A Design of AC Servo Motor Drive System

- BLDC T y ~ e-

Aktrsct-- A desim method of brushleas DC type AC servo

motor drive system is presented. This servo drive systr
is &signed to be applied to factory autaation. AC servo
motor we use is the trapezoidal type designed and made by
Oaeroo Heavy Industries. .Ltd. % drive system m i s t s of
velocity controller. current controller and inverter.
In the drive systm, power transistor is used as Sri tching
devices and a 16 bit one chip microprocessor is .pplied for
the implementation of digital control. The velocity control
algorithm is basically PI control with appropriate
filtering. And there has been m y considerations for the
improvement of low-speed characteristics. the calculation
of accurate speed feedback from the incremental encoder of
2000 PPR. the determination of control gains, etc.
The current controller is also based on PI control. which
is iaplwented in annlog circuits to reduce the ti- delay
Fig.1 The External Appearance of AC Servo Motor Driver
effect. The designed servo drive shows good performance
up to velocity of 4500 rp. which is sufficient for the
most of factory automation applications. exchanging m e r elsments and couple of other eleaents and
setting Dip switch and jumper. System structure is shown
in Fig.2.

I. INlRowcTIoN
Significance of servo actuator is increasing as factory
automation becoaes the mtter of interest due to rapid
grwing of labor cost. Permanent .agnet AC servo motor
coq."d with DC servo motor has virtues of small size,
light weight and maintermme free due to brushlessness.
It becomes easier to control AC servo motor with the
develop.ent of microelectronics and semiconductor techniques.
which increases the use of AC servo motor and drives. ?he
developed servo motor drives which consists of five types
(50-5001) can be appiled to XI table. assably robots.
chip mounting d i n e and coil winding d i n e s . llm
external appearence of the developed AC servo mtor and
drives is shown in Fig.l.
M - s series use. our o m developed WPS (Switching Mode
Power supply) in order to reduce its size.wei&t and coat
and puts inverter circuits in it to simplify framework.
All types of servo motor drives(50-5001) use identical PCB
and fr- so that i t is possible to change the type by
11-1. MAIN CIRCUIT
AC 22OVflOK. 6OHz single-phase full-bridge rectifier
drives is used as the power source. A bleed resistor is
used to prevent current surging into smoothing capacitor
during charging ti-. Inverter uses base driver module and
power transistor module which consists of 6 TR to reduce
size. And three types of 200.300 and 5001 have
regenerative resistors in t h so as to be loaded by wide
range of load inertia up to 10 times of motor inertia. In
order to protect malfunction and resulting loss. trouble
detecting functions are included as follows :
- Overvoltage : operates when DC link voltage exceeds IOOV.
- Undervol tage : operates when DC link voltage drops under
2ooV.
- Overcurrent : operates when current exceeds 3oow of
fated current.
- Overload : operates when motor is overloaded.
- Overspeed : operates h e n speed exceeds 4900RR1
- MCCB trip(AC) : operates when power source is off.
- Encoder error : operates .hen encoder pu1.e error

@7803-1227-9/93/$3.00@1993 IEEE 658

 Fig. 2 System Structure

or connector is opened. ( 2 ) Foreground routine

- cpo error : operates .hen software error occurs. - Speed c M a n d input
- Regenerative trouble : operates .hen rqeneratim - Speed f-prRarL calculation
continues over certain period. - Collpensation of speed f e " & at lor .peed
- Overheat : operates .hen regenerative resistor or - Execution of speed cmtrol algorithm
power TR is overheated. - Alarm detection
(3) Badygwnl routine
It-2. sPEEDm0uF.R
- Setting control parameter
- Setting current limit value
Spead controller is implemented by digital control
- AI" detectian
method using 8795BH. a 16 bit one-chip microprocemor.
As a result of that.
- Servo an/off processing
which has ROM and RAM in it.
- Speed and parameter display
speed controller is not affected by drift due to temperature
( 4 ) Interrupt service routine
and various control algorithm can be applied to it.
- Servo off, gate off and m e r source off .hen
alarm occurs.
11-2-1. SoFIlARE SrRUcNRE
- Alan display
Software structure of speed controller is as follows :
Speed control system is shom in Fig.3.

