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DL 2126B – Servomotor
DL2126B
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Summary
Introduction......................................................................................................... 3
Types of Motors.................................................................................................. 4
DC Motors....................................................................................................... 9
Introduction ................................................................................................... 19
Brush-type DC ........................................................................................... 22
Brushless DC ............................................................................................ 23
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Measuring performance ................................................................................ 25
Torque curve................................................................................................. 31
Resolver........................................................................................................ 33
General ......................................................................................................... 37
Features........................................................................................................ 40
Overview ....................................................................................................... 40
References: ...................................................................................................... 61
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Introduction
As the name suggests, a servomotor is a servomechanism. More
specifically, it is a closed-loop servomechanism that uses position feedback to
control its motion and final position. The input to its control is some signal, either
analogue or digital, representing the position commanded for the output shaft.
The motor is paired with some type of encoder to provide position and
speed feedback. In the simplest case, only the position is measured. The
measured position of the output is compared to the command position, the
external input to the controller. If the output position differs from that required,
an error signal is generated which then causes the motor to rotate in either
direction, as needed to bring the output shaft to the appropriate position. As the
positions approach, the error signal reduces to zero and the motor stops.
The DL 2126B is a training tool for servo motor, that uses a ABB MS series
servo motor a ABB high performance machinery drive ACSM1 and a control
panel ACS-CP-U to control the ACSM1, read status data, and adjust
parameters, that permits all operations of the servo system as in a real
situation.
The MS series servo motors are robust and are designed for operation in
harsh environmental conditions. The resolver feedback is highly reliable, even
under demanding mechanical stress levels and in high ambient temperatures.
ABB high performance machinery drives provide speed, torque and motion
control for demanding machines. They can control induction, synchronous and
asynchronous servo and high torque motors with various feedback devices.
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Types of Motors
Electric Motors and the Concept of Electromagnetism
The direct current (DC) motor is one of the first machines devised to
convert electrical energy to mechanical power. Its origin can be traced to
machines conceived and tested by Michael Faraday, the experimenter who
formulated the fundamental concepts of electromagnetism. These concepts say
basically that if a conductor, or wire, carrying current is placed in a magnetic
field, a force will act upon it. The magnitude of this force is a function of strength
of the magnetic field, the amount of current passing through the conductor and
the orientation of the magnet and conductor. The direction in which this force
will act is dependent on the direction of current and direction of the magnetic
field.
AC Motors
Induction Motor
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If the induction motor is viewed as a type of transformer, it becomes easy
to understand. By applying a voltage onto the primary of the transformer
winding, a current flow results and induces current in the secondary winding.
The primary is the stator assembly and the secondary is the rotor assembly.
One magnetic field is set up in the stator and a second magnetic field is induced
in the rotor.
The interaction of these two magnetic fields results in motion. The speed
of the magnetic field going around the stator will determine the speed of the
rotor. The rotor will try to follow the stator's magnetic field, but will "slip" when a
load is attached. Therefore induction motors always rotate slower than the
stator's rotating field.
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Synchronous Motor
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The synchronous motor is basically the same as the induction motor but
with slightly different rotor construction. The rotor construction enables this type
of motor to rotate at the same speed (in synchronization) as the stator field.
There are basically two types of synchronous motors: self-excited (as the
induction motor) and directly excited (as with permanent magnets).
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Oftentimes the notches or teeth are termed salient poles. These salient
poles create an easy path for the magnetic flux field, thus allowing the rotor to
"lock in" and run at the same speed as the rotating field.
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DC Motors
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Most of the world's adjustable speed business is addressed by DC
motors. DC motor speeds can easily be varied, therefore they are utilized in
applications where speed control, servo control, and/or positioning needs exist.
The stator field is produced by either a field winding, or by permanent magnets.
This is a stationary field (as opposed to the AC stator field which is rotating).
The second field, the rotor field, is set up by passing current through a
commutator and into the rotor assembly. The rotor field rotates in an effort to
align itself with the stator field, but at the appropriate time (due to the
commutator) the rotor field is switched. In this method then, the rotor field never
catches up to the stator field. Rotational speed (i.e. how fast the rotor turns) is
dependent on the strength of the rotor field. In other words, the more voltage on
the motor, the faster the rotor will turn.
