Observer-based tuning of two-inertia servo-drive systems with integrated SAW torque transducers

This paper proposes controller design and tuning methodologies that facilitate the rejection of periodic load-side disturbances applied to a torsional mechanical system while simultaneously compensating for the observer’s inherent phase delay. This facilitates the use of lower-bandwidth practically realizable disturbance observers. The merits of implementing full- and reduced-order observers are investigated, with the latter being implemented with a new low-cost servo-machine-integrated highband width torque-sensing device based on surface acoustic wave (SAW) technology. Specifically, the authors’ previous work based on proportional–integral–derivative (PID) and resonance ratio control (RRC) controllers (IEEE Trans. Ind. Electron., vol. 53, no. 4, pp. 1226–1237, Aug. 2006) is augmented with observer disturbance feedback. It is shown that higher-bandwidth disturbance observers are required to maximize disturbance attenuation over the low-frequency band (as well as the desired rejection frequency), thereby attenuating a wide range of possible frequencies. In such cases, therefore, it is shown that the RRC controller is the preferred solution since it can employ significantly higher observer bandwidth, when compared to PID counterparts, by virtue of reduced noise sensitivity. Furthermore, it is demonstrated that the prototype servo-machine-integrated 20-N · mSAWtorque transducer is not unduly affected by machine-generated electromagnetic noise and exhibits similar dynamic behavior as a conventional instrument inline torque transducer

SAW torque transducers for disturbance rejection and tracking control of multi-inertia servo-drive systems

The paper proposes a resonance ratio control (RRC) technique for the coordinated motion control of multi-inertia mechanical systems, based on the measurement of shaft torque via a SAW-based torque sensor. Furthermore, a new controller structure, RRC plus disturbance feedback is proposed, which enables the controller to be designed to independently satisfy tracking and regulation performance. A tuning method for the RRC structure is given based on the ITAE index, normalized as a function of the mechanical parameters enabling a direct performance comparison between a basic proportional and integral (PI) controller. The use of a reduced-order state observer is presented to provide a dynamic estimate of the load-side disturbance torque for a multi-inertia mechanical system, with an appraisal of the composite closed-loop dynamics. It is shown that the integrated formulation of the tuning criteria enables lower bandwidth observers to be implemented with a corresponding reduction in noise and computational load. The control structures are experimentally validated via a purpose designed test facility and demonstrate significant improvement in dynamic tracking performance, whilst additionally rejecting periodic load side disturbances, a feature previously unrealisable except by other, high-gain control schemes that impose small stability margins

High-performance control of dual-inertia servo-drive systems using low-cost integrated SAW torque transducers

Abstract—This paper provides a systematic comparative study of compensation schemes for the coordinated motion control of two-inertia mechanical systems. Specifically, classical proportional–integral (PI), proportional–integral–derivative (PID), and resonance ratio control (RRC) are considered, with an enhanced structure based on RRC, termed RRC+, being proposed. Motor-side and load-side dynamics for each control structure are identified, with the “integral of time multiplied by absolute error” performance index being employed as a benchmark metric. PID and RRC control schemes are shown to be identical from a closed-loop perspective, albeit employing different feedback sensing mechanisms. A qualitative study of the practical effects of employing each methodology shows that RRC-type structures provide preferred solutions if low-cost high-performance torque transducers can be employed, for instance, those based on surface acoustic wave tecnologies. Moreover, the extra degree of freedom afforded by both PID and RRC, as compared with the basic PI, is shown to be sufficient to simultaneously induce optimal closed-loop performance and independent selection of virtual inertia ratio. Furthermore, the proposed RRC+ scheme is subsequently shown to additionally facilitate independent assignment of closed-loop bandwidth. Summary attributes of the investigation are validated by both simulation studies and by realization of the methodologies for control of a custom-designed two-inertia system

Improved performance of motor-drive systems by SAW shaft torque feedback

The paper describes the application of a non-contact, high bandwidth, low cost, SAW-based torque measuring system for improving the dynamic performance of industrial process motor-drive systems. Background to the SAW technology and its motor integration is discussed and a resonance ratio control (RRC) technique for the coordinated motion control of multi-inertia mechanical systems, based on the measurement of shaft torque via a SAW-based torque sensor is proposed. Furthermore, a new controller structure, RRC plus disturbance feedback is proposed, which enables the controller to be designed to independently satisfy tracking and regulation performance. A tuning method for the RRC structure is given based on the ITAE index, normalized as a function of the mechanical parameters enabling a direct performance comparison between a basic proportional and integral (PI) controller. The use of a reduced-order state observer is presented to provide a dynamic estimate of the load-side disturbance torque for a multi-inertia mechanical system, with an appraisal of the composite closed-loop dynamics. The control structures are experimentally validated and demonstrate significant improvement in dynamic tracking performance, whilst additionally rejecting periodic load side disturbances, a feature previously unrealisable except by other, high-gain control schemes that impose small stability margins

Observer based tuning techniques and integrated SAW torque transducers for two-inertia servo-drive systems

