Motion Control Systems 101: Key Elements and Their Importance
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⌚Timestamps:
00:00 - Intro
00:21 - What is motion control?
01:42 - Essential components
02:34 - Actuator
02:59 - Controller
04:11 - Amplifier
04:51 - Feedback device
06:12 - Control loop
06:57 - Summary
Motion control refers to the methods used to precisely regulate and control the movement and position of mechanical systems. The two keywords in that statement are “movement” and “position.”
In a well-tuned Motion Control system, the actual position must closely follow the target or setpoint position.
Motion control is used in the manufacturing industry on CNC machines, assembly lines, and packaging equipment.
It is also used in Robotics, where the precise movement of robot arms is required. Aerospace, another field that uses motion control, controls the motion of aircraft components.
The four essential components of a motion control system are the controller, driver/amplifier, sensing/feedback devices, and actuator.
We base our discussion on a system where we control the position of saw blades on a sawmill conveyor belt to ensure precise and accurate lumber cutting.
Actuators convert electrical, hydraulic, or pneumatic energy into mechanical motion.
In our sawmill scenario, the actuator must move the saw blades to a precise position relative to the lumber passing through the conveyor. Proportional valves control the movement and speed of actuators such as hydraulic cylinders or motors.
The Controller is the Device that examines the difference between our controlled Variable's current state and its desired state. The controller determines what action is to take place and generates an output signal that is a function of the result of this comparison.
You can choose motion controllers based on the number of axes, update time, resolution, and the type of motion supported.
Can you use the same device for process control and motion control? Several years ago, the answer to that question would have been a “hard no.” Many of today’s controllers are capable of both process and motion control.
Vendors like Delta have dedicated motion controllers like the RMC75, which can control two axes. This little beauty has full PID loop control with velocity and acceleration feedforwards.
Older traditional PLC controllers cannot offer the precision control available on the Delta controller.
The RMC75 requires an additional device, such as the Delta MA1, to provide the drive and amplification needed to move the actuator.
Amplifiers convey the amount of current and voltage needed to drive the actuator. In other words, the amplifier receives information from the motion controller and relays it to the actuator through a driver.
Vendors such as Omron offer multi-function controllers. The Omron NX5 can be both a process and motion controller while simultaneously controlling up to 64 axes.
Feedback devices are sensors that provide information about the moving parts' position, speed, and other parameters.
Standard feedback devices include encoders to measure the position and speed of rotating shafts and linear displacement devices such as a magnetostrictive linear displacement transducer or MLDT.
A commonly used MLDT in the sawmill industry to determine position and speed is the “Temposonics L-Series Start-Stop”.
An MLDT works based on the principle of magnetostriction, which is the property of certain ferromagnetic materials to change their shape or dimensions in a magnetic field.
The Temposonics MLDT informs the controller of the saw position. The Controller compares the actual position with the desired Target Position.
The controller performs rapid calculations based on preset conditions and provides corrective action to the amplifier. The hydraulic proportional valve moves the saw actuator to the desired position.
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Temposonics website: https://www.temposonics.com/
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