The following will briefly explore the various wound field motors and the
permanent magnet (PMDC) motors.
With the shunt wound, the rotor and stator (or field windings) are connected in
parallel. The field windings can be connected to the same power supply as the
rotor, or excited separately. Separate excitation is used to change motor speed
(i.e. rotor voltage is varied while stator or field winding is held constant).The
parallel connection provides a relative flat speed-torque curve and good speed
regulation over wide load ranges. However, because of demagnetization
effects, these motors provide starting torques comparatively lower than other
DC winding types.
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Series Wound Motors
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In the series wound motor, the two motor fields are connected in series.
The result is two strong fields which will produce very high starting torque. The
field winding carries the full rotor current. These motors are usually employed
where large starting torques are required such as cranes and hoists. Series
motors should be avoided in applications where they are likely to lose load
because of the tendency to "run away" under no-load conditions.
Compound motors use both a series and a shunt stator field. Many
speed torque curves can be created by varying the ratio of series and shunt
fields. In general, small compound motors have a strong shunt field and a weak
series field to help start the motor. High starting torques are exhibited along with
relatively flat speed torque characteristics. In reversing applications, the polarity
of both windings must be switched, thus requiring large, complex circuits.
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Stepper Motor
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Step motors are electromechanical actuators which convert digital inputs
to analog motion. This is possible through the motor's controller electronics.
Independent of stepper type, all are devices which index in fixed angular
increments when energized in a programmed manner. Step motors' normal
operation consists of discrete angular motions of uniform magnitude rather than
continuous motion.
Most step motors are used in an open loop system configuration, which
can result in oscillations. To overcome this, either complex circuits or feedback
is employed – thus resulting in a closed loop system.
Stepper motors are, however, limited to about one horsepower and 2000
rpm, therefore limiting them in many applications.
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PMDC Motor
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The predominant motor configuration utilized in demanding incrementing
(start-stop) applications is the permanent magnet DC (PMDC) motor. This type
with appropriate feedback is quite an effective device in closed loop servo
system applications.
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OPEN LOOP/CLOSED LOOP
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In a system the controller is the device which activates motion by
providing a command to do something, i.e. start or change speed/position. This
command is amplified and applied onto the motor. Thus motion commences . . .
but how is this known?
There are several assumptions which have been made. The first
assumption is that power is applied onto the motor and the second is that the
motor shaft is free to rotate. If there is nothing wrong with the system, the
assumptions are fine – and indeed motion commences and the motor rotates.
If for some reason, either the signal or power does not get to the motor,
or the motor is somehow prevented from rotating, the assumptions are poor and
there would be no motion.
Systems that assume motion has taken place (or is in the process of
taking place) are termed "open loop". An open loop drive is one in which the
signal goes "in one direction only". . . from the control to the motor. There is no
signal returning from the motor/load to inform the control that action/motion has
occurred.
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A stepper drive is a perfect example of an open loop system. One pulse
from the control to the motor will move the motor one increment. If for some
reason the stepper does not move, for example due to jamming, the control is
unaware of the problem and cannot make any corrections.
The return signal (feedback signal) provides the means to monitor the
process for correctness. From the automatic pick and place application example
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previously cited, if the shaft cannot rotate to bins B and C, the feedback will
inform the control of an error and the control can activate a light or a horn to
alert the operator of the problem.
When would an application use an open loop approach? First of all, just
think of how simple it would be to hook up – a few wires and no adjustments.
Stepper motors are traditionally employed in open loop systems . . . they are
easy to wire, they interface easily with the user's digital computer and they
provide good position repeatability. Stepper motors, however, are limited to
approximately one horsepower. Their upper speed limit is about 2000 rpm.
The weaknesses of the open loop approach include: It is not good for
applications with varying loads, it is possible for a stepper motor to lose steps,
its energy efficiency level is low and it has resonance areas which must be
avoided.
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Because of additional components such as the
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feedback device,
complexity is considered by some to be a weakness of the closed loop
approach. These additional components do add to initial cost (an increase in
productivity is typically not considered when investigating cost). Lack of
understanding does give the impression to the user of difficulty.
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WHAT IS A SERVO?
What is a servo? This is not easily defined or self-explanatory since a
servomechanism, or servo drive, does not apply to any particular device. It is a
term which applies to a function or a task.
