Advanced Setpoints

12
Trajectory Planning, Setpoint Generation

and Feedforward for Motion Systems
Paul Lambrechts
Digital Motion Control (4K410), 2003
Faculty of Mechanical Engineering, Control Systems Technology Group 1/42

12
Overview
• Industrial motion control
– Motion control and factory automation;
– Current methods for feedforward control
– Performance characteristics for trajectory planning
– Second order trajectory planning algorithm
• Fourth order feedforward for electromechanical motion systems

• Fourth order trajectory planning algorithm
• (Further) implementation aspects
– Architecture
– Switching times
– Discrete time integration and synchronization
– First order filter implementation
• Simulation results
• Conclusions

12
Industrial motion control
• Robots
• Pick-and-place units
• Wafersteppers
Motion Control Tasks:

• Safety, Communication, etc.
• System compensation
• Trajectory planning
• Feedforward control
• Feedback control Industrial Robot

12
Main digital control functions
Error Application
handling interface
+
I/F Setpoints Hc I/F
-
Integrated I/F
functions Hardware
interfaces
An introduction to Digital Control #10

12
‘Simple’ rigid-body feedforward
x
F
m
k
1 DOF rigid-body model
mẍ + k ẋ = F ⇒ Fff = ma + kv
x is position, m is (equivalent) mass or inertia, k is viscous damp-
ing, F is actuator force and Fff is feedforward force.

12
Feedforward based on inverse model
ms 2
xs 1 x
K p Kv s
ms 2
Digital Motion Control 8

Feedforward design

12
Trajectory profiles for rigid-body feedforward
Second order trajectory profiles
5
a [m/s2]
−5
0 0.2 0.4 0.6 0.8 1
1.5
v [m/s]
1
0.5 Fff = ma + kv
0
0 0.2 0.4 0.6 0.8 1
1
x [m]
0.5
0
0 0.2 0.4 0.6 0.8 1
time [s]

12
General controller implementation
Kfst
static feedforward
Setpoint
+
direction
Kfc +
Setpoint Coulomb friction compensation
+
velocity
Kfv +
velocity feedforward
Setpoint
+
acceleration
Kfa
Setpoint acceleration feedforward +
position +
Kp
Setpoint + + +
-2 +1
generator +
- +
d + + LowPass
dt Kv Ki ³ LeadLag Notch /
Saturation
LeadLag
measured position
integrator anti-windup

12
Second order feedforward:
a
m
Acceleration v
k
profile generator
F
1 1 1
PD x
s s m.s2+k.s
Velocity Position Controller 2nd order model

12
Trajectory planning performance (p2p)
5 • Timing: minimal trajectory
a [m/s2]
execution time
0
• Realizability: constrained
−5
0 0.2 0.4 0.6 0.8 1 dynamics (ā and v̄)
1.5
• Accuracy: trajectory ends at
v [m/s]
1
0.5 desired end position (x̄)
0
0 0.2 0.4 0.6 0.8 1
• Complexity: calculation time
1 • Reliability: always
x [m]
0.5 valid solution

0 • Implementation:
0 0.2 0.4 0.6 0.8 1
time [s] discretization, quantization
12
Profiles given ā, v̄ and x̄:
q
1. Forget v̄ : x̄ = 2 × 12 āt2 ⇒ tā = x̄ ⇒ t = 2t
ā x̄ ā
2. Calculate maximal velocity: v̂ := ā · tā
3. v̂ > v̄ ?; true: tā = āv̄ , false: tā = 12 tx̄
4. xā := 2 × 21 āt2ā ≤ x̄
(x̄−xā)
5. tv̄ = v̄

12
Properties of trajectory planning algorithm
5
ta • Timing: minimal,
a [m/s2]
tv
0 determined by tā and tv̄
ta
−5 • Realizablity: guaranteed
0 0.2 0.4 0.6 0.8 1
1.5
by ā and v̄
v [m/s]
1 • Accuracy: exact within

0.5
machine accuracy
0
0 0.2 0.4 0.6 0.8 1 • Complexity: low
1
• Reliability: always valid
x [m]
0.5
solution
0
0 0.2 0.4 0.6 0.8 1 • Implementation: later
time [s]

12
Extensions of rigid body feedforward
• Smoothing and shaping
– third order trajectories with rigid body feedforward ?
– filtering of second order trajectories and feedforwards ?
• Model inversion
– using second or third order trajectories ?
– focus on frequency domain properties ?
– learning techniques ?
→ back to basics !