(1) Initial routine

- Initialization of variables It-2-2. SPEED m a ( CAUXRATION
- Setting parameter complying with capcity
- Initialization of A/D. D/A In foreground routine, we concentrate on accurate speed

V d :- VeheiN Command Ki:lnt-tiolul Gain KT:Mo~w Torque C " t m

.
WM:DipiUl VekciN C m d
KA0:NX: Cain

# :# -
:Fraiher Cvtoff 6rp.
KVKP
KP:Ra-l
I
K D A : D MGain
Gain
D : c o ~ u t i o nTim Delay

Kw:Pouver h p TmnronducPrre Gain

I:Mo"t
K:U& Con-
oi land. Or T d
Fwta
K l e ~ V e l o c iFccdbrk
n : w rorpve l~ Gain
svlcm

659
 feedback calculation, particularly at lower speed range. We determine the control gains such that the following
In speed measurement from the incremental encoder output. conditions are satisfied.
there are two commonly used methods ; that is, M method
(encoder output pulses during a prescribed period of time (1) The bandwidth of the speed control loop is 100 Hz.
are digitized by utilizing a counter) and T method (the (2) The overshoot of the velocity step response should be
reciprocal of the duration between two consecutive pulses less than 51%.
is obtained), But. M method has low accuracy and IOW ( 3 ) The torque ripple at low speed (about 10 rpo) should
resolution at a low speed, while T method has low accuracy be less than 24%.
and low resolution at a high speed. (4) The applicable load inertia should be more than
So we applied the M/T method [2] for overcoming the 10 times of the motor inertia.
above problems, that is, for obtaining high resolution and (5) The disturbance torque rejection characteristic should
high accuracy. Another important point is that the speed be good.
detecting time should be as short as possible for preventing (6) 0.1 a< <
p 0.2 a is satisfied [4].
the increase of the lag time in the velocity control system. ( where a : zero of the current controller
But owing to the processing speed of CPU we used. we select
19 : zero of the speed controller )
0.5 msec as the speed detecting time. (This also corresponds For example. in the case of 3OOW drives, KP = 2.0 &
to the sampling time of the velocity control loop. ) B = 60.0 are determined. Fig.5 shows the result of
In the M/T mthod. speed measurements are &ne as the velocity step response and Fig.6 shows the result of
described in the Fig.4. torque ripple at 10 rp..

DETECTING TIME

CLOCK PULSE

Fig.4 Description of M/T method in Speed Measurement

Fig.5 Velocity Step Response
In this figure, the detecting time Td is determined by
synchronizing the generated output pulse first after the
prescribed period of time Tc (which is 0.5 .sec in our case).
that is Td = Tc + AT. Here, m1 is the nunber of the
encoder output pulses during Td and m~ is the number of
the clock pulses of the frequency fc(Hz) during Td.

The measured variable of the speed Nr(rpm) is then

calculated by the following :

60 fc m i
Nr = where P is the number of
P mz encoder pulses per each revolution.

In this case, P = ZOO0 and fc = 5OOKHz.

