Servo Drives

State of the Art

and Modern Developments

Prof. Dr.-Ing. J. M. Pacas, Institut fr Leistungselektronik und El ektrische Antri ebe,

Univer si tt Si egen
Prof. Dr. -Ing. R. M. Kennel, Lehrstuhl fr elektr ische Maschinen und Antriebe,
Bergische Un iversitt Wuppertal
Outline
General Requirements, State of the Art,
Structure and Components of Servo Drives
Drive Control with Position/Speed Encoder
Motion Control
Drive Control without Position/Speed Encoder

Data Exchange (Communication)

Prof. Dr. -Ing. J. M. Pacas, University of

Typical Machine Tool
feed drives
control the position
between working piece
and working tool

main drives
provide
processing power

Prof. Dr. -Ing. J. M. Pacas, University of

Parallel Kinematics

TriCenter DMT 100

(Deckel Maho)

Prof. Dr. -Ing. J. M. Pacas, University of

Characteristics of Servo Drives
feed high maximum torque

high efficiency constant maximum torque

drives
small size speed range < 10.000 rpm

axis rated power < 20 kW

smooth
Spindle operation high rated/continuous torque
at low speeds
constant maximum power
drives 4 quadrant
speed range < 20.000 rpm
operation
main rated power < 100 kW

Prof. Dr. -Ing. J. M. Pacas, University of

Hystory of Motor Types in Servo Drives

ASM
asynchronous
motor ASM
?
SM ?
DC synchronous SM SM
motor

EC
brushless
DC

1970 ff. 1980 ff. 1990 ff.

Prof. Dr. -Ing. J. M. Pacas, University of

State of the Art: AC Servos

High Speed Spindle

(Siemens) DSD Servo
(Baumller)
High Torque Motor
(Baumller) Spindle Motor
(Franz Kessler)

Prof. Dr. -Ing. J. M. Pacas, University of

Inverters for Servo Drive Applications

Prof. Dr. -Ing. J. M. Pacas, University of

Encoders
Advantages
low cost
high accuracy
(e. g. by gear ratio)

Disadvantages
elastic effects
and back lash

source : ERN-Geber, Heidenhain

Prof. Dr. -Ing. J. M. Pacas, University of

Encoder Technologies
technology Mebereich
measuring area Auflsung
resolution Robustheit
robustness Massenproduktio
mass production
measuring area resolution robustness n
mass production

Resolver:
magnetic
magnetisch circular low good bad
magnetic
tooth wheel: (multipole resolver: 20
point Bit)

problematic very good

optisch high (sensitive to (photographic
optical
optical point temperature production)
(CCD: > 30 Bit) and shock)

Too less experience to make knowledge-based statements.

kapazitive
capacitive
capacitive
circular high good good

Prof. Dr. -Ing. J. M. Pacas, University of

 AC Servo Drive Control
speed
M-Regler
current
Strom-
controller controllers
Regler
n* i*q
M
-
* i*d
-
ej
3~
- -
field weakening Feld-Regler
field controller
Feldschwchung
i
Ma-
machine
e -j

schinen- for asynchronous Encoder

modell machines
model u
e-j

for synchronous
machines
Prof. Dr. -Ing. J. M. Pacas, University of
Motion Control (e. g. Electronic Gear)

Virtual
V irtu e lle r Synchronized
S y n c h ro n is ie rte
K o m m u n ik a tio n
communication
Mmaster
a s te r

H main
a u p t a drive
n tr ie b

Prof. Dr. -Ing. J. M. Pacas, University of

Sensorless Control Categories

fundamental models models based on anisotropies

emf-model, flux ... dq-inductance rotor slotting main field ...

Observer modulation effect saturation

Prof. Dr. -Ing. J. M. Pacas, University of

Industrial Drives with Sensorless Control
since several years / decades sensorless control is investigated
and published on conferences and magazines
- acceptance in industry, however, is rather low

Why ?
new ideas and concepts are interesting for industry,
only if they do not result in higher cost or higher effort!!!
What does that mean
for industrial drives with sensorless control ?

no additional or more powerful processors / controllers

no additional hardware or additional sensors (e. g. voltage sensors)
no increased installation effort with respect to parameter adjustments

Prof. Dr. -Ing. J. M. Pacas, University of

Drives with Diagnostic Features

Prof. Dr. -Ing. J. M. Pacas, University of

Distributed/Decentralized Control

Prof. Dr. -Ing. J. M. Pacas, University of

 SERCOS interface

MDT
MST AT 1 AT 2 AT m AT M MST

t1.1
t1.2
t1.m
t1.M
t2
tScyc

t1.x AT transmission starting time

t2 MDT transmission starting time
tScyc SERCOS cycle time

Prof. Dr. -Ing. J. M. Pacas, University of

Future Developments
Motors (Actors)
synchronous motors with surface mounted permanent magnets as a standard
- different solutions in special applications only (for cost reasons)

Signal Processing
further developments on speed/position encoders to be expected
sensorless/encoderless control only, if
no additional hardware effort (processors and/or sensors)
no parameter dependencies during operation

Data Exchange/Communication
synchronized communication systems are demanded
for multi axis servo drive systems for high requirements

Prof. Dr. -Ing. J. M. Pacas, University of