The signal then passes into the servo control or "amplifier" section. The
servo control takes this low power level signal and increases, or amplifies the
power up to appropriate levels to actually result in movement of the servo
motor/load.
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These low power level signals must be amplified: Higher voltage levels
are needed to rotate the servo motor at appropriate higher speeds and higher
current levels are required to provide torque to move heavier loads.
This power is supplied to the servo control (amplifier) from the "power
supply" which simply converts AC power into the required DC level. It also
supplies any low level voltage required for operation of integrated circuits.
As power is applied onto the servo motor, the load begins to move . . .
speed and position changes.
As the load moves, so does some other "device" moves. This other
"device" is a tachometer, resolver or encoder (providing a signal which is "sent
back" to the controller). This "feedback" signal is informing the positioning
controller whether the motor is doing the proper job. The positioning controller
looks at this feedback signal and determines if the load is being moved properly
by the servo motor; and, if not, then the controller makes appropriate
corrections. For example, assume the command signal was to drive the load at
1000 rpm. For some reason it is actually rotating at 900 rpm. The feedback
signal will inform the controller that the speed is 900 rpm. The controller then
compares the command signal (desired speed) of 1000 rpm and the feedback
signal (actual speed) of 900 rpm and notes an error. The controller then outputs
a signal to apply more voltage onto the servo motor to increase speed until the
feedback signal equals the command signal, i.e. there is no error.
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Guide to motion control drives
Introduction
With motion control, there is always feedback of the real position. This is
compared to the reference value and the difference is corrected continuously by
the motion controller’s profile generator.
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Accuracy can be improved if the controller is a high performance motion
controller but in this case, the dynamics and the sample time (generally several
milliseconds) of the standard drive become limiting factors.
In a system with centralized control, one unit contains all the software
and the drives just follow the reference value. There is no intelligence within the
drive.
This means that the cost of the control unit is reduced, as far less
performance is required centrally.
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Comparison between decentralized and centralized systems
*This means that feedback is connected directly to drive. It does not go to PLC
or motion controller for calculation which might cause delay.
– Motion control hardware: this controls the operation of the system; it can be
centralized or decentralized.
– Motor – provides mechanical energy with the required speed and torque to
drive the load in the specified way.
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Drive and motor combination
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The drive and motor are normally supplied as a package to suit the
application. The main drive, motor types and features are described here.
Brush-type DC
The basic principle is the same as in industrial high power DC drives, the
main difference being that there is no magnetizing circuit. Instead, the motor
carries permanent magnets on the stator side. Rotor current and voltage is
supplied by brushes and a commutator. Normally, it is not possible to use the
supply voltage. Instead, a transformer is used to reduce the voltage. Some
drives have a rectifier circuit, while others need an external voltage rectifier.
The electronics are relatively simple and only speed feedback is required
for the speed controller. Brush-type DC drives is one of a small number of
control platforms that actually use a tacho as a feedback device for the speed
reference.
When this type of drive and motor combination is used in motion control,
a pulse encoder is quite often fitted to the motor shaft. Pulses are sent to the
motion controller for calculating the position.
The main players in the drives industry do not use this technology
anymore. Typically these kinds of products are based on old analogue platform.
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Brushless DC
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The power circuit of a brushless DC servo drive is similar to that of an AC
drive. Input current is rectified and filtered in a diode bridge with associated DC-
link capacitance. The inverter unit consists of six power devices.
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Asynchronous servo
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The amount of slip forces current to the rotor determines the torque. This
motor type has a light and small diameter rotor to minimize inertia. This means
that the inertia, which is inversely proportional to acceleration, is lower than in
induction motors, although it is higher than in permanent magnet servo motors.
Suitable control methods are closed loop vector or DTC control. This
method gives performance equal to that of drives with asynchronous servo
motors. The main limiting factor is the motor. This drive can often be referred to
as a servo drive, due to the nature of the motor or a closed loop control for
standard AC induction motors.
Synchronous servo
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Synchronous technology
The drive or amplifier delivers a sinusoidal output modulated from the
DC-link voltage (traditional modulator or an advanced method like DTC). This
makes the power circuit identical to that of a conventional drive. Using
permanent magnet motors, the basic algorithm only needs to produce current
for the torque – no magnetizing current is needed.
