By- Gaurav Khanna 13/PIT/082 Neel kamal Singh 13/PIT/085 Rohit Kapoor 13/PIT/090 M.

Tech ( WCN)

What is an automatic control system ?

A system in which we control the state of

a process. We provide the reference to the system which is the required state of the process. At the output the transducers are used to generate similar signals to represent the actual values at the output of a process. Compare the actual values at the output to the reference or required values and generate an error signal. This error signal is fed to the actuator and gearing arrangement to make the actual output closer to the reference input. This process ends if the error signal is zero or if the output becomes exactly equal to the reference input.

What is an analog closed loop system?

Error signal Amplifier Geared Motor

Input Transducer

Comparator

Voltage signals Output transducer

What is a Digital closed loop system?

Computer

Input Transducer

Digital Controller

Geared Motor

Digital signals Digital Output transducer

What is a Servo motor?

A servo motor is an electromechanical device in which an electrical input determines the position of the armature of the motor. The position of armature is determined by the duty cycle of a periodic rectangular pulse train.

What is a servo motor?

A Servo is a small device that has an output shaft. This shaft can be positioned to specific angular positions by sending the servo coded signal. As long as the coded signal exists on the input line, the servo will maintain the angular position of the shaft. As the coded signal changes, the angular position of the shaft changes

Futaba S 148 Servo

What is a servo motor?

The servo motors are small, have built in control circuitry, and are extremely powerful for their size. A standard servo such as the Futaba S-148 has 42 oz/inches of torque, which is pretty strong for its size. It also draws power proportional to the mechanical load. Thus a lightly loaded servo does not consume much power.

Three sets of wires for input, Control Signal, Power (+5 V) and Ground.

The main components of a servo motor are: 1. Electric Motor 2. position feedback potentiometer 3. Reduction gear 4. Actuator arm 5. Control Circuitry

How does Servo Motor Work?

Potentiometer is connected to the output shaft of the motor through gears. As the motor rotates the resistance of the pot changes, so that the circuit can measure exactly in what direction motor shaft is pointing. This pot allows the control circuitry to monitor the current angle of the servo motor. If the shaft is at the correct angle, then the motor shuts off. If the circuit finds that the angle is not correct, it will turn the motor in the correct direction until the angle is correct. The output shaft of the servo is capable of travelling somewhere around 180 degrees. A normal servo is used to control an angular motion between 0 and 180 degrees. A normal servo is mechanically not capable of turning any farther due to a mechanical stop built on to the main output gear. The amount of power applied to the motor is proportional to the distance it needs to travel. So, if the shaft needs to turn a large distance, the motor will run at full speed. If it needs to turn only a small amount, the motor will run at a slower speed. This is called proportional control.

How does a servo motor work?

The control wire is used to communicate the angle. The angle is determined by the duration of a pulse that is applied to the control wire. This is called Pulse Coded Modulation. The servo expects to see a pulse every 20 milliseconds (.02 seconds). The length of the pulse will determine how far the motor turns. A 1.5 millisecond pulse, for example, will make the motor turn to the 90 degree position (often called the neutral position). If the pulse is shorter than 1.5 ms, then the motor will turn the shaft to closer to 0 degress. If the pulse is longer than 1.5ms, the shaft turns closer to 180 degress.

How does a servo motor work?

How does a servo motor work?

When these servos are commanded to move they will move to the position and hold that position. If an external force pushes against the servo while the servo is holding a position, the servo will resist from moving out of that position. The maximum amount of force the servo can exert is the torque rating of the servo. Servos will not hold their position forever though; the position pulse must be repeated to instruct the servo to stay in position.

When a pulse is sent to a servo that is less than 1.5 ms the servo rotates to a position and holds its output shaft some number of degrees counterclockwise from the neutral point towards zero. When the pulse is wider than 1.5 ms the opposite occurs towards 180 degrees.

Control Circuitry in servo motor

The control circuitry contains a chip M51660L , which

compares the error in positioning the motor. The chip contains a timer that produces pulse signals from the potentiometer. These signals are similar to the ones you supply. These two pulse signals (the ones you are sending and the ones generated by the potentiometer) are fed into a pulse width comparator. This comparator produces the signals indicating which direction the motor should turn in.

Control Circuitry in servo motor

Types of servo motors

AC Servo Motors based on Induction Motor Designs: AC servos can handle higher current surges and tend to be used in industrial machinery. DC Servo Motors based on DC Motor Designs DC servos are not designed for high current surges. Generally speaking, DC motors are less expensive than their AC counterparts.

