Sensors and Actuators:

Servomotors and Servo Drives

Notes: From Omron Technical Guide

http://www.ia.omron.com/support/guide/14/introduction.html

ME 423: Machine Design

Instructor: Ramesh Singh
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 Outline
• Servomotors and Servo Drive
• Definition of key terms
• Selection of Servomotors

ME 423: Machine Design

Instructor: Ramesh Singh
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 Servomotors & Servo Drive
• A servomotor is a structural unit of a servo system and
is used with a servo drive
• The servomotor includes :
– Motor that drives the load
– Position detection component, such as an encoder.
• The servo system varies the controlled quantity,
– Position, speed, or torque, according to the set target value
(command value) to precisely control the machine operation

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What Is a Servomotor and What Is a Servo Drive?

Servo System Configuration

A servomotor is a structural unit of a servo system and is used with a servo drive. The servomotor includes the motor that drives
the load and a position detection component, such as an encoder.
The servo system vary the controlled amount, such as position, speed, or torque, according to the set target value (command
value) to precisely control the machine operation.

Servo System Configuration Example

(1) Command section (2) Control section (3) Drive and detection section
Outputs command Controls the motor Drives the controlled object and
signals for operation. according to commands. detects that object.

Servomotor
Power transmission Encoder
mechanism
Target values Motor power signals Ball screw
Table

Feedback signals Feedback signals

Controller Servo drive Servomotor

Courtesy: Omron

ME 423: Machine Design

Instructor: Ramesh Singh
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 Features of Servomotors
• Precise, High-speed Control
– Servomotors excel at position and speed control
– Precise and flexible positioning is possible
– Servomotors do not stall even at high speeds
– Deviations due to large external forces are corrected
because encoders are used to monitor movement.

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 • Servomotors do not stall even at high speeds. Deviations due to large e

Fully-closed Loop
to monitor movement.

Fully-closed Loop Ope

• The most reliable formreliable
The most of closed
form ofloop.
closed A fully-closed
loop. A fully-closedloop
loop isis A st
used when high precision
used when high is required.
precision is required. feed
The motor is controlled while directly reading the position of The
• The motor is controlled while directly
the machine (workpiece or table)reading the encoder
using a linear positionandof perf
comparing the read position with the command value (target pitc
the machine (workpiece or table)
value). Therefore, there is no need to compensate for gear stal
– Using a linearbacklash
encoderbetween
and comparing
the motor the
and read position
mechanical with the
system, feed actu
command value (target
screw value)or error due to feed screw torsion or
pitch error, Ope
expansion.
– Therefore, there is no need to compensate for gear backlash between spe
the motor and mechanicalLoop
Fully-closed system, feedConfiguration
System screw pitch error,
Exampleor error due Ope
to feed screw torsion or expansion Servomotor

Power transmissi
mechanism
Ball screw
Table

Controller Servo drive

ME 423: Machine Design Linear encoder

Instructor: Ramesh Singh
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Semi-closed Loop
 Switches
Open Loop Open Loop
loop is A stepper motor is used instead of a servomotor. There is no
• A stepper motor is used instead of a servomotor. There is no feedback
feedback loop.
loop.
ition of The overall configuration is simple. Positioning can be

Safety Components
der and • The overall configuration
performed is simple.
at low cost, but gearPositioning can be
and ball screw performed
backlash and at low
e (target cost, but
pitchgear andcannot
errors ball screw backlash andWhen
be compensated. pitch errors cannot
a stepper motorbe
r gear compensated.
stalls, an error will occur between the command value and the
, feed • Whenactual
a stepper motor stalls,
movement. an error
This error cannotwillbeoccur between the command
compensated.
or value Open
and theloop control
actual is suitableThis
movement. for low-precision,
error cannot be low-cost, low-
compensated.
• Open speed, and low-load-change
loop control applications. low-cost, low- speed, and
is suitable for low-precision,
e low-load-change
Open Loopapplications.
System Configuration Example

