SANYO DENKI TECHNICAL REPORT No.

8 November-1999
New Products Introduction

AC Servo Amplifier "PY"

Izumi Yui Hidenao Shoda Tsuyoshi Kobayashi
Hiroyuki Kitazawa Yoshihiko Oouchi

1. Introduction

Since it developed the first AC servo system "BL82 SERIES" in Japan in 1982,
Sanyo Denki has been releasing a number of servo amplifiers. The "867Z," which hit the
market in 1993, is particularly remarkable. It is a fully digitally controlled servo amplifier.
Since then, on the basis of the "867Z," the company has been providing the market
with different series: "PZ," which meets servo motors having different capacities over
a wide range from 30W to 30kW; "PU," which is designed for small-capacity servo
motors less than 1kW; and "PV," which is based on a PU but with enhanced functions.
However, market demands these days cover a wide range, including small size, low cost,
high performance, and conformance to international standards. This makes it impossible
to meet those requirements with traditional series alone.

The "PY" servo amplifier series is designed to meet this wide variety of market
requirements.

Particular attention is paid to amplifiers designed to drive 30W to 1.5kW motors,

which amplifiers represent a large market size. For these products, the company
provided "PY2" amplifiers, which are compact and low-cost but with the same
performance as conventional models. For the increasingly electrical hydraulic machines
market, the company provided "PY0" amplifiers, which cover up to 15kW motors in an
attempt to meet various market requirements. "PY" is also suitable for use jointed to
the company's linear servo motors.

This paper describes the features and characteristics of "PY" servo amplifiers.

2. Features and main characteristics of AC servo

amplifiers "PY"

2.1 Features of the control unit

The control unit of the "PY" servo amplifier centers around two processors: DSP
and CPU. The portion connected directly to sequence interface alarm processing and
other customer controllers is handled by the CPU. Position loop operations, speed loop
operations, and various corrections, which are the basic operations conducted by the
servo amplifier, are handled by a special-purpose DSP.

The multiple interface, at which Sanyo Denki is strong, is implemented only on the
CPU. The operation unit is made independent to achieve high performance, in an
attempt to increase development efficiency.

For the "PY" servo amplifiers, the authors proceeded further with inter-processor
interface technology that the company had cultivated through its "867Z" and "PZ"
servo amplifiers, and enhanced the capability of the processor itself in order to greatly
reduce operation time.

This dramatic reduction of operation time allowed the authors to obtain a frequency
characteristic about four times as high as that of traditional servo amplifiers as shown
in Table 1.

Fig.1 Configuration of the control unit

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 2.2 Features of the control power supply and power unit

The control power supply of the "PY" servo amplifier incorporates a switching power
supply transformer consisting of a thin-film print coil, instead of a normal winding
transformer, which results in the use of fewer parts because of highly stable output
voltage and a compact control power supply.

Similarly, the use of a switching power device consisting of integrated peripherals for
driving the transformer as well has helped reduce the control power supply.

Furthermore, every one of the "PY" servo amplifier series employs an intelligent
power module (IPM). This has reduced the number of peripherals and increased
reliability.

Fig.2 "PY2" servo amplifier

Table 1 Comparison of the "PY" series and older servo amplifier models
in terms of performance and functions
Specifications and
PU PV PZ PY
functions
AC200V
AC100/
Voltage system AC200V AC200V (100VAC is
200V
possible for PY2)
Number of power 1
1 3 3 /1
phases (3 for 50A)
Main power/
Separate Separate Separate Separate
control power
15/30/50/100A
Amplifier output 15/30/50/100A
15/30/50A 15/30A 150/300
capacity 150/300A
/600/900A
Applicable motor
30 1000W 30 1000W 30 30000W 30 15000W
capacity
Position/speed Position/speed Position/speed Position/speed
Control mode
control /torque control /torque control /torque control
Incremental 2000 4P/R 2000 4P/R 2000 4P/R 2000 4P/R
Basic type (parallel) (parallel) -1 (parallel) -1 (parallel) -1
Feedback
specifications Absolute
8192P/R (serial) 2048P/R (serial) 2048P/R
type -2 (serial) -2
Operating
0 55 C 0 55 C 0 55 C 0 55 C
temperature
Operating 90% maximum 90% maximum 90% maximum 90% maximum
Operating humidity (non-condensing) (non-condensing) (non-condensing) (non-condensing)
conditions Vibration
resistance 4.9m/S 2 4.9m/S 2 4.9m/S 2 4.9m/S 2

Impact
resistance 19.6m/S 2 19.6m/S 2 19.6m/S 2 19.6m/S 2

Built-in Built-in
Built-in tray type Built-in tray type
Structure book-type power book-type power
power supply power supply
supply supply
Front/rear
Method of installation (rear only for Rear Front/rear Front/rear
50A)
Frequency
characteristics 50Hz or more 100Hz or more 100Hz or more 400Hz
Perform-ance (J L =J M )
Maximum command
600kpulse/s 600kpulse/s 500kpulse/s 2Mpulse/s
pulse frequency
Regeneration Internal Internal Internal Internal
Dynamic brakes
Encoder dividing output
Speed acceleration/
Built-in
deceleration
functions
Jogging
Electronic gear
Internal speed
command

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 Position and
Control mode speed/position;
switchover torque/speed
and torque
Auto-tuning

