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Drives and Control for Industrial Automation

By: Kiong, Tan Kok.
Contributor(s): Putra, Andi Sudjana.
Material type: materialTypeLabelBookPublisher: London Springer 2010, c2010Description: 182.ISBN: 978-1-4471-2606-5.Subject(s): AutomotiveDDC classification: 629.8
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Reference 629.8 KIO (Browse shelf) Not For Loan 014568

Drives and Control for Industrial Automation presents the material necessary for an understanding of servo control in automation. Beginning with a macroscopic view of its subject, treating drives and control as parts of a single system, the book then pursues a detailed discussion of the major components of servo control: sensors, controllers and actuators. Throughout, the mechatronic approach – a synergistic integration of the components – is maintained, in keeping with contemporary practice.

The authors’ holistic approach does not preclude the reader from learning in a step-by-step fashion – each chapter contains material that can be studied separately without compromising understanding. Drives are described in several chapters organized according to the way they are usually classified in industry, each comprised of its actuators and sensors. The controller is discussed alongside. Topics of recent and current interest – piezoelectricity, digital communications and future trends – are detailed in their own dedicated chapters.

Drives and Control for Industrial Automation is primarily written for engineers and researchers interested in the applications of sensors, actuators and control systems in the automated environment. The discussion is thorough with the basics laid out succinctly but in sufficient detail to be useful to non-expert readers so students will also find this monograph a profitable source of information.