Relays
Stepper motor

wer transmissi Ball screw

Control Components
chanism Table

able
Controller Stepper motor drive

ME 423: Machine Design

Automati
Instructor: Ramesh Singh
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 detector
Semi-closed
Behind motor Loop
Installation location of Motor side of
feed screw
Opposite of
motor side of
feed screw
• This method is commonly used in servo systems.
Compensation Compensation
Gear backlash
• It is faster and has better positioning precisionnot
required than an open loop.
required
• Typically an encoder
Ball screw or other detector
or nut torsion Affectedis attached behind the motor.
Hardly The
affected
encoderBall detects the rotation
screw expansion or angle of a feed screw (ball screw) and
provides it contraction Affected(workpiece or table) travel
as feedback of the machine
position. This means that theCompensation
position of the machine is not detected
Ball screw pitch error
directly. required
• The characteristics depend on where the detector is installed.
Semi-closed Loop System Configuration Example

Servomotor

Ball screw
Table

Controller Servo drive

ME 423: Machine Design
Instructor: Ramesh Singh
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(ball screw) and provides it as feedback of the machine
Location of Encoder
(workpiece or table) travel position. This means that the
position of the machine is not detected directly.
The characteristics depend on where the detector is installed.
Opposite of
Installation location of Motor side of
Behind motor motor side of
detector feed screw
feed screw
Compensation Compensation
Gear backlash
required not required
Ball screw or nut torsion Affected Hardly affected
Ball screw expansion or
Affected
contraction
Compensation
Ball screw pitch error
required

Semi-closed Loop System Configuration Example

Servomotor
ME 423: Machine Design
Instructor: Ramesh Singh
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 Servo Operation and Configuration
• Controls motor operation in closed loop
• The actual position, speed, or torque of the
servomotor is fed back to compare to the command
value and errors
• Then the servo drive corrects the operation of the
servomotor in real time using this error
• This cycle of feedback, error detection, and
correction is called closed-loop control.

ME 423: Machine Design

Instructor: Ramesh Singh
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 Servo Operation
• The control loop is processed by either of servo drive
or motion controller, or both
• The control loops for position, speed, and torque are
independently used to achieve the required operation.
• Applications will not always require all three control
loops
• In some applications, only the control loop for torque
control will be required.
• In other applications, current and speed for speed
control are required
• In some cases, three control loops for position control
are required.

ME 423: Machine Design

Instructor: Ramesh Singh
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be required. In other applications, current and speed for
Principle
speed control are required, and in still other applications,
three control loops for position control are required.

Torque control Speed loop gain

Speed loop integral time constant
Speed control
Control Error/ Drive
Error speed
section Oscillator counter conversion Motor

Position Frequency/
Current
control speed
Position conversion feedback
Position Speed
command loop gain
feedback
Speed
command Multiplication

Position feedback Encoder

Servomotor
The most common types of industrial servomotors are those
ME 423: Machine Design
based on brushless motors. The
Instructor: rotor
Ramesh Singhhas a powerful
12
permanent magnet. The stator is composed of multiple
 Servomotors
• Servomotors based on brushless motors are most
common
• The rotor has a powerful permanent magnet
• The stator is composed of multiple conductor coils,
and the rotor spins when the coils are powered in
the specified order.
• The movement of the rotor is determined by the
stator’s frequency, phase, polarity, and current

ME 423: Machine Design

Instructor: Ramesh Singh
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determined by the stator’s frequency, phase, polarity, and
Servomotors
current when the correct current is supplied to the stator coils
at the appropriate time.

Speed,
position,
or torque
Encoder
Motor shaft
Case

A servo
• Comm
• Encod
adjust
• I/O pr
Rotor Permanent Stator coils opera
magnet

ME 423: Machine Design

Instructor: Ramesh Singh
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 Encoders
• Servomotors are different from typical motors in that they have
encoders. This allows high-speed and high-precision control
according to the given position and speed commands
• Encoders are one of the hardware elements that form the core of a
servo system, and they generate speed and position feedback.
• In many cases, the encoder is built into the servomotor or attached
to the servomotor.
• In certain applications, the encoder is an independent unit that is
installed away from the servomotor. When the encoder is installed
in a remote location.
• Encoders are divided into two kinds:
– Incremental encoders
– Absolute encoders
• Multi-turn absolute encoders are typically used for servomotors

ME 423: Machine Design

Instructor: Ramesh Singh
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 Servo Drive
• Servo drives follow commands from the host controller
and control the output torque, rotation speed, or
position
• The position, speed, or torque are controlled according
to inputs from a motion controller, feedback encoder,
and the servomotor
• The servo drive supplies the appropriate amounts of
power to the servomotor at the appropriate times.
• The basic operating principle is the same as for an
inverter, in which the motor is operated by converting
AC power to DC power to be a certain frequency

ME 423: Machine Design

Instructor: Ramesh Singh
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nt
amounts of power to the servomotor at the appropriate times.

