Servo Tuning. Dr. Rohan Munasinghe Department. of Electronic and Telecommunication Engineering University of Moratuwa. Thanks to Dr.

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1 Servo Tuning Dr. Rohan Munasinghe Department. of Electronic and Telecommunication Engineering University of Moratuwa Thanks to Dr. Jacob Tal Overview

2 Closed Loop Motion Control System Brain Brain Muscle Human Arm Manager of the whole system Tells to perform a move Tells the driver what to do Amplifier, the device that supplies required power The most important part The payload to be moved Tells where the motor is Eyes Closed loop motion control systems Servo systems Some motion control systems are open loop (step motor systems) - No closed loop, so, no tuning involved

3 Typical Servo System Communication environment Servo Design Kit Software tool to aid in tuning and analysis of servo systems

System Compensation with PID Simply closes the loop Closing the loop gives the position error which goes to the PID filter PID filter is used in almost all servo

To stabilize the system D is required which suppresses the action of P.

4 System Compensation with PID Simply closes the loop Closing the loop gives the position error which goes to the PID filter PID filter is used in almost all servo systems in the world P makes the system responsive and stiff, it could destabilize the system (under delay). To stabilize the system D is required which suppresses the action of P. With P and D system is stable, yet, there could be steady state errors due to friction and gravity etc. I control generates a signal whenever there is such error and tries to correct it Step Response Fast rising to step, with very little overshoot Great performance No Integrator Motor doesn t get to zero

Problem Extremely responsive to noise and resonances Introduces

5 Too Low K D Problem System is under damped Low damping produces overshoot (and undershoot) D stands for stability Too High K D Problem Extremely responsive to noise and resonances Introduces vibrations (dither) while following the step response Note: Find the optimum K D

Then set and optimize PID filter gains Absolute Stability Test K D =300 K P = 20 K I = 0 Deliberately introduce A MAJOR

6 Auto-tuning tuning crossover Frequency Pretty good response SDK applies driving signal to the motor and measure its motion to identify system parameters such as inertia, friction (system identification). Then set and optimize PID filter gains Absolute Stability Test K D =300 K P = 20 K I = 0 Deliberately introduce A MAJOR DISTURBANCE, which makes amplifier saturation, and check whether the position is still stable. If the system is stable under worst condition, you should be happy with that.

70% of the command magnitude at 115Hz (crossover frequency) Higher BW is preferable in motion control System can comfortably follow commands up to 115Hz.

7 Frequency Response Back and forth motion at different frequencies. For slow frequencies, motor could follow the slowly varying command. As frequency increases, command tends to vary fast making it difficult for the motor to follow it - The system attenuates high frequencies 120Hz response, 60% mag command response Response drops to 70% of the command magnitude at 115Hz (crossover frequency) Higher BW is preferable in motion control System can comfortably follow commands up to 115Hz. At 120Hz, the response is less than what we asked, and the system can only follow up to 60% of the 120Hz command magnitude. Frequency at which the response drops to 70% in magnitude is the system BW Most practical motion control systems have 20Hz<BW<70Hz on load. Under no load condition the system has more bandwidth.

8 Motion Commands Point-to to-point Motion Trajectory Tracking using two- axes eg: X-Y table

Repetitive Motions Program is downloaded

wait 50ms position error motor command~0.

9 Repetitive Motions Program is downloaded from the host PC to the controller and is stored, and executed from there Diagnostics position velocity wait 50ms position error motor command~0.5v shows what the amplifier is doing, saturation at 10V?

gains, repeat motion, obtain error envelop, calculate the change of error, adapt gains

10 PID Tuning Using X-Y X Y Motion I want to tune PID filter to shrink this envelop smaller and smaller Tuning PID filter: Start with initial PID gains, watch the error, change the gains, repeat motion, obtain error envelop, calculate the change of error, adapt gains Error after tuning PID filter The tuning method is directly on hardware, results are 100% trustworthy

Advanced Tuning System Elements motion controller (software) position encoder Desired position generator is a piece of software that generates reference position command.

11 Advanced Tuning System Elements motion controller (software) position encoder Desired position generator is a piece of software that generates reference position command. Position decoder decodes the position feedback from the position encoder. Position error X is converted to control signal Y by the filter (say PID). DAC converts the control signal to analog.

