Servo types

Vector control technology combines an induction motor with a feedback device, such as an encoder. With feedback, the motor speed can be controlled down to zero rpm. And, a programmable controller lets users command position.

Positioning is commonly thought of as a servo requirement, which puts vector- controlled motors in a class with brush and brushless servos. Brush-type servos provide proven reliability and well known technology. Linear and predictable performance makes them easy to integrate in designs.

Brushless servos offer higher speed capability, higher torque in smaller packages, lower inertia for quicker positioning, and long, reliable, maintenance-free life.

Once the proper technology is determined, the next step is motor selection. This involves analyzing the mechanics of the application. The inertia that the motor sees, and torque levels for each section of the duty cycle must be determined.

Performance plus

Acceleration capability determines how quickly the load can be positioned. Vectors acceleration capability is 150% of continuous. Brush and brushless servos, on the other hand, have at least twice the acceleration capabilities of continuous, more if you over-size the control. But dont forget about cost.

Bandwidth is a measure of system response, or how fast the motor reacts to changes in command, disturbances, and torque variations. Velocity loop bandwidth is a measure of how fast a drive reacts to speed commands. Position loop bandwidth is usually dominated and determined by the load.

Reading speed-torque curves

In constant-speed applications, motors are defined in terms of horsepower (which is torque at a base speed). In positioning applications, motors normally operate over a wide range, not simply at base speed, so they are typically not rated at base conditions.

Speed-torque curves, therefore, display continuous torque (that won t overheat the motor) and peak torque (intermittent) thats essentially acceleration torque. The voltages necessary to reach various speeds and current required to deliver specific torque is provided in table form to help designers select a control.

For example, look at an application requiring a continuous torque (torque over the duty cycle) of 30 lb-in. at a speed of 3,750 rpm, and a peak torque (or acceleration torque) of 80 lb-in. The bus voltage required is 300 Vdc. The continuous and peak currents required are 7 and 18 A. This motor will operate successfully in the application because the applications continuous torque is in the motors continuous operation area.

Application tips

The load and motor inertia should be compared. A maximum ratio of 10 (load) to 1 (motor) is recommended. This ratio affects response, resonance, and power dissipation.

As the inertia mismatch increases, oscillations tend to occur and it takes longer for the load to settle in position. To prevent this, the controls gain is reduced. However, this extends settling time and leads to lower acceleration and slower positioning, and may not be acceptable for some applications.

An equation for the load, motor, and the applications transmission can be derived to show the mechanical resonant frequency.

where J_L = load inertia

J_M = motor inertia

K = transmission stiffness

This equation indicates that the mechanical resonant frequency depends on transmission stiffness and that its lower for high inertia loads.

For best response, the resonant frequency should be outside the system bandwidth, typically five to 10 times the servo loop bandwidth. The easiest, quickest, and least expensive ratio improvement methods are using gearing or a larger motor with more inertia.

Continue on page 2