AC Brushless Servo Motors based on Synchronous Motor Designs.

What is servo mechanism?

A servomechanism, or servo is an automatic device that uses error-sensing negative feedback to correct the performance of a mechanism. The term correctly applies only to systems where the feedback or error-correction signals help control mechanical position or other parameters. A servomechanism may or may not use a servomotor. For example, a household furnace controlled by a thermostat is a servomechanism, yet there is no motor being controlled directly by the servomechanism. A common type of servo provides position and velocity control. Servos use electric motor as the primary means of creating mechanical force. Other types of servos use hydraulics, pneumatics or magnetic principles.

Uses of servo mechanism

Servomechanisms were first used in military, fire control and marine navigation equipment. Also used in automatic machine tools, satellite tracking antennas, remote control air planes, automatic navigation systems in boats and planes, anti air craft gun control systems. Radio controlled models, Auto focus cameras to accurately position the lens. Modern hard disk drives use magnetic servo systems with sub micrometer positioning accuracy, Width and thickness control equipment in industry. Opening and closing valves in furnaces.

Summary of servo mechanism

Servos operate on the principle of negative feedback where the control input is compared to the actual position of the mechanical system as measured by some sort of transducer at the output. Any difference between the actual and wanted values (an "error signal") is amplified and used to drive the system in the direction necessary to reduce or eliminate the error.

What is the difference between stepper motor and servo motor control?
A
stepper motor has winding in such a way that the rotation has a certain number of discrete "steps". These steps are where the magnetic fields cause the motor to want to settle in one of these positions. The number of steps per revolution is rather high, around two hundred or so, and varies by model and manufacturer. Often operated in open loop. Which can lead to errors if the motor is unable to comply with the controller command Cost is lesser

Servo motor is much smoother in motion as compared to stepper motor.

operated in closed loop set ups, so provide better control and accuracy. Cost is high

What is the difference between stepper motor and servo motor control?
Produce
more noise and vibrations than servos. Not suitable for high speed used for small torques and speeds. Slow linear response Simpler in design. Not suitable for systems with varying loads. low powers upto 1 hp and speed upto 2000 rpm. Faster linear responses. Higher torque, low armature inertia. marginal cooling smooth and precise control use mainly for transient response improvement. Reduction in steady state errors. Reduction in sensitivity. Complex in design due to feedback high torque in comparison to its size

Types of Feedback Devices

1. Analog Tachometers 2. Digital Tachometers (Optical Encoders)

Absolute Encoder
3. Resolver

Incremental Encoder

Types of feedback Devices

Analog Tachometer:
These are miniature motors, wire gauge is thin so that less current carrying capability is there. Reverse of motor operation. The faster shaft is turned larger is the magnitude of the voltage. Polarity of the voltage is indicates the direction of rotation. They provide directional and rotational information. If tachometer voltage gradient = 2.5 V /1000 rpm, motor shaft rotates at 3600 rpm then voltage shown on the tachometer is = 3. 6 krpm x 2.5 V / Krpm = 9V Voltage gradient is sensitivity of tachometer.

Types of feedback Devices

Digital Tachometer: Usually called optical encoder is also a mechanical to electrical conversion
device The encoders shaft is rotated and an output signal results which is proportional to the distance or angle the shaft is rotated through. The output signal may be sinusoidal or square wave providing an absolute position. Two types 1) absolute encoder 2) Incremental encoder

Types of feedbacks
Absolute encoder:
This type provides a specific address for each shaft position throughout 360 degrees.. It might have a contact (brush) or non contact type of sensing position. The contact scheme incorporates a brush assembly to make direct electrical contact with the electrically conducive path of the coded disc to read information. The non contact scheme uses photoelectric detection. The number of tracks on the disc can be increased to desired accuracy. The disc has a built in memory system, so the disc does not return to home or start position upon re energizing power.

Types of feedbacks
Absolute encoder:

Types of feedbacks
Incremental encoder:
The Incremental encoder provides either pulses or sinusoidal output signal as it is rotated through 360 degrees. The distance data is obtained by counting the pulses. The disk is manufactured with opaque lines. A light source passes the beam through the transparent segments onto a photosensor which outputs a square pulse train.

Types of feedbacks
Incremental encoder:
The number of opaque lines on the disc measure the positional accuracy of the encoder. Either one or two channel outputs can be provided. The two channel version provides a signal relationship to obtain motion direction. A zero index pulse can be provided to determine the home position.