12
4th order model for electro-mechanical motion
system
x 1 x 2
c
F
m 1 m 2
k 1 2
k 1 k 2
1 DOF 4th order model
x1 and x2 are actuator and load position, m1, m2 masses, k1, k2

viscous damping, c spring stiffness, k12 internal viscous damping,
F is actuator force.

12
4th order feedforward
Equations of motion:

m1ẍ1 = −k1ẋ1 − c(x1 − x2) − k12(ẋ1 − ẋ2) + F
m2ẍ2 = −k2ẋ2 + c(x1 − x2) + k12(ẋ1 − ẋ2)
Laplace transform and substitution:




 q1 = m1 m2
q1 s 4 + q2 s 3 + q3 s 2 + q4 s q2 = (m1 + m2)k12 + m1k2 + m2k1

F = ·x2
k12s + c 
 q3 = (m1 + m2)c + k1k2 + (k1 + k2)k12

q
4 = (k1 + k2)c
Feedforward force calculation:

1
Fff = · {q1d + q2 + q3a + q4v}
k12s + c
12 1000
Trajectory profiles
d [m/s4]
−1000
0 0.2 0.4 0.6 0.8 1 1.2
for 4th order
50
feedforward
j [m/s3]
−50
0 0.2 0.4 0.6 0.8 1 1.2
5
a [m/s2]
−5
0 0.2 0.4 0.6 0.8 1 1.2 q1 d + q2  + q3 a + q4 v
1.5 Fff =
1
k12s + c
v [m/s]
0.5
0
0 0.2 0.4 0.6 0.8 1 1.2
1
x [m]
0.5
0
0 0.2 0.4 0.6 0.8 1 1.2

12
4th order feedforward: Fff =
q1 d + q2  + q3 a + q4 v
k12s + c
d
q1
Derivative of jerk
profile generator q2
Rigid Body Feedforward
q3
q4
1
k12.s+c
F
1 1 1 1 Motion
PD x
s s s s System
Jerk Acceleration Velocity Position Controller 4th order model

12 1000
d [m/s4]
4th order trajectory 0
−1000
planner ?? 50
0 0.2 0.4 0.6 0.8 1 1.2
j [m/s3]
0
• Point-to-point move
(all derivatives zero −50
0 0.2 0.4 0.6 0.8 1 1.2
at start and end) 5
a [m/s2]
0
• Given: displacement x̄
and bounds d,¯ ̄, ā and v̄ −5
0 0.2 0.4 0.6 0.8 1 1.2
1.5
• Performance criteria !? 1
v [m/s]
0.5
0
0 0.2 0.4 0.6 0.8 1 1.2
1
x [m]
0.5
0
0 0.2 0.4 0.6 0.8 1 1.2

12
4th order trajectory specification:
Second order trajectory profiles: 3 time periods, 2 sizes and max a
5
ta
tv
a [m/s2]
ta
−5
0 0.2 0.4 0.6 0.8 1
Fourth order trajectory profiles: 15 time periods, 4 sizes and max d
1000
t t t t
500 d d d d
t t t t t t t
d [m/s4]
j a j v j a j
0
−500 td td td td
−1000
0 0.2 0.4 0.6 0.8 1
time [s]

12
Fourth order trajectory profiles
4th order calculations 1000

d0
d [m/s4]
500
0
0.39 0.4 0.41 0.42 0.43 0.44 0.45 0.46
d(t) = d0 0
j [m/s3]
−20
−40 j0
(t) = d0t + 0 0.39 0.4 0.41 0.42 0.43 0.44 0.45 0.46
2
a [m/s2]
1 2 1 a0
a(t) = 2 d0 t + 0t + a0
0
0.39 0.4 0.41 0.42 0.43 0.44 0.45 0.46
1 1.5
v(t) = 6 d0 t
3
+ 12 0t2 + a0t + v0 v
v [m/s]
0
1.45
0.39 0.4 0.41 0.42 0.43 0.44 0.45 0.46
1 4 1 3
x(t) = 24 d0 t + 6 0 t + a0t2 0.35
x [m]
0.3
x0
+v0t + x0 0.25
0.39 0.4 0.41 0.42 0.43 0.44 0.45 0.46
time [s]

