure 6.33 Generic structure of the inner loop (current loop)

Figure 6.34 Stator current space vector

Figure 6.35 Inner loop implementation for AC induction motor using vector control

Figure 6.36 Inner loop implementation for AC servo motor using vector control

Figure 6.37 Simulation model for the velocity loop and inner loop for an AC induction motor. (a) Velocity loop for AC induction motor. (b) Inner loop details for vector control of an AC induction motor

Figure 6.38 Details of the desired ids* and desired iqs* current blocks. (a) Desired -axis current component, . (b) Desired -axis current component,

Figure 6.39 Details of the flux position calculator block

Figure 6.40 Simulation model for the velocity loop and inner loop for an AC servo motor. (a) Velocity loop for AC servo motor. (b) Inner loop details for vector control of an AC servo motor

Figure 6.41 Settling time as a measure of responsiveness

Figure 6.42 Percent overshoot as a measure of stability. (a) System response with 13% overshoot (b) System response with 36% overshoot

Figure 6.43 Input selection with a switch to tune the velocity and current loops

Figure 6.44 Current loop tuning. (a) ; (b)

Figure 6.45 Velocity loop tuning. (a) ; (b) ; (c)

Figure 6.46 Tracking trapezoidal velocity input. (a) initial tuning with ; (b) tuned velocity controller with

Figure 6.47 AC servo motor controlled by a PID position controller (a) Single loop PID position controller with AC servo motor. (b) PID controller details

Figure 6.48 Tuning a PID position controller for an axis with an AC servo motor. (a) ; (b) ; (c)

Figure 6.49 PID position controller for an AC servo axis with low gain (). A load disturbance torque (8 Nm) at 0.15 s causes following error, which cannot be eliminated by the controller

Figure 6.50 Tuning results with two different settings using continuous integration. PID position controller for an AC servo axis with . The following error due to the load disturbance is eliminated with but the overshoot is now 30%

Figure 6.51 System setup for tuning the PID position controller for an AC servo axis using the integrate-when-in-position approach. (a) Control system configuration. (b) Inside the PID block. The integrator was set up to be triggered by an external signal (velocity)

Figure 6.52 Tuning results with the integrate-when-in-position method. PID position controller for an AC servo axis with

Figure 6.53 Phase currents and torque in trapezoidal move with the integrate-when-in-position method. PID position controller for an AC servo motor with . (a) Phase currents. (b) Torque

Figure 6.54 System response with continuous integration. (a) no integrator clamping and ; (b) integrator clamping with and

Figure 6.55 System setup for tuning the PID position controller for an AC servo axis using the Integrate-When-In-Position approach

Figure 6.56 Tuning gains in a cascaded velocity/position controller with feedforward. (a) ; (b) ; (c)

Figure 6.57 Type-1 system response using a cascaded velocity/position controller with feedforward (). (a) Position response; (b) following error

Figure 6.58 System response using a cascaded velocity/position controller with feedforward (). (a) Position response; (b) following error

Figure 6.59 System response using a cascaded velocity/position controller with feedforward (). A disturbance load torque of 8 Nm was applied at 0.15 s

Figure 6.60 Position control of the turret axis in Example 3.11.1 with AC induction motor and gearbox. The motion controller uses cascaded velocity /position controller with feedforward. (a) Control system configuration. (b) Inside the PID block. The integrator was set up to be triggered by an external signal (commanded velocity)

Figure 6.61 Turret axis response using a cascaded velocity/position controller with feedforward (). A disturbance load torque of was applied at

Figure 6.62 First two intervals of the transistor switching waveforms for the 180 conduction method, Problem 1

Figure 6.63 First two intervals of the line-to-line voltage waveforms for the 180 conduction method, Problem 2

Figure 6.64 Parabolic velocity input, Problem 8

Chapter 7: Motion Controller Programming and Applications

Figure 7.1 Circular moves in the plane

Figure 7.2 Blended moves. (a) Blending of velocities between two consecutive moves. (b) Two linear moves (Left) with and (Right) without blending

Figure 7.3 Linear axis with two limit switches and a home switch

Figure 7.4 Homing search based on the move-until-trigger scheme (Adapted by permission of Delta Tau Data Systems, Inc. [12])

Figure 7.5 Triggering with the home switch and encoder index channel pulse to capture a more accurate home position

Figure 7.6 Gantry machine with set-point coordinated base axis. (a) Gantry machine with two motors driving the base axis. (b) Same set-point commanded to both motors of the base axis

