This document discusses electric drives and servo systems. It defines an electric drive as a machine that converts electrical energy to mechanical energy and provides electrical control of processes. A servomotor is defined as a rotary or linear actuator that allows precise control of position, velocity, and acceleration using a motor, position feedback sensor, and controller. Servomotors are used in robotics, CNC machinery, and automated manufacturing. The document goes on to discuss types of servomotors including AC vs DC motors and their advantages and disadvantages. It also discusses DC motors, stepper motors, and direct drive actuators.
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UNIT-3 Robot Drive Mechanisam
This document discusses electric drives and servo systems. It defines an electric drive as a machine that converts electrical energy to mechanical energy and provides electrical control of processes. A servomotor is defined as a rotary or linear actuator that allows precise control of position, velocity, and acceleration using a motor, position feedback sensor, and controller. Servomotors are used in robotics, CNC machinery, and automated manufacturing. The document goes on to discuss types of servomotors including AC vs DC motors and their advantages and disadvantages. It also discusses DC motors, stepper motors, and direct drive actuators.
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Unit-2
Electric Drives and Servo System
• An electrical drive is defined as a form of machine equipment designed to convert electrical energy into mechanical energy and provide electrical control of the processes. Classification of Motor Drives Servomotor • A servomotor is a rotary actuator or linear actuator that allows for precise control of angular or linear position, velocity and acceleration.
• It consists of a suitable motor coupled to a sensor for
position feedback. It also requires a relatively sophisticated controller, often a dedicated module designed specifically for use with servomotors. • Servomotors are not a specific class of motor although the term servomotor is often used to refer to a motor suitable for use in a closed-loop control system.
• Servomotors are used in applications such as
robotics, CNC machinery or automated manufacturing. Types of Servomotor AC vs DC Motors • A.C. motors are powered from alternating current (A.C.) • while D.C. motors are powered from direct current (D.C.), such as batteries, D.C. power supplies or an AC-to-DC power converter. ... • A.C. induction motors do not use brushes; they are very rugged and have long life expectancies Why is AC motor preferred over DC? • The main advantage of Ac motor over Dc motor is that the speed - torque characteristic of AC motor is very close to the ideal characteristic. • Torque of Ac motor is constant up to certain speed and then decreases, but in case of Dc motor torque linearly decreases as speed increases Can AC motors run on DC?
• An AC motor cannot run on an DC SUPPLY.. The DC
series motor can run on both AC &DC supply .It is also called as an Universal motor. ... Because DC can not produce rotating magnetic field What is the advantage of DC over AC?
• DC has advantages over AC in applications where
battery, solar, or fuel cell power is present. It also has the advantage of better motor speed control than AC. Disadvantages of DC motors:
• High initial cost.
• Increased operation and maintenance cost due to presence of commutator and brush gear. • Cannot operate in explosive and hazard conditions due to sparking occur at brush ( risk in commutation failure) DC Motor • A DC motor is any of a class of rotary electrical machines that converts direct current electrical energy into mechanical energy. • The most common types rely on the forces produced by magnetic fields. • Nearly all types of DC motors have some internal mechanism, either electromechanical or electronic, to periodically change the direction of current flow in part of the motor. DC Motor Principle
• A machine that converts DC electrical power into
mechanical power is known as a Direct Current motor. DC motor working is based on the principle that when a current carrying conductor is placed in a magnetic field, the conductor experiences a mechanical force. Brushless DC motor and a brushed DC motor Principal: • The principle behind the internal working of both a brushless DC motor and a brushed DC motor are essentially the same. • When the motor windings become energized, a temporary magnetic field is created that repels and/or attracts against permanent magnets. • This force is converted into shaft rotation, which allows the motor to do work. • As the shaft rotates, electric current is routed to different sets of windings, maintaining electromotive repulsion/attraction, forcing the rotor to continually turn. Construction Differences
• Brushes inside electric motors are used to deliver
current to the motor windings through commutator contacts. Brushless motors have none of these current-carrying commutators. The field inside a brushless motor is switched via an amplifier triggered by a commutating encoder, such as an optical encoder. • Windings are on the rotor (rotating part of motor) for brush motors and on the stator (stationary part of motor) for brushless motors. Brush Motor: Windings on rotor, magnets on stator By positioning the windings on the outside stationary portion of the electric motor, the need for brushes can be eliminated
Brushless Motor: Windings on stator, magnets on rotor
What is DC current used for?