Automation Systems
ack

on
Servo Drive
The basic operating principle is the same as for an inverter, in
which the motor is operated by converting AC power to DC
Encoder power to be a certain frequency.

Fixed frequency Required frequency

ors are those (50/60 Hz) (0 to 400 Hz)

Motion / Drives
werful Converter Smoothing Inverter
multiple section circuit section section

oils are
of the rotor is
olarity, and Motor

Energy Conservation Support /

Environment Measure Equipment
he stator coils

PWM

Speed,

Power Supplies /
position, Control circuits

In Addition
or torque Encoder

Servo drive
ME 423: Machine Design
Instructor: Ramesh Singh
A servo drive also has the following functions. 17
• Communications with the motion controller
 Functions of Servo Drive
• A servo drive also has the following functions.
– Communications with the motion controller
– Encoder feedback reading and realtime closed-
loop control adjustment
– I/O processing for safety components, mode
inputs, and operating status output signals

ME 423: Machine Design

Instructor: Ramesh Singh
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Servomotor Selection Flow Chart

s
2 1

Sensors
START Selection Explanation References
• Determine the size, mass, coefficient of friction,
and external forces of all the moving part of the Calculate Regenerative Energy • Calcu

Switches
Has the machine NO Explanation
servomotor the rotation of which affects. References
Been Selected? of all t
• Determine the size, mass, coefficient of friction,
and external forces of all the moving part of the ---

Switches
Has the machine NO servomotor the rotation of which affects.
Been Selected?
YES
--- • Check

Safety Components
meets
YES • Determine the operating pattern (relationship • Operation Pattern NO
Formula Is the Resolution
between time and speed) of each part that must OK?

Safety Components
Has the Operating NO be controlled.
Pattern Been Selected? • • Convert
Determine the operating
the operating pattern
pattern of each controlled
(relationship • Operation Pattern Formula
between element
time and into the motor
speed) shaft
of each operating
part that mustpattern. YES
Has the Operating NO be controlled. • Check
Pattern Been YES
Selected? • Convert the operating pattern of each controlled of the

Relays
element into the motor shaft operating pattern. If not,
Calculating the Load Inertia For • The elements of the machine can be separated • Inertia Formulas NO Are the Check Items
Motor Shaft Conversion Value so that inertia can be calculated for each part and re
YES on Characteristics
that moves as the servomotor rotates.

Relays
All OK?
• • Calculate
The elements the machine
of the inertia applied
can betoseparated
each element to
• Inertia Formulas
Calculating the Load Inertia For
Motor Shaft Conversion Value so that calculate
inertia can thebetotal load inertia
calculated of the
for each motor shaft
part

Control Components
conversion value.
that moves as the servomotor rotates. YES
• Calculate the inertia applied to each element to
• Calculation of Friction Specia
Calculating the Added Load calculate the total load inertia Torque
of the motor shaft • Load Torque Formulas
I

Control Components
Calculates
conversion value. the frictional force for each element,
Torque For Motor Shaft
where necessary, and converts it to friction Load Ine
Conversion Value torque
Calculating the Added Load • Calculation of for a motor
Friction shaft.
Torque • Load Torque Formulas
• Calculation
Calculates of External
the frictional force forTorque
each element,
Torque For Motor Shaft Effective

Automation Systems
Calculates the
where necessary, andexternal
convertsforce for each element,
it to friction
Conversion Value where
torque for necessary,
a motor shaft. and converts it to external
• torque
Calculation of of a motorTorque
External shaft.
• Calculates the total load
fortorque for the motor