12
Fourth order trajectory profiles, no bounds on j, a or v
1000
4th order planning t
d
t
d
t
d
t
d
d [m/s4]
0
calculate td¯ −1000

t
d
t
d
t
d
t
d
0 0.2 0.4 0.6 0.8 1 1.2
100
j [m/s3]
td¯ only depends on d¯ and x̄ 0
−100
q 0 0.2 0.4 0.6 0.8 1 1.2
x̄
⇒ td¯ = 4
8d¯
10
a [m/s2]
0
−10
q
3 v̄
v̄ violated: td¯ = 2d¯
0 0.2 0.4 0.6 0.8 1 1.2
v [m/s]
1
q
ā
ā violated: td¯ = d¯ 0
0 0.2 0.4 0.6 0.8 1 1.2
1
̄
̄ violated: td¯ =
x [m]
d¯ 0.5
0
0 0.2 0.4 0.6 0.8 1 1.2
time [s]

12
Fourth order trajectory profiles, final td
1000
d
t
d
t t
d d
d [m/s4]
0
final td¯ −1000

t t
d d
t
d
t
d
0 0.2 0.4 0.6 0.8 1 1.2
50
j [m/s3]
0
−50
0 0.2 0.4 0.6 0.8 1 1.2
Note:
2
a [m/s2]
• No bounds violated 0
−2
• Final td¯ always ≤ first td¯ 0 0.2 0.4 0.6 0.8 1 1.2
0.2
• Consequently: x̄ not reached
v [m/s]
0.1
0
0 0.2 0.4 0.6 0.8 1 1.2
0.04
x [m]
0.02
0
0 0.2 0.4 0.6 0.8 1 1.2
time [s]

12
Fourth order trajectory profiles, no bounds on a or v
1000
d tj tj
t
d tj
t t
d d tj
d [m/s4]
0
calculate t̄ −1000

t t
d d
t
d
t
d
0 0.2 0.4 0.6 0.8 1 1.2
50
j [m/s3]
Add periods of constant jerk 0
until x̄ is reached again −50

0 0.2 0.4 0.6 0.8 1 1.2
10
a [m/s2]
t̄ follows from: 0
t3̄ + (5td¯)t2̄ + (8t2d¯)t̄ + (4t3d¯ − 2dtx̄¯ ¯) = 0 −10

0 0.2 0.4 0.6 0.8 1 1.2
d
2
v [m/s]
1
0
v̄ violated: t2̄ + 3td¯t̄ + 2t2d¯ − dt¯v̄ ¯ =0 1
0 0.2 0.4 0.6 0.8 1 1.2
d
x [m]
0.5
ā
ā violated: t̄ = − td¯
̄ 0
0 0.2 0.4 0.6 0.8 1 1.2
time [s]

12
Fourth order trajectory profiles, final td and tj
1000
d tj tj
t
d tj
t t
d d tj
d [m/s4]
0
final td¯ and t̄ −1000

t t
d d
t
d
t
d
0 0.2 0.4 0.6 0.8 1 1.2
50
j [m/s3]
0
−50
0 0.2 0.4 0.6 0.8 1 1.2
Note: 5
a [m/s2]
−5
• Final t̄ always ≤ first t̄ 0 0.2 0.4 0.6 0.8 1 1.2
0.8
0.6
v [m/s]
0.4
0.2
0
0 0.2 0.4 0.6 0.8 1 1.2
0.2
x [m]
0.1
0
0 0.2 0.4 0.6 0.8 1 1.2
time [s]

12
Fourth order trajectory profiles, no bounds on v
1000
d tj ta tj
t
d tj
t
d ta
t
d tj
d [m/s4]
0
calculate tā −1000

t
d
t
d
t
d
t
d
0 0.2 0.4 0.6 0.8 1 1.2
50
j [m/s3]
Add periods of constant 0
acceleration until x̄ reached −50