• Direct current (DC) is the unidirectional flow of
an electric charge. A battery is a prime example of DC power. Direct current may flow through a conductor such as a wire, but can also flow through semiconductors, insulators, or even through a vacuum as in electron or ion beams. AC Motor Stepper Motor Difference Between Synchronous Motor And Induction Motor • AC motors can be divided into two main categories – • Synchronous motor • Asynchronous motor. An asynchronous motor is popularly called as Induction motor. • Both the types are quite different from each other. Major differences between a synchronous motor and an induction motor are discussed further. Constructional Difference • Synchronous motor: Stator has axial slots which consist stator winding wound for a specific number of poles. • Generally a salient pole rotor is used on which rotor winding is mounted. • Rotor winding is fed with a DC supply with the help of slip rings. A rotor with permanent magnets can also be used. • Induction motor: Stator winding is similar to that of a synchronous motor. It is wound for a specific number of poles. • A squirrel cage rotor or a wound rotor can be used. In squirrel cage rotor, the rotor bars are permanently short- circuited with end rings. • In wound rotor, windings are also permanently short- circuited, hence no slip rings are required. Difference In Working • Synchronous motor: Stator poles rotate at the synchronous speed (Ns) when fed with a three phase supply. • The rotor is fed with a DC supply. The rotor needs to be rotated at a speed near to the synchronous speed during starting. • If done so, the rotor poles get magnetically coupled with the rotating stator poles, and thus the rotor starts rotating at the synchronous speed. • Synchronous motor always runs at a speed equal to its synchronous speed. • Induction motor: When the stator is fed with two or three phase AC supply, a Rotating Magnetic Field (RMF) is produced. • The relative speed between stator's rotating magnetic field and the rotor will cause an induced current in the rotor conductors. • The rotor current gives rise to the rotor flux. • According to Lenz's law, the direction of this induced current is such that it will tend to oppose the cause of its production, i.e. relative speed between stator's RMF and the rotor. • Thus, the rotor will try to catch up with the RMF and reduce the relative speed. • Induction motor always runs at a speed which is less than the synchronous speed. Direct Drive Actuator • Theoretically, the term ‘direct drive’ can be applied to any motor which directly drives a load or rotor without transmission elements such as gears, pulleys or chains. • More usually, the term refers to brushless, permanent-magnet, synchronous motors which transmit their torque directly to their load or rotor. How it works • Direct drive motors work in much the same way as most brushless DC motors. Magnets are attached to the motor’s rotor and windings are arranged on the motor’s stator. • As the windings are energized, they produce electromagnetic fields which either attract or repel the rotor’s magnets. • Appropriate switching or ‘commutation’ of power to the windings produces a controlled motion. • There are linear and rotary direct drive motors but rotary versions are by far the most frequently used. • Direct drive motors usually have a large number of poles (>30 and sometimes >100) which allows them to produce high torque at no or low speed (usually <1000rpm). • Direct drive motors with diameters of >1m are possible, able to produce torque of >10,000Nm. • Many direct drive motors are ‘frameless’ which means that they are supplied without a housing, bearings or feedback sensor. • This allows machine builders and system integrators to streamline their housing, shaft and bearing design to optimize overall size, shape, weight and dynamic performance. • The torque-to-inertia ratio is also higher in direct drive motors than traditional motor arrangements and there is a low electrical time constant. • This means that the torque is applied quickly when voltage is applied, achieving what control engineers refer to as good servo ‘stiffness’. Advantages of the direct drive approach are • Excellent dynamic performance and accurate control of position and/or speed • No backlash or wear • High reliability due to low part count & elimination of gears, pulleys, seals, bearings etc. • Compact – with low axial height and large bore feasible • High torque to inertia ratio and high torque to mass ratio • Low torque ripple or ‘cogging’ . Torque ripple is an effect seen in many electric motor designs, referring to a periodic increase or decrease in output torque as the motor shaft rotates. • It is measured as the difference in maximum and minimum torque over one complete revolution, generally expressed as a percentage. • High torque at low speeds • Energy efficiency from eradication of losses in intermediate mechanical elements • Low acoustic noise or self-induced vibration • No/low maintenance • Low cooling requirements due to advantageous thermal geometry • Relatively large air gaps and hence good resistance to shock and resilience in dirty environments. Applications • Direct drive applications are found in a antenna systems (e.g. vehicle mounted satellite communications), surveillance & CCTV cameras, scanners, telescopes, electro-optics, rate tables, radar and weapons systems. • There are also applications in CNC machine tools, packaging equipment, robotics and even high end record turntables. Mathematical Modeling • Modeling is important in process industries. There is no definite algorithm to construct a mathematical model that performs better in all situations. • Modeling is viewed as a state-of-art technique. It involves mathematical knowledge of the system of interest and making the knowledge to create models. • Researchers have different knowledge base, and a unique way of looking at problems. Various researchers may come up with variety of models for the same system. • There is usually plenty of room for argument about which model is “best". • It is very important to understand at the outset that for any real system, no “perfect” model exists. All the models are subjected to realistic assumptions. • A mathematical model is defined as the set of equations that describes the behaviour of the system. • It is the art of translating problems from an application area into tractable mathematical formulations whose theoretical and numerical analysis provides insight, answers and guidance useful for the originating application.
