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Motion Control Feedback Device

This document discusses motion control systems and components, focusing on quadrature encoders. It defines a quadrature encoder as a type of incremental encoder that uses two tracks phase shifted by 90 degrees to sense rotation direction. This allows the controller to determine clockwise or counterclockwise movement. It also provides high resolution by counting leading and trailing edges from both tracks. Quadrature encoders are useful for closed-loop control applications requiring bidirectional position sensing.

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Zyzerull Saad
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105 views20 pages

Motion Control Feedback Device

This document discusses motion control systems and components, focusing on quadrature encoders. It defines a quadrature encoder as a type of incremental encoder that uses two tracks phase shifted by 90 degrees to sense rotation direction. This allows the controller to determine clockwise or counterclockwise movement. It also provides high resolution by counting leading and trailing edges from both tracks. Quadrature encoders are useful for closed-loop control applications requiring bidirectional position sensing.

Uploaded by

Zyzerull Saad
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Motion Control

Feedback Device
quadrature encoder

Motion control
Motion control can be simply defined as the precise
control of anything that moves. The system consists of
advance motion controllers, wiring and connectivity
devices, motor drive units, software tools and interface to
third party devices. Controllers generate trajectories,
which the motor follows. Drives then take the signals sent
by the controller and change them into signals that will
actually move the motor. Feedback devices are used to
close the control loop in closed-loop systems.

Components of a Motion Control


System:

Mechanical elements Motors are designed to provide torque to some mechanics. These include
linear slides, robotic arms, and special actuators.
Feedback device or position sensor A position feedback device is not required for some motion control
applications (such as controlling stepper motors), but is vital for servo
motors. The feedback device, usually a quadrature encoder, senses the
motor position and reports the result to the controller, thereby closing the
loop to the motion controller.

Overview
Incremental encoders provide a specific number of equally
spaced pulses per revolution (PPR) or per inch or
millimeter of linear motion. A quadrature encoder is a
type of incremental encoder used in many general
automation applications where sensing the direction of
movement is required.

How does a Quadrature Encoder


work?
The code disk inside a quadrature encoder contains two tracks usually
denoted Channel A and Channel B. These tracks or channels are coded
ninety electrical degrees out of phase, as indicated in the image below, and
this is the key design element that will provide the quadrature encoder its
functionality.
In applications where direction sensing is required, a controller can
determine direction of movement based on the phase relationship between
Channels A and B. As illustrated in the figure below, when the quadrature
encoder is rotating in a clockwise direction its signal will show Channel A
leading Channel B, and the reverse will happen when the quadrature
encoder rotates counter clockwise.

Apart from direction, position can also be monitored with aquadrature encoderby
producing another signal known as the marker, index or Z channel. This Z signal,
produced once per complete revolution of the quadrature encoder, is often used to
locate a specific position during a 360 revolution

When to use Quadrature


Encoders?
Quadrature encoders are used in bidirectional position sensing and length
measuring applications. However, in some unidirectional start-stop applications,
it is important to have bidirectional information (Channel A & B) even if reverse
rotation of the shaft is not anticipated. An error in count could occur with a
single-channel encoder due to machine vibration inherent in the system.
For example, an error in count may occur with a single-channel encoder in a
start/stop application if it mechanically stops rotating when the output
waveform is in transition. As subsequent mechanical shaft vibration forces the
output back and forth across the edge the counter will up-count with each
transition, even though the system is virtually stopped. By utilizing a quadrature
encoder, the counter monitors the transition in its relationship to the state of
the opposite channel, and can generate reliable position information.

Achieving higher resolution with


Quadrature Encoders
When more resolution is needed, it is possible for the
counter to count the leading and trailing edges of the
quadrature encoders pulse train from one channel, which
doubles (x2) the number of pulses per revolution.
Counting both leading and trailing edges of both channels
of a quadrature encoder will quadruple (x4) the number of
pulses per revolution. As a result, 10,000 pulses per turn
can be generated from a 2,500 PPR quadrature encoder.
Typically with a Dynapar encoder, this 4x signal will be
accurate to better than 1 count.

Absolute rotary encoder


An "absolute" encoder maintains position information
when power is removed from the system. The position of
the encoder is available immediately on applying power.
The relationship between the encoder value and the
physical position of the controlled machinery is set at
assembly; the system does not need to return to a
calibration point to maintain position accuracy. An
"incremental" encoder accurately records changes in
position, but does not power up with a fixed relation
between encoder state and physical position.

Absolute

Code disc for absolute


encoders

LED

Lens

Scanning mask
Code disc

Provides a unique value for every shaft or


linear position

Absolute encoders retain their position after


a power cycle

Signals typically use SSI, parallel, or field bus


interfaces (Ethernet/IP, EtherCAT, Profinet,
Devicenet, CANopen, Profibus, etc)

Absolute encoders are used in applications


were position information is necessary

PhotoElements

Construction of absolute
encoder
It have in two basic types: optical and mechanical.
Mechanical absolute encoders
A metal disc containing a set of concentric rings of
openings is fixed to an insulating disc, which is rigidly
fixed to the shaft.
A row of sliding contacts is fixed to a stationary object so
that each contact wipes against the metal disc at a
different distance from the shaft.

As the disc rotates with the shaft, some of the contacts touch metal, while
others fall in the gaps where the metal has been cut out. The metal sheet is
connected to a source of electric current, and each contact is connected to a
separate electrical sensor.
The metal pattern is designed so that each possible position of the axle
creates a unique binary code in which some of the contacts are connected
to the current source (i.e. switched on) and others are not (i.e. switched off).
Optical absolute encoders
The optical encoder's disc is made of glass or plastic with transparent and
opaque areas. A light source and photo detector array reads the optical
pattern that results from the disc's position at any one time
This code can be read by a controlling device, such as a microprocessor or
microcontroller to determine the angle of the shaft. The absolute analogue
type produces a unique dual analogue code that can be translated into an
absolute angle of the shaft.

Singleturn

Measures the Absolute


position within 1
revolution/turn

Multiturn

Measures the Absolute


position within 1
revolution/turn
In Addition, measures the
number of revolutions as
well.
Multi-turn encoders are
recommended for
applications involving
multiple revolutions of the
encoder shaft.

HOW ABSOLUTE ENCODER


WORK?

Absolute Encoder Interfaces


Absolute
Electronic Interface

Parallel

SSI

BUS

Parallel Output
Parallel Output

First form of communication for absolute encoders

Connection

Point-to-point communication where each output wire


represents a different data bit

Benefits
Direct output to digital inputs
Fast (60us typically)

Drawbacks
- Complex cabling due to separate bit wires
- High cost

Synchronous Serial Interface (SSI)


Synchronous Serial Interface (SSI)
Very common serial interface standard for industrial applications
Developed by Stegmann in 1984 for absolute encoders now in many products

Connection
Point-to-point connection from a master (PLC, microcontroller) to a slave (encoder)

Benefits Drawbacks

Simple cabling, especially compared to Point-to-point connection, topology restrictions


parallel outputs

Fast communication speeds


Low cost

Advantages of Absolute
Non-Volatile Memory. Absolute encoders are non-volatile position
verification devices. True position is not lost if the power fails.
Continuous reading of position is not required.
Safety. In some applications, a loss of position could result in
damage to the machinery or injury to the operator. An absolute
encoder provides position verification the moment power is applied
without requiring movement to a reference position.
Noise Immunity. Absolute encoders determine position by
continually reading a coded signal. Stray pulses will not accumulate
and accurate position is available again on the next reading

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