12 Advanced Motion Control (Integrator Limit) acceleration feedforward velocity feedforward offset proportional derivative Single pole software limit ±5V integral software limit

Closes the loop, react quickly, according to the sign of the error provides phase lead opens up BW Structural resonances and distributed components (things are not perfect in nature) contribute to

13 Closes the loop, react quickly, according to the sign of the error provides phase lead opens up BW Structural resonances and distributed components (things are not perfect in nature) contribute to high frequency dynamics, which is amplified by too large D gain As long as there is any (even a slightest) error due to friction, the integrator keeps building up the control signal until it becomes large enough to overcome friction, and eventually makes the motor rotate to reduce the error. Low K I slow growing of signal (response delay) High K I overshoot and instability Integrator Design (twice as big as friction) ±2V, but not more reduce overshooting and undershooting We need the integrator action at the end of the motion to reduce position error If we accumulate error during point to point motion, at the destination the integrator will probably be charged, and could cause undue overshoots

Low Pass Filter Filter is not activated Limits

Too low pass band will counter act the action

14 Low Pass Filter Filter is not activated Limits the gain at high frequency so that the loop wont respond to structural resonances and noise. Too low pass band will counter act the action of derivative control (reduce stability). Filter BW should be slightly bigger than system BW.

Notch Filter Resonance frequency There are imperfect couplings between motor and load that cause deflections

To avoid resonance activation, one means is to significantly reduce the system bandwidth (undesirable) Its

The new poles can be placed farther to the ve.

15 Notch Filter Resonance frequency There are imperfect couplings between motor and load that cause deflections and the plant behaves as a spring which has a certain resonance frequency. To avoid resonance activation, one means is to significantly reduce the system bandwidth (undesirable) Its not possible to place only two zeros, but two new poles with them. The new poles can be placed farther to the ve. Perfect pole-zero cancellation is not essential 20~30% offset would have enough cancellation of resonance poles. Three parameters of the notch filter NZ, NB, and NF have to be decided Simple Notch Filter Design (simple observation) simple guess

16 Feedforward Design Offset Fed directly to DAC Torque Limit Torque Limit Voltage limiter just before it goes to the amplifier

17 Dual Loop Compensation Backlash Dilemma delay phase loss instability

Design Approaches put encoder on the motor [get rid of gears/belts

applications practical methods Open Loop Compensation If you know

in a while So that the load always lags behind the motor low

18 Design Approaches put encoder on the motor [get rid of gears/belts direct drive] happens to be expensive, not found in general applications practical methods Open Loop Compensation If you know it how much - not overly acceptable (stable) calibrate every once in a while So that the load always lags behind the motor low friction causes inertia to make overshoots If it is the case, OLC does not work properly

(multiple error correction) Need two encoders (expensive) (sensor is on the motor) error

19 Final Point Correction drive the motor to approximate position check error drive again check error drive again.(multiple error correction) Need two encoders (expensive) (sensor is on the motor) error remains along the path - not good for engraving (+ 20~100ms, may/not be acceptable) because the load encoder is not part of the closed loop, thus the loop doesn t see disturbances

20 Conventional Dual Loop Control stable inner loop supervisory outer loop backlash delay stability gain has to be reduced motor error Improved Dual Loop Control Redistribution of PID in an optimal way much better performance strong good loop weak bad loop

It responds only for the steady state errors due to backlash and disturbances Comparison Single loop: No integrator to make the system stable, thus, motor never gets to desired

21 Frequency Response load loop motor loop load loop reacts to a wider range of frequencies. It will react to backlash transients undesirable load loop motor loop load loop reacts for low frequencies only. It responds only for the steady state errors due to backlash and disturbances Comparison Single loop: No integrator to make the system stable, thus, motor never gets to desired position. Low gain low bandwidth long settling time Dual loop: higher BW responds quickly short settling time, however, gain has to be controlled low enough to as integrator react to higher frequencies as well. Improved dual loop: Integrator is restricted to low frequency bandwidth of the inner loop can be further increased to react even fater.

Advanced Servo Tuning

Advanced Servo Tuning Dr. Rohan Munasinghe Department of Electronic and Telecommunication Engineering University of Moratuwa Servo System Elements position encoder Motion controller (software) Desired