• Developing a precise model of the system is
difficult, but the model validates if it describes the dominating dynamic properties of the system. • Modeling can be performed using experimental data referred to as system identification and by physical principles. A model may consist of algebraic, differential, or integral equations, stochastic processes, geometrical structures, etc. • Mathematical modeling increases the understanding of the system, predicts the future system behaviour, carry technical and quantitative computations for control design from which optimization can be done. Various steps involved in developing dynamic model of a system are as follows • Step 1 :Define System Boundaries • Step2 : Make Simplifying Assumptions • Step3 : Formulate the balance equations • Step4 : Draw a block diagram involving all inputs, outputs, parameters. • Step5 : Present the Model in State Space or transfer Function form • A general model exists which includes the system of interest as a special case, but it is very difficult to compute with or analyze the general model. • The goal is then to simplify or make approximations to the general model which will still reflect the behaviour of the particular system of interest. • The scientific method of modeling process is given below. • Step 1 : Make general observations of phenomena • Step 2 : Formulate a hypothesis • Step 3 : Develop a method to test hypothesis Step 4 : Obtain data • Step 5 : Test hypothesis against data • Step 6 : Attempt to confirm or deny hypothesis • Specific reasons for modeling is related in one way or other with the following two categories. First category is to gain understanding. • A mathematical model accurately represents some behaviour of a real-world system of interest which can often gain improved understanding of that system through the analysis of the model. • Furthermore, in the process of building the model, certain factors are most important in the system, and how different parts of the system are related. • Second category is to predict or simulate. • Very often it becomes mandatory to know how a real-world system behaves, as in the case of nuclear reactor, space flight etc. • It is expensive, impractical, or impossible to experiment directly with the system. • Modeling is an important task to be carried out in such situations and based on the mathematical model, computer simulations can be performed before implementing the same on hardware. • A reasonable trade off exists between accuracy, cost and flexibility. • Increasing the accuracy of a model generally increases cost and decreases flexibility. • The goal in creating a model is usually to obtain a sufficiently accurate and flexible model at a low cost. Flow diagram of Modeling • The flow diagram of modeling process is shown in Figure . • Real world data represents quantitative measurements of the system of interest. • This data is processed and the information pertaining to the real world data have been collected. • Based on the collective information of data obtained, models have to be formulated or constructed. Formulated Model is analyzed and mathematical results are obtained. • Interpretation on the results is carried out and predictions on input-output behaviour of the system under consideration were studied. The obtained results with the formulated model are tested with real world data. • Mathematical modeling is indispensable in many applications, successful in many further applications, gives precision and direction for problem solution , enables a thorough understanding of the system modelled, prepares the way for better design or control of a system and allows the efficient use of modern computing capabilities. • Modeling finds its applications in Anthropology for Modeling, classifying and reconstructing skulls, in Archaeology for Reconstruction of objects from preserved fragments, in Artificial intelligence for Computer vision, Image interpretation, Robotics, Speech recognition, Optical character recognition and Reasoning under uncertainty, in Arts for Computer animation (Jurassic Park), in Astronomy for Detection of planetary systems, correcting the Hubble telescope, Origin of the universe and • Evolution of stars, in Biology for Protein folding, Human genome project and Population dynamics, in Chemical engineering for Chemical equilibrium and Planning of production units, in Chemistry for Chemical reaction dynamics, Molecular modeling and Electronic structure calculations, in Computer science for Image processing, Realistic computer graphics (ray tracing), Criminalist science, Finger print recognition and Face recognition, in Economics for Labour data analysis, in Electrical engineering for Stability of electric circuits, Microchip analysis, Power supply network optimization, in Finance for Risk analysis and Value estimation of options, • In Fluid mechanics for Wind channel and Turbulence, in Geosciences for Prediction of oil or ore deposits, Map production, Earth quake prediction, in Internet for Web search and Optimal routing , in Linguistics for Automatic translation, in Materials Science for Microchip production, Microstructures and Semiconductor modeling, in Mechanical engineering for Stability of structures (high rise buildings, bridges, air planes), Structural optimization and Crash simulation, in Medicine for Radiation therapy planning, Computer-aided tomography, Blood circulation models, in Meteorology for Weather prediction, Climate prediction (global warming, what caused the ozone hole), in Music for Analysis and synthesis of sounds, • In Neuroscience for Neural networks, Signal transmission in nerves, in Pharmacology for Docking of molecules to proteins, Screening of new compounds, in Physics for Elementary particle tracking and Laser dynamics, In Political Sciences for Analysis of elections, in Space Sciences for Trajectory planning, Flight simulation and Shuttle re-entry, in Transport Science for Air traffic scheduling, Taxi for handicapped people and Automatic pilot for cars and airplanes. • Steady state occurs after the system becomes settled and at the steady system starts working normally. • Steady state response of control system is a function of input