11-2-3. m 0 L GAINS ETERMINATION 11-3. C"r c0"IUsR

In the block diagram of Fig.3. the parameters are DAMC-S series is of the trapizoidal type drives which
as follows. supplies trapizoidal current complying with the
displacement of the rotor of the motor. The current
T = 0.5 msec KTC = 1 controller is implemented in analog circuits to redm time
a = 600% rad/sec rD 0.2 .sec delay effect. The control algorith. is also based on PI
KDA = 0.01 Vlcount Kpr = 1.1 A/V control .ethod. The comparator produces switching signal
K = 9.5493 -/rad sec-' KT = 0.29 Fb/A based upon comparison of current control output with the
triangular signal. The dified PIM circuit is designed 1. SPEClFlCATlONS
and used to improve performance during acceleration or
deceleration. The dead time of switching &vices is reduced D M - S series for speed control uses an incrmntal
with suitable switching technique in inverter circuits. encoder(2000 PPR) as a speed detector and consists of
Fig.7 shows the definition of forward running and phase 5 types of 50.100.2oO.300 and 5001. Table.1 shows
relation between encoder commutation signal output and standard specifications for servo drives.
phase-current during forward running.
Fig.8 is the current controller block diagram. The
bandwidth of current control loop is 850 Hz. The current
control gains are selected to meet this bandwidth and Table.1 Ratings and Specifications of AC servo Driver
the other considerations such as rising time, overshoot
and settling time. The detailed design values are omitted DAMC-S Series
in this paper. Fig.9 shows phase-current of motor at
rated point in this case.

@ Running
Forunrrl
(CCW

forward running

Cmtl- Output f0.75 f1.W fZ.42 33.44 35.06

Curnnt (a)
0 salzo~lwico.jmw
WaxOutput aUr.(AEI f3 f4 f8 ill f16
encoder comutation signal output
A l l d l o G D k&a 3.04 5.0 20.28 33.04 108.8

Ponr Supply I-RUU nov f lor 60k

Cmtml kthad I - R u u , full-wave mAlfying. T m i m t o r PIM

S p d F a htiul M r (2OOO prlmg/mv)

phase-current during forward running. &lent T r p n t u r r 0 - *55' c

Fig.7 Definition of Forward Running & Phase-currents

I
I I
' !
!
I hcdar htput I A+. Be. 2 9 : Llm Driver k Open Collector I
Servo A l u r . C u r n n t Liait. E ON.
Servo Ready. Alarm cods(4 b i t )

Dywic 8 d a At Main P a e r OFF. Servo Alan.Servo OFF

-tion 50.1001 : Not Rovidd

20O.rw).5001: Rovidd ( h t a i n b. ) -.

,..
-..o
v.0.0 Y. ,..-
Fig.9 Phase-current of the Motor at Rated Point

661
 DAMC-S series. AC servo motor drives for €A, is of
trapezoidal type drives using PIM transistor CMtldled
by single-phase full-bridge rectifier. It can be applied
t o x( table. assedly robots. chip m m t i n g machine and
coil winding machines.
We also note that in order to obtain the mm accurate
speed feedbadc f r a the inexpensive low precision encoder
output. the instantanears speed obsemer schere in [31
can be applied using the armature current together with
the encoder output pulse. But this method requires
DSP(Digita1 Signal Processor) for a very short sampling
period(e.g. lOo/m) and w a s not considered in this pnper.
This method will be applied to cur next adel of higher
accuracy version.
662
[11 S.M.Lee. Y.H. Ch. K . H . M . N . C . K d . "Technical RepDrt
on AC Servo Motor Driver W - S Series", Central R&D
Institute. Deewoo Heavy Industries L t d . . 1991
121 Tsutou ohrae. Toshiniko Matsuda. Kenzo Kamiyaul and
Makoto Tachikawa. 'A Microprocessor-Controlled High
Accuracy Wide-Range Speed Regulator for hbtor Drives".
IEEE Trans. cm Industrial Electronics. Vol. IE-29.No.3.
pp.207-211. A w t . 1982
[31 Yoichi Hori. Takaji Lbeno. Toshiyuki udrida and Yusuke
Konno. "An Instantaneous Speed Observer for High Perfo-e
Control of DC Servo Motor Using Dsp and Lor Precision Shaft
Encoder". EPE F i m e . pp.3-647-3-652. 1991
[I1 I1 tkmg Suh. Seung Ho bang and Zemg" Bien. "A Design
and Experiment of speed Controller with PI-plus Bang--
Action for a Dc Servomotor with Transistorized PIM hiwe".
IEEE Trans. on IE. Vol. IE-31. No.4. pp.338-345. 1981