Measuring performance
Typical good speed control loop has bandwidth of 100 Hz and torque loop has
800 Hz. Increasing the frequency means that the amplifier tends to loose its
ability to respond. Normally, the bandwidth is measured up to a level where the
output is 3 db less than the reference level.
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– The motor has high power density – there is no rotor current and thus no
build-up of heat in the rotor.
– The motors can run with high temperature rise, for example, at 40 degrees
ambient, temperature rise/class H=125 °C is allowed.
– IP65 is the typical protection degree, compared to IP54 for standard induction
motors.
– High torque overload capability depends on the basic motor design and its
magnetic materials. Generally, synchronous servo motor motors can deliver up
to 2-5 times or more overload during short periods.
– Recent development of drives and motion control systems, along with lower
cost magnetic materials, has increased the market and number of applications
for synchronous servo motor rapidly.
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Synchronous servo motor – principle of
operation
The synchronous servo motor does not have commutator or brushes.
The drive (amplifier) maintains correct current distribution at the right vector
angles and the right angular speed.
These are the forces that build up torque and cause the motor shaft to
rotate. This operation needs a feedback device that senses angular position of
the shaft at all times, enabling the amplifier to set up sine output to the right
angles.
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Special conditions during startup
New motors can sometimes have a difference between the actual rotor
position and that given by the feedback device. This needs to be corrected as
otherwise inaccurate feedback results in the motor not being able to produce full
torque and optimum performance.
Initial startup:
– The drive features phasing error software which identifies the error during the
commissioning run and uses its control algorithm to compensate for the error.
– Some motor producers build in zero phase error during manufacture – this is
the preferred option as it avoids the above tasks.
– When powering up, the rotor position is known if the feedback device (such as
resolvers and some SinCos encoders with communication bus) can give
absolute position within one revolution.
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Traditional speed and current control
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The figure bellow shows the basic principle of speed and current control.
The role of the servo drive or amplifier is to make sure that the motor
speed and torque follows the reference value. The motor´s feedback gives
actual speed to the speed controller. The speed controller is typically a PID
controller comparing reference and feedback signals.
The error signal is passed to the current controller. The current controller,
typically a PI amplifier, sets up the correct current so that the right torque is
available to keep the speed at the reference level.
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Typical servo motors data
Torque Constant
Back EMF
The permanent magnet motor acts like generator and builds up back
EMF voltage which is related to angular speed. Back EMF is opposite to the
supply voltage and is in direct relation to the angular speed.
Torque curve
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– T peak which is maximum torque which is typically 2 to 5 times nominal
torque.
When the speed increases, the back EMF increases. This means there is
a limit where the back EMF would be equal to or higher than the drive’s
maximum output voltage.
On the other hand there are technical solutions that make it possible to
run synchronous motors in field weakening area.
This means that motor needs more current to the motor windings. This is
achieved by increasing the voltage and thus there must be margin between
nominal and maximum voltage. This is also the reason why maximum torque
output starts to decrease when the speed becomes closer to nominal speed.
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Feedback devices
High performance drives often use rotational feedback devices to give:
Resolver
The resolver has a three coil arrangement. The reference signal, for
instance an 8 kHz sine wave, is connected to the rotating part of the device via
a transformer. This enables the coil carrying reference to rotate at the same
speed as the shaft.
Two other coils are placed in 90 degrees phase shift. The rotational coil
induces voltage in these coils. Output signals are fed to the amplifier and the
speed and the position of the rotor is resolved by using these signals.
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Incremental encoders
The basic operation is based on a light source, a disk and a photo cell
(sensor). The disk is installed between the light source and the sensor. The disk
has a very fine mesh, enabling light to be visible or obscured to the sensor. The
sensor output is digitized to form a square pulse when light is seen. When the
disk rotates, the sensor produces a pulse train. The frequency of the pulse train
is in relation to the speed of the axis and the receiving end can calculate this.
There are various specifications for encoders, but for motion control, two
channels plus a zero channel is the most commonly used. Each channel is
typically differential so that the output is A, A inversion, B, B inversion and Z, Z
inversion.
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SinCos encoder
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The absolute position of the rotor is also needed at startup. This can be
established by using a data link (next chapter) or by an additional sine/cosine
channel. This channel provides one full sine and cosine cycle per revolution and
makes it possible to find the rotor position. The Z-pulse position can be checked
by ensuring that the Z pulse is “high” when the sine/cosine channels show zero
position.