0 0.2 0.4 0.6 0.8 1 1.2
5
tā follows from:
a [m/s2]
0
{t2d¯ + td¯t̄} t2ā +
−5
0 0.2 0.4 0.6 0.8 1 1.2
{6t3d¯ + 9t2d¯t̄ + 3td¯t2̄ } tā + 2
v [m/s]
1
{8t4d¯ + 16t3d¯t̄ + 10t2d¯t2̄ + 2td¯t3̄ − x̄d¯} = 0
0
0 0.2 0.4 0.6 0.8 1 1.2
1
¯ 3 −3dt
¯ 2 t̄ −dt
¯ ¯t2
x [m]
v̄−2dtd¯ d¯ d ̄ 0.5
v̄ violated: tā = ¯ 2 ¯
dt +dt ¯t̄
d¯ d 0
0 0.2 0.4 0.6 0.8 1 1.2
time [s]

12
Fourth order trajectory profiles, final ta, td and tj
1000
d tj ta tj
t
d tj
t
d ta
t
d tj
d [m/s4]
0
final td¯, t̄ and tā −1000

t
d
t
d
t
d
t
d
0 0.2 0.4 0.6 0.8 1 1.2
50
j [m/s3]
0
−50
0 0.2 0.4 0.6 0.8 1 1.2
Note: 5
a [m/s2]
−5
• Final tā always ≤ first tā 0 0.2 0.4 0.6 0.8 1 1.2
1.5
v [m/s]
1
0.5
0
0 0.2 0.4 0.6 0.8 1 1.2
0.6
For final step:
x [m]
0.4
determine obtained position xā 0.2
0
0 0.2 0.4 0.6 0.8 1 1.2
time [s]

12
Fourth order trajectory profiles, final tv, ta, td and tj
1000
d tj ta tj
t
d tv tj
t
d ta
t
d tj
d [m/s4]
0
calculate tv̄ −1000

t
d
t
d
t
d
t
d
0 0.2 0.4 0.6 0.8 1 1.2
50
j [m/s3]
Final step: add period of 0
constant velocity until x̄ reached −50

0 0.2 0.4 0.6 0.8 1 1.2
5
a [m/s2]
0
x̄ − xā
tv̄ = −5
v̄ 0 0.2 0.4 0.6 0.8 1 1.2
1.5
v [m/s]
1
0.5
0
Finished: trajectory completely 0 0.2 0.4 0.6 0.8 1 1.2
1
determined by 5 parameters !
x [m]
0.5
0
0 0.2 0.4 0.6 0.8 1 1.2
time [s]

12
(Further) Implementation aspects
• Architecture
• Switching times
• Discrete time integration and synchronization
• First order filter implementation

12
How to deliver setpoint data?(cont.)
Solution 3: Split off setpoint interpolation
Trajectory setpoint
GUI controller
generation interpol.
?? CPU
CPU
Additional requirement : Datalink CPU1 to CPU2

12
Architecture
1
Force
1
p 2
Reference
1
v
Derivative of jerk
5 p,v,a,j,d
a t,d t,d djerk djerk FF Demux
Jerk
45 Ts Ts
enable start Generate
j Plan Trajectory
Feedforward Acceleration
1000 Generate Profile
d
Velocity
0
1
Position
Trigger/Enable
Step Profiles

12
Fourth order trajectory profiles: intervals
1000
Switching 500
td td td td
tj ta tj tv tj ta tj
d [m/s4]
times 0
−500 td td td td
−1000
0 0.2 0.4 0.6 0.8 1
Switching times
1000
500
d [m/s4]
t2 t3 t4 t5 t8 t9 t14 t15
0
t0 t1 t6 t7 t10 t11 t12 t13
−500
−1000
0 0.2 0.4 0.6 0.8 1
Synchronisation with sampling instances at 100Hz?
1000
500
tj
d [m/s4]
t8 t9
0
t10
−500 td
−1000
0.65 0.7 0.75 0.8
time [s]

12
Switching times synchronization
Make sure that each interval is a multiple of the sampling time Ts
Example: r
x̄
td¯ = 4 ¯
8d

t¯
t0d¯ = ceil d × Ts
Ts
Correct d¯
x̄
d¯0 = 0 4
8td¯
Note that with t0d¯ ≥ td¯ we must have d¯0 ≤ d¯

12
4th order feedforward in discrete time ?
d
q1
Derivative of jerk
profile generator q2
Rigid Body Feedforward
q3
q4
1
k12.s+c
F
1 1 1 1 Motion
PD x
s s s s System
Jerk Acceleration Velocity Position Controller 4th order model