Types of feedbacks
Resolver:
it is a rotating transformer. simplest resolver contains a single winding on rotor and two windings on stator located 90 degrees apart. Any reference signal applied to rotor winding causes voltage on the stator winding to change through transformer action, the change in the stator voltage is proportional to the angle gone through by rotor. One electrical cycle of output voltage is equal to each 360 degrees of mechanical rotation. This is fed to controller and inside it a R to D ( resolver to digital) converter analyzes the signal and produces an output representing angle of rotor movement and also the speed.

Types of feedbacks
Resolver:
Resolver with three stator windings 120 degrees apart is called as synchro.

Types of actuators
Air Motors : use compressed air to create motion, Pressure and flow determine the speed and torque. Hydraulic Motors: use pressurize oil to move piston. Stepper Motors: Electromechanical device to convert one digital pulse into a specific rotational movement or displacement. AC Induction Motors: widely used for constant speed requirements. Servo motors: A motor with a feedback device, controls speed and position accuracy.

Simulation of servo system

Servo system is used to control load.
Main application of control system is to vary and

maintain the speed of motor. The servo system must provide a) Required torque b) Required speed c) Required accuracy

 System modelling is used to understand the working of

control system. Consider a direct current position control servo system. System is made up of an electric motor with an output shaft. Let the shaft internal load is W, electric circuit input voltage V which is transformed by the motor in torque . Friction exist between bearing of the motor and load. an equation can be written as.
2 2 +

Where, a is constant representing friction. of servo output shaft.

 The objective is to control the shaft position . It can be achieved by simulation run for different

set of values of gain and time constant. Gain K and time are related to voltage by differential eqn.

2 2

=KV

Different values of gains and time constants are evaluated by simulation run by using different control system design tools

 Different values of gains and time constants are

evaluated by simulation run by using different control system design tools. Rearranging the system transfer model gives the state space form, for position and velocity of servo system output shaft. Software contains all the required mathematical formulas used to determine the inertia of the load and critical parameter used in selecting a servo system.

Uses of Servo controllers

Use in manufacturing company as production lines

need to be controlled. Useful in transportation system because of the electric motors. In communication network using hard disk drives. In focusing and tracking of the laser beam of the CD.

SIMULATORS ON SERVO SYSTEM CE 110

 Self-contained and compact bench-mounting unit Ideal for classroom demonstrations and student project work Shows problems of speed and position control of a servomotor

under different loads Mimics industrial, transport and aeronautical problems - with realistic results All inputs and outputs buffered for connection to TecQuipments optional controllers or other suitable controllers Front panel includes a mimic diagram of the process so that students can clearly see what they are controlling Shows basic control of speed, with advanced studies of nonlinear effects of hysteresis, deadzone and saturation

Essential Base Unit

Controller (CE120) A controller with analogue and

digital controls and instruments or Digital Interface (CE122) An interface which connects between most products in the Control Engineering range and a suitable computer (not included) or Other suitable controller with 10 V inputs and outputs Both the CE120 and the CE122 include TecQuipments CE2000 Control Software (see separate datasheet) with editable, pre-made control experiments for use with the CE110.

 The CE110 Servo Trainer shows d.c. servo position and

speed control systems using typical industrial techniques. It has a d.c. servomotor, a d.c. generator and a flywheel mounted on a common shaft. Analogue 0 to 10 V control signals vary the servomotor shaft speed in either direction. An optical sensor measures the speed and shows it on a panelmounted digital meter.

Operating Conditions
Operating environment: Laboratory environment Storage temperature range: 25C to +55C (packed)

Operating temperature range: +5C to +40C

Operating

relative humidity range: 80% at temperatures < 31C decreasing linearly to 50% at 40C

CE 120 CONTROLLER

Display and function generator:

Digital display of voltage measured (+/- 15 V) or

frequency of function generator. Function generator gives square, sinusoidal or sawtooth signals at variable frequency. Signals can be offset and amplitude adjusted. Frequency range 0.01 to 100 Hz

FUNCTIONS
Temperature (thermal) control

Level control
Engine speed control Servo control

OTHER SIMULATORS
Thermal Process Control (CE103)
Coupled Tanks (CE105 and CE105MV) Ball and Beam (CE106)

Engine Speed Control (CE107)

Coupled Drives (CE108) Ball and Hoop (CE109) Servo Trainer (CE110)