Interpolation within one cycle in SinCos encoder (1024 cycles per revolution)
SinCos encoders are also available with data bus. A data bus can give
absolute position after power-down, a common requirement in today’s
applications. This eliminates the need for homing routines after power-down.
This makes the machine design simpler and increases the machine’s
production time. Data of absolute position is also used at startup to identify the
rotor position.
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Motion control
General
Motion control covers many different functions. This topic deals with
basics of speed and motion and functional differences.
Speed controlled drives change speed mainly in steps and the response
is not very fast. Speed reference commands are given in certain levels and the
drive frequently has its own ramp to move from one level to another. The drive
does not follow a continuously changing reference track.
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Motion control formulas and profiles
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The following formulas are the key motion parameters.
Motion profile
The illustration shows how the position advances against a set target. It
also shows the velocity profile and the corresponding acceleration and
deceleration rates.
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Position interpolator
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The position interpolator calculates the speed from which the drive can
decelerate to a stop within the target distance, using the defined deceleration
reference. The calculated speed is used to generate an optimized position
reference, which guides the drive to its target position. The illustration refers to
shows how the position interpolator generates a position reference.
– Acceleration
– Run speed
– Deceleration
– Target position
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ACSM1 Control Panel
Features
Overview
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Glossary of terms
Acceleration
Accuracy
A front end processor which receives data from both upstream and
downstream equipment and makes changes without reference to externals
controls.
Actual position
AC servo
Alarm
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Analog servo
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Most commonly found in hydraulic and similar systems, an analog servo
uses analog control and feedback systems such as voltage variation and
changes in pressure.
Analog signal
A signal that varies in step with the parameter being measured. Typical
examples include a 0-10 volt motor control signal and a pneumatic control
pressure.
Axes of motion
Axis
Brushless servo
Bus
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A series of conductors acting as path to send information between
control elements and components.
Centralized control
A system with the software located in one physical unit. All input
information from sensors and feedback devices are connected to this unit and
control commands are sent from it.
Circular interpolation
Collision detection
Commutation
Ensuring that the correct motors phase receive the correct currents or
voltages. It can be done electromechanically via the brushes and commutator
as in brush type motors, or electronically as used in brushless motors.
Converter
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Co-ordination
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Integration two or more axes of motion to produce an otherwise
impossible motion. Sensors and other internal or external commands may also
be used to assist the movements.
Current controller
Cut to length
DC bus
Deceleration
Decentralized control
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time required to read a specific set of instructions and return to the initial
instruction.
Diagnostic code
Digital servo
A servo motor that uses binary code for all calculations and feed back.
Digital signal
Drive
Efficiency
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Electronic clutch
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A method of using electronic cams or gearing functions to produce a
slave profile based on a master position.
Electronic gearing
Encoder
Encoder resolution
EnDat
A standard interface for serial data transfer, particularly for position and
parameters.
EMC/CE
European Directive that sets standards and limits for conducted and
radiated emissions. Drives may need line filters or other components to conform
to the directive.
Emergency stop
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– It must override all other functions and operations under all conditions
Ethernet
A very widely used open networking standard. Normally used for office
automation and operating at a communications speed of 1.5 megabits/sec,
newer versions are capable of up 100 megabits/sec.
Event
Fault
Feedback
Feedback device
Give information of the actuators’ real speed and position to the motion
controller.
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Feed forward
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A method that compensates for known errors in a control loop. It
depends only on the command, not the measured error.
Fiber optic
A glass or plastic fiber guide that transmits light that is translated into
current or used to determine the open/close state of a current path.
FieldBus
Flying restart
Following error
The difference between the commanded position of an axis and its actual
position, a difference that varies with the speed of the axis.
Frameless motor
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Gantry
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An overhead framework that can move in the X, Y, and/or Z axes,
carrying a variety of tools or devices to perform tasks.
G code
A switch that alters the electric circuit associated with the machine or
equipment and which is operated by some part or motion of a power-driven
machine or equipment.
Holding brake
Home position
Homing
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IGBT insulated-gate bipolar transistor
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The IGBT is usually used in switching power supplies and in motor
control applications and forms the basis of the most modern and capable
variable speed drives.