12
d d
Discrete time Derivative of Jerk

profile generator
Ts
-----
----
j Ts
-----
----
a Ts
-----
----
v Ts
-----
---- x
z-1 z-1 z-1 z-1
integration Jerk Acceleration Velocity Position
Normalized discrete time fourth order profiles, compared with continuous time profiles
a: not synchronized b: synchronized, delayed by 2Ts
Synchronization of
profiles:
d
d with 2Ts,
j with 1 12 Ts,
j
a with Ts,
v with 12 Ts.
a
→ 12 Ts ?
v
1
In1
1
0.5
z
Unit Delay 1
x
Out1
0 0.2 0.4 0.6 0.8 1 0 0.2 0.4 0.6 0.8 1

time [s] time [s]

12 1
u y
k12.s+c
First order filter Continuous time
1
implementation u 1/k12
s
y
c/k12
Algebraic loop !!
Ts(z+1)
u 1/k12 --------
------- y
2(z-1)
ZOH
Discrete-Time
Integrator: Trapezoidal
c/k12
Algebraic loop !!
1
u 1/k12 Ts 1/2 y
z
ZOH
Transfer function:
c/k12
Ts
2k12 +cTs (z + 1) NO algebraic loop !!
y= 2k12 −cTs
u 1
z − 2k12+cTs u -K-
z
y
ZOH Ts/(2*k12+c*Ts)
-K-
(2*k12-c*Ts)/(2*k12+c*Ts)

12
Digital 4th order feedforward
[d] derivative of jerk

d position
Demux
ZOH1 T [j] T [a] T [v] T [p1]
Profile Generator Position
dJerk with error correction z-1 z-1 z-1 z-1
[p2]
jerk acceleration velocity position
position correction Quantizer prevent

negative
ZOH2
derivative of jerk [d] 1/z 1/z -K- -K-

[d]
m1*m2 1/c
jerk
[j] [j] 1/z 0.5*Ts -K- Feedforward Force
(m1+m2)*k12+m1*k2+m2*k1 1
acceleration -K- 1
[a] z
[a] 1/z -K- 1/k12*Ts/(2+c/k12*Ts) Force
Unit Delay4
velocity (m1+m2)*c+k1*k2+(k1+k2)*k12
[v]
[v] 0.5*Ts -K- -K-
[p1] position (k1+k2)*c
(2-c/k12*Ts)/(2+c/k12*Ts)
[p2]
Trajectory
Profiles
[p2] 0.5*Ts 2
Ref

12
Bound selection
• Velocity:
– back EMF smaller than power supply voltage
– motor or gearbox specification (temperature)
• Acceleration:
– maximum power supply or motor current
– mechanical restrictions
• Jerk:
– power amplifier rise time
– mechanical restrictions
̄
• Derivative of jerk upper bound: Ts
12
Open loop fourth order feedforward response of servo error with plant variations
Simulation x 10
−5 Dashed line gives nominal rigid body FF response
8
results Parameter Value Unit Variation
m1 20 Kg m1 ∈ {15· · ·25},
6 m2 10 Kg m2 =30−m1
Robustness k1 10 Ns/m k1 ∈ {5· · ·15},
k2 10 Ns/m k2 =20−k1
against variations 4 c 6 ·105 N/m ±33 %
in additional k12 500 Ns/m ±100 %
Position error [m]
parameters 2
−2
−4
−6
0 0.5 1 1.5 2 2.5 3
time [s]

12
Open loop feedforward response of servo error
−5
x 10 Optimal second, third and fourth order feedforward
Simulation 8
second order FF
third order FF
results 6
fourth order FF
Position error [m] 4
2
Effect of order
of feedforward
0
−2
−4
−6
0 0.5 1 1.5 2 2.5 3
time [s]

12
−5
x 10 Digital ff response: 4th order, minimal c, Ts=5e−3
4
Simulation x 10
−6
8
results 3 6
4
2 2
Position error [m] 0
−2
1 −4
Discrete time 0.3 0.35 0.4 0.45
vs. continuous
0
time
−1
−2
−3
0 0.5 1 1.5 2 2.5 3
time [s]

