New designs for servo amplifiers are leveraging extra bandwidth to create more sophisticated control algorithms for adaptive auto-tuning, vibration suppression and faster, more precise positioning.
Auto-tuning advances are at the forefront because they address a primary design goal of reducing commissioning time and complexity of configuring drives. Effectively using serial feedback at power-up to exchange digital information between the motors and drives simplifies setting configuration parameters. But advanced algorithms and auto-tuning wizards are taking automated setup a step further, dynamically adjusting for inertial mismatches up to 20:1 and achieving settling times in the 0 to 4 msec range with minimal manual fine-tuning of the system.
Vibration suppression technology provides the ability to automatically adjust for general machine resonances and dramatically improve motion performance.
HIGH-PERFORMANCE SERVO DRIVES CAN REDUCE ENERGY CONSUMPTION
Sigma-5 amplifiers from Yaskawa Electric America offer high-performance positioning accuracy and a power range from 50W to 15 kW. An auto-tuning function provides real-time adaptive load control optimized for sophisticated applications. Intelligent software algorithms allow for precise and fast positioning, high machine speeds, vibration-less motion and smooth operation across the entire speed range. An automatic filter function suppresses oscillations and produces optimum control for a wide range of inertia ratios. No manual fine-tuning is required. Yaskawa's SigmaWin Plus software allows for both simplified setup of the servo amplifier and fast, easy selection of a servomotor. Using the drives with Sigma 5 servomotors that feature an advanced stator design, winding technologies and high-density magnets, can reduce energy consumption by up to 30 percent.
DIGITAL SERVO DRIVES SIMPLIFY TUNING
S200 digital servo drives from Danaher Motion offer a velocity loop bandwidth of 800 Hz, high-resolution (24-bit) feedback and high-performance (3 to 5 kHz) current loop bandwidth. The use of an intelligent feedback device, with electronic motor nameplate, allows plug-and-play commissioning, eliminating the need for drive parameter setup and servo loop tuning in most applications. The drives come standard with torque and velocity control base, electronic gearing, up to an 18-bit analog reference input, an encoder equivalent output and support for either indexing or SynQnet based programmable motion control. Drives are available for ac (120/240V ac) and dc (20 to 90V dc) operation with current ratings from 1.5A rms continuous to 48A rms peak.
ADVANCED FUNCTIONALITY IN ULTRA-COMPACT DESIGN
The R7D-B Series servo drives from OMRON Electronics addresses OEM concerns about the complexity of applying servo drives, faster start-up times and more reliable operation. Adaptive vibration suppression reduces the amount of vibration as work travels between positions, shortening the positioning times between motions and improving accuracy for higher productivity. A torque limiting function allows machine builders to set two torque limits and switch between them to handle applications such as part insertion and pressing for extrusion and embossing. The drives are available in power versions up to 400W, and connect to OMRON's R88M-G Series cylindrical and flat servomotors to provide speeds up to 3,000 rpm. The footprint of the drives, measuring 120 x 35 x 105 mm, reduces panel space requirements and leaves room for other controls on the same rail.
For industrial control applications, or even a simple assembly line, that machine can go almost 24/7 without a break. But what happens when the task is a little more complex? That’s where the “smart” machine would come in. The smart machine is one that has some simple (or complex in some cases) processing capability to be able to adapt to changing conditions. Such machines are suited for a host of applications, including automotive, aerospace, defense, medical, computers and electronics, telecommunications, consumer goods, and so on. This discussion will examine what’s possible with smart machines, and what tradeoffs need to be made to implement such a solution.