(Two-stage
Programmable filter (notch filter + (notch filter +
(LPF) notch filter +
LPF) LPF)
LPF)
Full-closed loop
capability (Optional)

PC graphic display
capability
Parameter change Operator Operator Operator Operator
Communication ability
with PC
Accessory
Connector type Accessory Accessory Accessory (Optional for
PY2)
Remote operator Optional Optional Optional Optional
Relay cable

Options (PY2 with an

Regenerative unit external
(resistor) regenerative
resistor)
Recommendable Recommendable Recommendable Recommendable
Line noise filter
model available model available model available model available
PC interface DOS Windows 95 DOS Windows 95
CE UL
(Authorization
Safety standards CE UL scheduled to be
achieved for
PY2)
*1:The *1:The *1:Conforms to
appropriate one appropriate one 500 to 65535
Other can be chosen can be chosen 4P/R.
from among 2000 from among 512 *2:The
to 4096 4P/R. to 8192 4P/R. appropriate one
*2:The can be chosen
appropriate one from among 2048
can be chosen to 2097152 P/R.
from among 8192
and 32768 P/R.

2.3 Functions

For "PY" servo amplifiers, the authors combined a "PZ" servo amplifier with
market-required functions and additional features listed below.
(1)Control mode switchover: While operation, the user can change position, speed,
and torque controls.

(2)Full-closed loop capability (optional): The amplifier can contain an external

incremental encoder processing circuit to perform positioning in a full-closed manner.

(3)Incremental pulse generation: Even when a sensor with only an absolute output
(serial output) is used - such as Sanyo Denki's ABS-E or ABS-RII - the amplifier can
generate incremental pulses to perform positioning on the customer controller without
a special receiving circuit.

The functions listed below are scheduled to be added one by one.

(4)Observer: This function estimates turbulence applied to the equipment and servo
system on the basis of current and speed, thus inhibiting the turbulence.

(5)Real-time auto-tuning: When the load inertia changes while operation, such as in
the case of a robot, this function automatically sets the parameters in the servo
amplifier according to those changes.

(6)Auto notch filter: This function automatically makes settings in the amplifier for

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the frequency of the notch filter, which the user used to set with a remote operator.

3. Features of the AC servo amplifier "PY2"

The following is a summary of the features of the "PY2" servo amplifier, designed
with the elements of the "PY" servo amplifier as a servo amplifiers designed to drive
motors 30W to 1.5kW.

(1)Simplified input power supply: Taking account of the MCCB which is always
installed at input position of servo amplifier unit, the "PY2" omitted fuses in main path,
instead of others having fuses. As optimization of printed circuit board layout and
arrangement, it was able to remove common mode capacitor which is usually contained
in conventional models.

(2)Simplified control power supply: The control power supply was reduced in size by
reducing the number of circuit components because of the higher withstand voltage of
the components and by removing the need for a ± 15V power supply due to the
ingenious circuit design.

(3)Review of the structure unit: A power connector has been introduced to

accommodate a compact die-cast radiator fin to reduce costs.
The implementation of these features resulted in a cut in volume by about 50%,
which used to be considered difficult (Table 2).

Table 2 Comparison of PY with earlier servo amplifier models in terms of volume

15A 30A 50A

205 235 205 235 205 235

50 50 75
(mm) (mm) (mm)
" PZ " series
(Note )
2408.8cm 3 2408.8cm 3
4690.5cm 3

205 235 205 235 205 235

50 50 75
" PY " series (mm) (mm) (mm)
" PY0 " type
(Note )
2408.8cm 3 2408.8cm 3
4690.5cm 3

168 130 168 130 168 130

50 70 100
" PY " series (mm) (mm) (mm)
" PY2 " type
1092.0cm 3 1528.8cm 3 2184.0cm 3

Size
reduction 45.3% 63.5% 46.6%
rate

Note: Includes the volume of the cooling fin for ducting at the rear of the unit. Other models are
designed so as to radiate heat from the side.

4. Conclusion

This paper has so far presented the features of the "PY" servo amplifier series,
which is the core of Sanyo Denki's AC servo amplifier line-up.

The authors are confident that the "PY" servo amplifier series is good enough to
meet the requirements for the fields of semiconductor-making units and electrically
driven hydraulic units, along with machines for general industries, which are expected
to see growing markets.

To remain competitive in the servo amplifiers market, where competition is expected

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to grow more and more cut-throat, the authors are determined to develop further the
technologies that they have cultivated through the development of "PY" servo
amplifiers, while also aiming to develop applications capable of meeting a wide range of
interface requirements.

Izumi Yui
Joined company in 1986
Servo Systems Division, 2nd Design Dept.
Worked on development and design of servo amplifiers

Hidenao Shoda
Joined company in 1990
Servo Systems Division, 2nd Design Dept.
Worked on development and design of servo amplifiers

Tsuyoshi Kobayashi
Joined company in 1991
Servo Systems Division, 2nd Design Dept.
Worked on development and design of servo amplifiers

Hiroyuki Kitazawa
Joined company in 1994
Servo Systems Division, 2nd Design Dept.
Worked on development of
uninterruptible power supplies,
then on development and design of servo amplifiers

Yoshihiko Oouchi
Joined company in 1984
Servo Systems Division, 2nd Design Dept.
Worked on development and design of servo amplifiers

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fig.1 Configuration of the control unit

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fig.2 "PY2"servo amplifier

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