Automation Systems
Calculates the external force each element, Maximum
shaft conversion
where necessary, value. it to external
and converts Torque
torque of a motor shaft.
• Calculates the total load torque for the motor
Select a motor temporarily shaft •conversion
Select a motorvalue.temporarily based upon the
motor shaft converted load inertia, friction

Motion / Drives
---
torque, external torque and r.p.m of a motor. Maximum
Select a motor temporarily • Select a motor temporarily based upon the Speed
motor• shaft
Calculate the Acceleration/Deceleration
converted load inertia, friction Torque • Acceleration/Deceleration

Motion / Drives
Calculate Acceleration/ ---
Deceleration Torque torque,from the Load
external torqueInertia or Operating
and r.p.m of a motor.Pattern. Torque Formulas

Calculate Acceleration/ • Calculate the Acceleration/Deceleration Torque • Acceleration/Deceleration

Energy Conservation Support /

Environment Measure Equipment
Deceleration Torque from the Load Inertia or Operating Pattern. Torque Formulas Regener
Confirm Maximum • Calculate the necessary torque for each part of • Calculation of Maximum

Energy Conservation Support /

Environment Measure Equipment
Momentary Torque and the Operating Pattern from the Friction Torque, Momentary Torque, Effective
Calculate Effective Torque External Torque and Acceleration/Deceleration Torque
Confirm Maximum Torque.
• Calculate the necessary torque for each part of • Calculation of Maximum Encoder
Momentary Torque and • ConfirmPattern
the Operating that thefrom
maximum valueTorque,
the Friction for the Torque Momentary Torque, Effective
Calculate Effective Torque ExternalforTorque
each operating part (Maximum MomentaryTorque
and Acceleration/Deceleration
Torque.Torque) is less than the Maximum Momentary Characte

Power Supplies /
Positione

In Addition
• ConfirmTorque
that theofmaximum
the motor.value for the Torque
• Calculate
for each operatingthe Effective
part Torque
(Maximum from the Torque
Momentary
Torque)foris each Operating
less than part, andMomentary
the Maximum confirm that it is

Power Supplies /
In Addition
Torqueless than
of the the Rated Torque for the motor.
motor. Operatin
• Calculate the Effective Torque from the Torque
ME 423: Machine Design
for each Operating part, and confirm that it is
* When ha
less than the Rated Torque for the motor.
2 1 Instructor: Ramesh Singh END Selection
capacity

Others
19
2 1

Othe
 Technical Explanation for Servomotors and Servo Driv

Formulas
Operating Patterns: Triangular
Formulas for Operating Patterns

Speed

v0 Maximum Speed X0
v0 = X0: Distance Moved in t0 Time [mm]
tA
v0: Maximum Speed [mm/s]

Triangular Acceleration/Deceleration Time X0

tA = t0: Positioning Time [s]
v0
tA: Acceleration/
Deceleration Time [s]
tA tA Time Travel Distance X0 = v0·tA

t0

X0

Maximum Speed X0
Speed v0 =
t0 – tA

v0 Acceleration/Deceleration Time tA = t0 – X0
ME 423: Machine Design v0
Instructor: Ramesh Singh
Total Travel Time t0 = tA + X0 20
v0
 tA = t0: Positioning Time [s]
v0
tA: Acceleration/
Deceleration Time [s]
Time Travel Distance X0 = v0·tA

Operating Patterns: Trapezoidal

tA tA

t0

X0

Maximum Speed X0
Speed v0 =
t0 – tA

v0 Acceleration/Deceleration Time tA = t0 – X0
v0

Total Travel Time t0 = tA + X0

v0

Trapezoid Constant-velocity travel time tB = t0 – 2 · tA = 2 · X0 – t0 = X0 – tA

v0 v0
Time
tA tB tA Total Travel Distance X0 = v0 (t0 – tA)

t0
v0 ·tA
Acceleration/Deceleration Travel Distance XA = = v0 ·t0 – X0
XA XB XA 2 2

X0 Constant-velocity travel distance XB = v0 · tB = 2 · X0 – v0 · t0

Speed
Ascending Time tA = v0 – v1
v0 ME 423: Machine Design
Instructor: Ramesh Singh
Ascending Time (tA) including distance moved
v1 21
Speed and Slope 1
v XA = ·tA2 + v1 ·tA