1 Overview of Servo Control ........................ 1
1.1 Objectives of Servo Control . . . . . . . . . . . . . . . . . . . . . 1
1.2 Elements of a Servo Control . . . . . . . . . . . . . . . . . . . . . 4
1.2.1 Measurement . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.2 Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.3 Power Moderation . . . ................... 5
1.2.4 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.5 Putting Them All Together ................. 7
2 Servo Hydraulic and Pneumatic Drive ................. 9
2.1 Overview of Servo Hydraulic and Pneumatic Drive ......... 9
2.2 Fundamentals of Hydraulic and Pneumatic Drives . . . . . . . . . 11
2.2.1 Basic Definitions and Principles . . . . . . . . . . . . . . . 12
2.2.2 Hydraulic Liquid . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.3 Benefits of Fluidic Drives . . . . . . . . . . . . . . . . . . 15
2.3 Components of Fluidic Drives Systems . . . . . . . . . . . . . . . 16
2.3.1 Primary Power Source . . . . . . . . . . . . . . . . . . . . 16
2.3.2 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . 16
2.3.3 Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . 22
2.3.4 Hydraulic Piston/Cylinder . . . . . . . . . . . . . . . . . . 25
2.3.5 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3.6 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.3.7 Auxiliary Equipment . . . . . . . . . . . . . . . . . . . . 39
2.4 Basic Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . 42
2.4.1 Constant Flow System . . . . . . . . . . . . . . . . . . . . 42
2.4.2 Constant Pressure System . . . . . . . . . . . . . . . . . . 43
2.4.3 Constant Power System . . . . . . . . . . . . . . . . . . . 43
2.4.4 Interlock of Hydraulic Circuits . . . . . . . . . . . . . . . 44
3 Electric Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.1 Overview of Electric Drives . . . . . . . . . . . . . . . . . . . . . 45
3.2 Electric Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.2.1 Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . 49
3.2.2 DC Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.2.3 AC Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.2.4 Linear Motor . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.3 Power Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.3.1 DC to DC Converter . . . . . . . . . . . . . . . . . . . . . 65
3.3.2 DC to AC Converter . . . . . . . . . . . . . . . . . . . . . 70
3.3.3 AC to AC Converter . . . . . . . . . . . . . . . . . . . . . 73
3.3.4 AC to DC Converter . . . . . . . . . . . . . . . . . . . . . 74
3.4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.4.1 Position Measurement . . . . . . . . . . . . . . . . . . . . 77
3.4.2 Velocity Measurement . . . . . . . . . . . . . . . . . . . . 81
3.4.3 Acceleration Measurement . . . . . . . . . . . . . . . . . 81
3.5 Configuring an Electric Drive Application . . . . . . . . . . . . . 83
4 Piezoelectric Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.1 Solid-state Actuators and Piezoelectric Actuators . . . . . . . . . . 87
4.2 Piezoelectricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.3 Nonlinearity in Piezoelectric Actuators . . . . . . . . . . . . . . . 90
4.4 Mechanical Linkages for Piezoelectric Drives . . . . . . . . . . . 93
4.4.1 Notch Joints . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.4.2 Cross-strip Pivot and Cartwheel Hinge . . . . . . . . . . . 95
4.4.3 Passive Joints . . . . . . . . . . . . . . . . . . . . . . . . 97
4.4.4 Compliant Revolute Joint . . . . . . . . . . . . . . . . . . 98
4.4.5 Compliant Translational Joint . . . . . . . . . . . . . . . . 98
4.5 Example of Application . . . . . . . . . . . . . . . . . . . . . . . 99
5 Control System in Servo Drives . . . . . . . . . . . . . . . . . . . . . 105
5.1 Open-loop Versus Closed-loop Control . . . . . . . . . . . . . . . 105
5.2 Servo Control Challenges . . . . . . . . . . . . . . . . . . . . . . 106
5.2.1 System Design . . . . . . . . . . . . . . . . . . . . . . . . 106
5.2.2 Nonlinear Dynamics . . . . . . . . . . . . . . . . . . . . . 107
5.2.3 Disturbances . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.3 Servo Control Structures . . . . . . . . . . . . . . . . . . . . . . . 114
5.3.1 Trajectory Generator . . . . . . . . . . . . . . . . . . . . . 114
5.3.2 Feedback Control . . . . . . . . . . . . . . . . . . . . . . 114
5.3.3 Feedforward Compensator . . . . . . . . . . . . . . . . . . 126
5.3.4 States Feedback with Observers . . . . . . . . . . . . . . . 127
5.3.5 Notch Filter . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.4 Implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.4.1 Digital Control . . . . . . . . . . . . . . . . . . . . . . . . 131
5.4.2 Analog Control . . . . . . . . . . . . . . . . . . . . . . . 134
5.5 IEC 61131-3 Programming Standards . . . . . . . . . . . . . . . . 135
5.5.1 Ladder Diagrams . . . . . . . . . . . . . . . . . . . . . . 136
5.5.2 Instruction List (IL) . . . . . . . . . . . . . . . . . . . . . 137
5.5.3 Structured Text (ST) . . . . . . . . . . . . . . . . . . . . . 137
5.5.4 Sequential Function Charts (SFC) . . . . . . . . . . . . . . 138
5.5.5 Function Block Diagrams (FBD) . . . . . . . . . . . . . . 140
5.5.6 Continuous Function Chart (CFC) . . . . . . . . . . . . . . 142
6 Digital Communication Protocols . . . . . . . . . . . . . . . . . . . . 143
6.1 Evolution of Fieldbuses . . . . . . . . . . . . . . . . . . . . . . . 143
6.1.1 Distributed Control Systems . . . . . . . . . . . . . . . . . 143
6.1.2 Issues of Proprietary Protocols . . . . . . . . . . . . . . . 145
6.2 Fieldbus Protocol Stack . . . . . . . . . . . . . . . . . . . . . . . 148
6.2.1 Physical Layer . . . . . . . . . . . . . . . . . . . . . . . . 149
6.2.2 Link Layer . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.2.3 Network Layer . . . . . . . . . . . . . . . . . . . . . . . . 154
6.2.4 Application Layer . . . . . . . . . . . . . . . . . . . . . . 154
6.2.5 User Layer . . . . . . . . . . . . . . . . . . . . . . . . . . 154
6.2.6 Traversing the Stack . . . . . . . . . . . . . . . . . . . . . 155
6.3 Common Fieldbuses . . . . . . . . . . . . . . . . . . . . . . . . . 155
6.3.1 CANopen . . . . . . . . . . . . . . . . . . . . . . . . . . 155
6.3.2 Profibus . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
6.3.3 Foundation Fieldbus . . . . . . . . . . . . . . . . . . . . . 157
6.3.4 Firewire . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
6.3.5 Sercos . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
6.3.6 Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
6.4 Applications in Hydraulic/Pneumatic and Electric Drives . . . . . 161
6.4.1 Fieldbuses in Hydraulic/Pneumatic Drives . . . . . . . . . 162
6.4.2 Fieldbuses in Electric Drives . . . . . . . . . . . . . . . . 162
7 Trends in Motion Control . . . . . . . . . . . . . . . . . . . . . . . . 163
7.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
7.1.1 Nanotechnology . . . . . . . . . . . . . . . . . . . . . . . 163
7.1.2 Biotechnology . . . . . . . . . . . . . . . . . . . . . . . . 164
7.2 Ultra-precision Machining . . . . . . . . . . . . . . . . . . . . . . 165
7.2.1 Ultra-precision Spindles . . . . . . . . . . . . . . . . . . . 165
7.2.2 Excimer Laser Micromachining . . . . . . . . . . . . . . . 165
7.3 Micro-fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . 166
7.3.1 Lithography . . . . . . . . . . . . . . . . . . . . . . . . . 166
7.3.2 Micro-electro-mechanical Systems (MEMS) . . . . . . . . 167
7.4 Micro-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
7.5 Precision Metrology and Test . . . . . . . . . . . . . . . . . . . . 168
7.6 Driving Technologies . . . . . . . . . . . . . . . . . . . . . . . . 168
7.6.1 Micromanufacturing . . . . . . . . . . . . . . . . . . . . . 168
7.6.2 Microassembly . . . . . . . . . . . . . . . . . . . . . . . . 169
7.6.3 Micrometrology . . . . . . . . . . . . . . . . . . . . . . . 169
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

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