Figure 7.7 Two types of master/slave programming. (a) Master encoder following: Feedback encoder of the master motor is the command input for the slave motor through a gear ratio. (b) Command position following: Commanded master position is also sent to the slave through a gear ratio

Figure 7.8 Mechanical cam-and-follower mechanism

Figure 7.9 Flying knife application to cut continuous material into fixed lengths

Figure 7.10 Speed ratio versus master position for synchronized motion of a flying knife (Adapted by permission of ABB Corp. [5])

Figure 7.11 Slave axis travel in ratio following

Figure 7.12 Spool winding to wind strands on a spool

Figure 7.13 Rotating knife to cut continuous material (web)

Figure 7.14 Rotating knife motion profile to cut material lengths that are shorter than the knife circumference

Figure 7.15 Flying knife with registration to cut continuous material at registration marks into fixed lengths

Figure 7.16 Typical converting process with unwind, internal, and rewind tension zones

Figure 7.17 Simplified converting machine

Figure 7.18 Closed-loop web tension control with load cell

Figure 7.19 Closed-loop web tension control with dancer roll

Figure 7.20 Constant tension, taper tension, and the corresponding rewind torques ()

Figure 7.21 SCARA and delta robots are examples of non-Cartesian mechanisms. (a) SCARA robot. Copyright © 2015, Adept Technology, Inc. (Reproduced by permission of Adept Technology, Inc.) [8]. (b) Delta robot (Reproduced by permission of ABB Corp.) [7]

Figure 7.22 Four-axis SCARA robot for kinematic analysis. (a) Four-axis SCARA robot. (b) Top view

Figure 7.23 SCARA silicon wafer handling robot for Problem 4

Figure 7.24 Force-controlled robot gripper for Problem 5

Figure 7.25 Laser scanner for surface defects for Problem 6

Figure 7.26 Bottle filling machine for Problem 7. (a) Machine. (b) Nozzle tip in the bottle. (c) Liquid “slice”

Appendix A: Overview of Control Theory

Figure A.1 Open-loop and closed-loop control systems

Figure A.2 Transfer function represented as a block

Figure A.3 Basic block connections and their equivalent replacements for block diagram simplification

Figure A.4 Step response of a first-order system

Figure A.5 Four different types of possible step responses of second-order systems

Figure A.6 Transfer function and step response of the second-order system in Example A.3.1. (a) Simulation model for the system. (b) Unit step response

Figure A.7 Specifications for underdamped response

List of Tables

Chapter 3: Drive-Train Design

Table 3.1 Types of drive-train design problems

Table 3.2 Comparison of vector-duty AC induction motors and AC servomotors operated with 460 VAC AC drives

Table 3.3 Pulley dimensions (in) for Problem 3

Chapter 4: Electric Motors

Table 4.1 Six-step commutation for the brushless motor in Figure 4.7

Chapter 5: Sensors and Control Devices

Table 5.1 Absolute encoder disk codes (3-bits)

Chapter 6: AC Drives

Table 6.1 Switching patterns for 120 conduction method

Table 6.2 Switching patterns for 180 conduction method

Chapter 7: Motion Controller Programming and Applications

Table 7.1 Distance traveled by the slave axis in each segment of master distance in Figure 7.10

Appendix A: Overview of Control Theory

Table A.1 Laplace transform theorems

Table A.2 Basic Laplace transforms

Table A.3 Steady-state errors as a function of input and system type combinations

INDUSTRIAL MOTION CONTROL

MOTOR SELECTION, DRIVES, CONTROLLER TUNING, APPLICATIONS

Hakan Gürocak

Washington State University

Vancouver, USA

© 2016, John Wiley & Sons, Ltd

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Preface

Over the past couple of decades, the academic community has made significant advances in developing educational materials and laboratory exercises for fundamental mechatronics and controls education. Students learn mathematical control theory, board-level electronics, interfacing, and microprocessors supplemented with educational laboratory equipment. As new mechanical and electrical engineering graduates become practicing engineers, many are engaged in projects where knowledge of industrial motion control technology is an absolute must since industrial automation is designed primarily around specialized motion control hardware and software.

This book is an introduction to industrial motion control, which is a widely used technology found in every conceivable industry. It is the heart of just about any automated machinery and process. Industrial motion control applications use specialized equipment and require system design and integration where control is just one aspect. To design such systems, engineers need to be familiar with industrial motion control products; be able to bring together control theory, kinematics, dynamics, electronics, simulation, programming and machine design; apply interdisciplinary knowledge; and deal with practical application issues. Most of these topics are already covered in engineering courses in typical undergraduate curricula but in a compartmentalized nature, which makes it difficult to grasp the connections between them.