signal and it is also called as forced response. • Steady State VS Transient State: Basically every system has a transient and a steady state. • The steady state is the state that is established after a certain time in your system. • The transient state is basically between the beginning of the event and the steady state. Fundamentals of Servo Motion Control • The fundamental concepts of servo motion control have not changed significantly in the last 50 years. • The basic reasons for using servo systems in contrast to open loop systems include the need to improve transient response times, reduce the steady state errors and reduce the sensitivity to load parameters 9592048025. • Improving the transient response time generally means increasing the system bandwidth. • Faster response times mean quicker settling allowing for higher machine output. • Reducing the steady state errors relates to servo system accuracy. • Finally, reducing the sensitivity to load parameters means the servo system can tolerate fluctuations in both input and output parameters. • An example of an input parameter fluctuation is the incoming power line voltage. • Examples of output parameter fluctuations include a real time change in load inertia or mass and unexpected shaft torque disturbances. • Servo control in general can be broken into two fundamental classes of problems. • The first class deals with command tracking. It addresses the question of how well does the actual motion follow what is being commanded. • The typical commands in rotary motion control are position, velocity, acceleration and torque. For linear motion, force is used instead of torque. • The part of servo control that directly deals with this is often referred to as “Feedforward” control. • It can be thought of as what internal commands are needed such that the user’s motion commands are followed without any error, assuming of course a sufficiently accurate model of both the motor and load is known. • The second general class of servo control addresses the disturbance rejection characteristics of the system. • Disturbances can be anything from torque disturbances on the motor shaft to incorrect motor parameter estimations used in the feedforward control. • The familiar “P.I.D.” (Proportional Integral and Derivative position loop) and “P.I.V. ” (Proportional position loop Integral and proportional Velocity loop) controls are used to combat these types of problems. • In contrast to feedforward control, which predicts the needed internal commands for zero following error, disturbance rejection control reacts to unknown disturbances and modeling errors. • Complete servo control systems combine both these types of servo control to provide the best overall performance. Hydraulic Piston Servo Robot Selection • According to Bosch Rexroth, the evaluation criteria you should follow is an outline referred to as LOSTPED— load, orientation, speed, travel, precision, environment and duty cycle.
• Using the LOSTPED approach can help you avoid
the common mistake of purchasing a high- performance SCARA robot with all the features you may think you need when your application really only needs a simpler Cartesian system. • “With a Cartesian robot, the building blocks for a basic system can be purchased and then later customized. Mounting brackets, actuators, motors and controls can be changed as application needs change,”
• If the workspace is tight, a compact SCARA robot
is likely more suitable. But if space is not an issue, a simpler Cartesian system can often be built without all the extra features included in a SCARA or six-axis design. • Application complexity is also an issue to consider. For example, a six-axis robot can move in all the planes that a human arm does. • So, for applications where there is a mechanical interference, such as a box in a corner with parts inside, a six-axis arm can bend to reach in and grab that part more easily.
• However, in a pick-and-place application with a
20 kg payload and no need for high accuracy, both a SCARA and a Cartesian robot could handle the application. “But a 20 kg payload is at the upper end of a SCARA robot’s capabilities, requiring more costly controls and components,”. • “With a Cartesian robot, a 20 kg payload is no problem, which makes it possible to save money by downsizing the mechanics, using smaller components, and less complex controls.”
• Cartesian robots also make sense when the
application involves long travel spans, he adds. For example, if the X-axis of robotic travel needs to be, say, 10 meters for an automated storage and retrieval system, a gantry system can be constructed from linear modules. But that length of travel cannot be handled by a SCARA or six-axis system. Computer Controlled Robot Computer Controlled Robot Motion Control There are two modes to control this robot arm, first is manual by dragging the track bars that controls a specific servo such as
• Gripper: click open & close button to open
and close the robot gripper.
• Base: Drag the tracking bar right & left or even
use keyboard arrows (right/left) to move the base right and left. • Shoulder: Drag the tracking bar right & left or even use keyboard arrows (up/down) to move the shoulder Up and Down
• Elbow: Drag the tracking bar right & left or
even use keyboard keys (w/s) to move the elbow motor Up and Down Motion Record • Once you want to automate the movement of the robot arm you have to record the position in every step by clicking "Rec. Position" Button or press (R) in keyboard, then the application will take care of it. • In every step you record the application detects the moved motor position and save it inside a list separately. • By clicking the button "Start Auto mood" the application will send those saved positions in a form of sequence orders. Monitoring • A graphical interface is there that draws every step in a graph to let the user notes any unusual change might happen, at the same time there is a table of data on the right side gives the specific angle and the accurate time for its move.
• So by using these features, any movements can be composed
and then send it to the Robotic Arm as a task, as they exactly do in manufacturing automation.