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Michal Kašpárek Technical University in Liberec Faculty of Mechanical Engineering

Utilization of digitally controlled servo drives in simplification of mechanical machine structure and the controllability analysis. Michal Kašpárek Technical University in Liberec Faculty of Mechanical Engineering Department of Applied Cybernetics michal.kasparek@tul.cz. Motivation.

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Michal Kašpárek Technical University in Liberec Faculty of Mechanical Engineering

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  1. Utilization of digitally controlled servo drives in simplification of mechanical machine structure and the controllability analysis Michal Kašpárek Technical University in Liberec Faculty of Mechanical Engineering Department of Applied Cybernetics michal.kasparek@tul.cz

  2. Motivation • Complex mechanical structures distributing driving power • Frictional resistance • Moment of inertia • Energy loss • High engine performance required • High energy consumption

  3. Motivation • New structureofmachines • Utilized in design ofnewstructureofthe drive ofsmall-diameterknittingmachine • Possibleapplication in other textile machinesanddifferentindustrysegments • Utilizationofseveralsmallerelectromotorsplaceddirectly in front ofcontrolmembers • Significantlylowerwattageandpowerdemandsrequired • Much more simplemechanicalconstruction • More robustpowerdistibution

  4. Applicationrequirements • Transmissionsandgearsreplacement: • Highprecisionelectroniccam • Mutliple drive movementsynchronization • Additionalcapabilities • Independent highprecisionmotioncontrol • Complexdrivingfunctiontracking • Virtualcamusability

  5. Testedassembly • Drive systemoffunctional model ofnewstructureofsmall-diameterknittingmachine • EmersonControlTechniquesassembly • Digitax ST servodrives • CTM4 series servomotor

  6. Testedassembly • Digitax ST - Plus • high performance drive • optimizedfor pulse duty servoapplications • highpeaktorque (up to 56.4Nm peak) • LED keypadand SM-Application module • Drive controllooprunsat 250 µs • Multiple drivesnetworkingcapabilities

  7. Testedassembly • ControlTechniques CTM4 series servomotor • highresolutionSinCosmulti-turnencoder • 330 V drivingvoltage • 2 A nominalcurrent • 2,5 NmTorque

  8. Activecurrentmeasurement

  9. Reducedenergyconsumption • Servos 25% torqueoforiginal motor • Loadwheelalsoreduced to 25% • Activecurrentmeasurement: • Peakunder 10% of maximum current limit • Hugereservefor 4x biggerrealload

  10. Electroniccamability

  11. Electroniccamability

  12. Virtualcam • Presentedmeasurementsutilizevirtualcamprinciple • Complextrajectoryofrotarymotion • Modelledwithhighorderpolynomials in order to ensuresmoothprogressofhigherderivatives (speed, acceleration) • Onerevolutionprogressionsampledintovirtualcam model ofdesiredpositionand speed • Virtualcamrevolution ≈ 2π ≈ 3600 samples • Limited module memory - 0.1º resolution

  13. Virtualcam Real positionofthespindleistransformedintotheangleofvirtualcamrevolution According to thisanglethe speed andpositiondemandisreturned Theencoder feedback isthereforerecalculatedandusedforcontrol data generation

  14. Positionmeasurement

  15. Speed measurement

  16. Conclusions Modernservodrivesweretested Hugepotentialofenergyconservationwasobserved Possibilityofdirect motor to actionmemberattachmentwasproven Electroniccamusabilitywastestedanddrivesdeviationwasdepicted Virtualcamcontaininghighorderpolynomialmotion model wasimplemented

  17. Conclusions • Typicalservomotorsbehaviourwasobservedatlowspeedstestedfortheknittingmachineoperationmodes • Constant speed fluctuationwithstablefrequency • Lowspeedsusedcompared to motor maximum of 4000 rpm (peakingover 5% of maximum) • Differentmotorswouldneed to betestedorintegratedtransmissionusagereconsidered • The influence ofhigh-orderpolynomicmotionfunctionwasdiminished by describedbehaviour, neverthelessfurtherinvestigationofpresentedphenomenonisnecessary

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