Inching
Indexer
Indexing
Inertia
In position window
Interpolation
Inverter
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Jerk limitation
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A feature that limits the rate of change of acceleration with the aim of
eliminating mechanical jerking during speed changes.
Jog
KP
Velocity Loop Proportional Gain. Determines how much velocity error the
servo system will allow during a move. See also: Tuning
KV
Length units
The linear units for programming and configuring an axis, often defined in
inches, feet, meters, or millimeters.
Linear
The time required to calculate the process variable from the following
error.
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Motion control
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Any tool or actuator controlled by motion software. The system can be
hydraulic, pneumatic, electronic or any combination of these. Whatever the
system, the profile for movement is written into the software code and the
actuator has to follow this as accurately as possible. The actual movement and
the reference are always compared by feedback devices and the motion
controller aims to minimize the discrepancy.
Modulo Value
The position increment at which a rotary axis position returns to 0, ie, 360
degrees.
Noise
Offset
Open architecture
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Overcurrent
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A current above the rated current of the drive, applied to maintain a set
position or move to a new position.
Override
The act of forcing an axis to move during a fault condition. It is often used
to force an axis to move away from an over travel limit switch.
Overshoot
Over temperature
A warning or alarm that indicates that a motor or drive is too hot, most
often the result of too high current demand.
PC
Personal Computer
Phasing
Adjusting the position of one axis with respect to others, to correct for
small registration problems, usually done while the axes are moving.
PLC
PLS
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Point-to-point wiring
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Wiring each drive directly to the PLC. The method cuts out the
communication delays introduced by a network.
Position error
Error caused when the difference between the actual position and the
command position is greater than a set amount.
Positioning
Position loop
Printmark synchronization
Profile
See PLS
Programming language
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Protocol
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A specified method of encoding information for transmission.
Pulse-width modulation
Quadrature
Rated speed
Real master
Rectifier
Referencing
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Regen
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A motor /drive system can produce regenerative power during
deceleration, power that can be fed to other machines on the network.
Resolver
Rollfeed
A function that keeps the linear speed of the feed material constant as
the diameter of the rotary axis changes.
Rotary
Safe off
A method of ensuring that power will not travel from the drive to the
motor.
S curve
Sequence of operation
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SERCOS
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Serial Real-time Communications Standard. An open communications
protocol for motion-control networks, with transmission speeds over a fiber-optic
cable of up to 4 megabits/sec.
Serial communications
Servo mechanism
Servo motor
A motor that can be precisely controlled. The drive that powers it gets
accurate feedback on the motor’s position from a resolver or encoder.
Shielded cable
A cable that has a metallic sleeve encasing the conductors at its center.
The metal sleeve is grounded to prevent electrical noise affecting the signals on
the cable.
SinCos
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SSI
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Acronym for Serial Synchronous Interface. A type of multi-turn absolute
encoder that sends position information as a serial string in Gray code format.
Synchronization
Tachometer
Task
TCP/IP
Teach position
The position of an axis that is “taught” into the motion control program.
Once the axis is moved to the desired position, the “teach position” is entered
into the motion program automatically by the control.
Telegram
Tele Service
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TN
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Velocity Loop Integral Action Time. Associated with KP. When the
measured velocity moves beyond the tolerance value set in KP, TN determines
how quickly the drive will bring the velocity back within the specified tolerance.
See also: Tuning
Torque limitation
Tuning
Twisted pair
Two wires twisted together with the aim of eliminating electrical noise.
VxWorksTM
Velocity
Velocity loop
Virtual master
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DL2126B
Warning
2126B
An error condition received from a drive or a controller, indicating that a
fault will occur if the problem is not rectified.
Wintel
The point at which the encoder position and the physical position of a
servo motor line up.
60
DL2126B
2126B
References:
Access:
http://www05.abb.com/global/scot/scot201.nsf/veritydisplay/6eb89ddd33db21c1c125761100365c1c/$file/e
n_acsm1_control_panel_ug_b.pdf
Access:
http://www05.abb.com/global/scot/scot201.nsf/veritydisplay/bbc682806eb5be78c125727c0043f50b/$file/te
chnical_guide_no.9_3afe68695201_en_revb.pdf
Access:
http://www.baldor.com/pdf/manuals/1205-394.pdf
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