12
Conclusions
• Superior performance of 4th order vs. rigid-body feedforward
• Algorithm no problem for state-of-the-art motion controllers
• Especially feedforward of djerk effective (for electro-mechanical
motion systems)
• Complete derivation (also for third order) available
• Simulink toolbox ‘motion’ available
• Report: ‘Trajectory planning and feedforward design for elec-
tromechanical motion systems’ available (DCT 2003-18)

12
Exercises
• .ZIP file available in OUTLOOK for Matlab release 12.1
• See exercises.pdf
– MAKE# and PROFILE# .M files
– The ‘motion’ library
– Feedforward in continuous and discrete time
– Real-time implementation

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12

Trajectory Planning, Setpoint Generation

Digital Motion Control (4K410), 2003

Faculty of Mechanical Engineering, Control Systems Technology Group 1/42

• Fourth order feedforward for electromechanical motion systems

Faculty of Mechanical Engineering, Control Systems Technology Group 2/42

Motion Control Tasks:

Faculty of Mechanical Engineering, Control Systems Technology Group 3/42

Faculty of Mechanical Engineering, Control Systems Technology Group 4/42

Faculty of Mechanical Engineering, Control Systems Technology Group 5/42

Feedforward based on inverse model

Digital Motion Control 8

Faculty of Mechanical Engineering, Control Systems Technology Group 6/42

Faculty of Mechanical Engineering, Control Systems Technology Group 7/42

An introduction to Digital Control #38

Faculty of Mechanical Engineering, Control Systems Technology Group 8/42

Faculty of Mechanical Engineering, Control Systems Technology Group 9/42

0.5 valid solution

2. Calculate maximal velocity: v̂ := ā · tā

3. v̂ > v̄ ?; true: tā = āv̄ , false: tā = 12 tx̄

Faculty of Mechanical Engineering, Control Systems Technology Group 11/42

1 • Accuracy: exact within

Faculty of Mechanical Engineering, Control Systems Technology Group 12/42

Faculty of Mechanical Engineering, Control Systems Technology Group 13/42

1 DOF 4th order model

x1 and x2 are actuator and load position, m1, m2 masses, k1, k2

Faculty of Mechanical Engineering, Control Systems Technology Group 14/42

Laplace transform and substitution:

Feedforward force calculation:

Faculty of Mechanical Engineering, Control Systems Technology Group 16/42

Rigid Body Feedforward

Faculty of Mechanical Engineering, Control Systems Technology Group 17/42

at start and end) 5

Faculty of Mechanical Engineering, Control Systems Technology Group 18/42

Faculty of Mechanical Engineering, Control Systems Technology Group 19/42

4th order calculations 1000

Faculty of Mechanical Engineering, Control Systems Technology Group 20/42

calculate td¯ −1000

Faculty of Mechanical Engineering, Control Systems Technology Group 21/42

final td¯ −1000

Faculty of Mechanical Engineering, Control Systems Technology Group 22/42

calculate t̄ −1000

until x̄ is reached again −50

t3̄ + (5td¯)t2̄ + (8t2d¯)t̄ + (4t3d¯ − 2dtx̄¯ ¯) = 0 −10

Faculty of Mechanical Engineering, Control Systems Technology Group 23/42

final td¯ and t̄ −1000

Faculty of Mechanical Engineering, Control Systems Technology Group 24/42

calculate tā −1000

acceleration until x̄ reached −50

Faculty of Mechanical Engineering, Control Systems Technology Group 25/42

final td¯, t̄ and tā −1000

Faculty of Mechanical Engineering, Control Systems Technology Group 26/42

calculate tv̄ −1000

constant velocity until x̄ reached −50

Faculty of Mechanical Engineering, Control Systems Technology Group 27/42

Faculty of Mechanical Engineering, Control Systems Technology Group 28/42

Additional requirement : Datalink CPU1 to CPU2

An introduction to Digital Control #17

Faculty of Mechanical Engineering, Control Systems Technology Group 29/42

Faculty of Mechanical Engineering, Control Systems Technology Group 30/42

Faculty of Mechanical Engineering, Control Systems Technology Group 31/42

Note that with t0d¯ ≥ td¯ we must have d¯0 ≤ d¯

Faculty of Mechanical Engineering, Control Systems Technology Group 32/42