A controller design and tuning methodology is proposed that facilitates the rejection of periodic load-side disturbances applied to a torsional mechanical system, whilst simultaneously compensating for the disturbance observer's inherent phase delay, thereby facilitating the used of lower bandwidth, practically realisable, disturbance observers. The merits of implementing both a full- and reduced order observer, is investigated, with the latter being implemented with a new low-cost, high-bandwidth torque sensing device based on surface acoustic wave technolog

Rotor Position Estimation of a Pseudo Direct Drive PM machine using Extended Kalman Filter

The paper describes an improved method to control a Pseudo Direct Drive (PDD) permanent magnet machine with only one sensor on the low-speed rotor (LSR). Due to the magnetic coupling between the two rotors, the PDD machine exhibits low stiffness and non-linear torque transmission characteristics, and hence, the position of the high-speed rotor (HSR) cannot be determined using a simple gear ratio relationship. An extended kalman filter is proposed to accurately estimate the position of the HSR which is used to provide electronic commutation for the drive. The technique has been implemented on a prototype PDD subjected to various speed and load torque profiles

Influence of control structures and load parameters on performance of a pseudo direct drive

The paper describes an in-depth and systematic analysis of a pseudo direct drive permanent magnet machine in closed loop control. Due to the torque being transmitted from the high-speed rotor (HSR) to the low-speed rotor (LSR), through a relatively low stiffness magnetic gear with non-linear characteristics, speed oscillations appear in the drive output with a conventional proportional integral (PI) controller. Therefore two candidate controllers have been proposed as an alternative to the PI control and all controllers have been optimally tuned with a genetic algorithm against a defined criterion. Furthermore, closed loop models are established in the complex frequency domain to determine the system damping and the cause of the oscillations. Consequently, the best controller structure that improves the dynamic behaviour of the system in terms of speed tracking and disturbance rejection could be identified, based on the frequency domain analysis. Experimental results are presented to validate the analysis and the proposed control technique

Pneumatic motion control systems for modular robots

This thesis describes a research study in the design, implementation, evaluation and commercialisation of pneumatic motion control systems for modular robots. The research programme was conducted as part of a collaborative study, sponsored by the Science and Engineering Research Council, between Loughborough University and Martonair (UK) Limited. Microprocessor based motion control strategies have been used to produce low cost pneumatic servo-drives which can be used for 'point-to-point' positioning of payloads. Software based realtime control strategies have evolved which accomplish servo-controlled positioning while compensating for drive system non-linearities and time delays. The application of novel compensation techniques has resulted in a significant improvement in both the static and dynamic performance of the drive. A theoretical foundation is presented based on a linearised model of a pneumatic actuator, servo-valve, and load system. The thesis describes the design and evolution of microprocessor based hardware and software for motion control of pneumatic drives. A British Standards based test-facility has allowed control strategies to be evaluated with reference to standard performance criteria. It is demonstrated in this research study that the dynamic and static performance characteristics of a pneumatic motion control system can be dramatically improved by applying appropriate software based realtime control strategies. This makes the application of computer controlled pneumatic servos in manufacturing very attractive with cost performance ratios which match or better alternative drive technologies. The research study has led to commercial products (marketed by Martonair Ltd), in which realtime control algorithms implementing these control strategy designs are executed within a microprocessor based motion controller

Electronic Control of Torque Ripple in Brushless Motors

Merged with duplicate record 10026.1/727 on 27.02.2017 by CS (TIS)Brushless motors are increasingly popular because of their high power density, torque to inertia ratio and high efficiency. However an operational characteristic is the occurrence of torque ripple at low speeds. For demanding direct drive applications like machine tools, robot arms or aerospace applications it is necessary to reduce the level of torque ripple. This thesis presents an in depth investigation into the production and nature of torque ripple in brushless machines. Different torque ripple reduction strategies are evaluated and one reduction strategy using Park's transform as a tool is identified as the promising strategy. The unified machine theory is checked to clarify the theory behind Park's transform; in particular assumptions made and general validity of the theory. This torque ripple reduction strategy based on Park's transform is extended to include the effect of armature reaction. A novel adaptive torque ripple reduction algorithm is designed. The ineffectiveness of the conventional approach is demonstrated. Further a novel torque ripple reduction strategy using direct measurements of the torque ripple is suggested, reducing implementation time and allowing higher accuracies for torque ripple reduction. Extensive measurements from the experimental system show the validity of the novel torque ripple reduction strategies. The experimental results allow derivation of a formula for all load situations. This formula makes it possible to further increase the reduction accuracy and enables improved real time implementation of the torque ripple reduction algorithm. The work presented here makes a substantial contribution towards understanding the nature of torque ripple in brushless motors and solving the associated problems. The novel reduction strategies form the basis for the development of intelligent dynamometers for motor test beds. Further the torque ripple reduction method presented here can be used to overcome manufacturing imperfections in brushless machines thus removing the cost for precise manufacturing tools. Future designs of controllers can "build" their own correction formula during set-up runs, providing a motor specific torque ripple correction.Automotive Motion Technology Lt