Repair And Exchange Of Servo Amplifier In Industrial Electronics

It is essential to include the exchange programs when deciding about the right company to select for repairing industrial electronics or servo motors. This is because these companies that is on the exchange program send a motor that works to help the customer to continue their normal life activities using this replacement till they repair the part. It is possible to continue working till the repaired unit is returned.

Factor in this consideration regarding the exchange program when you decide about the best service company for industrial repairs. You can continue to work without interruptions at the facility where you work as well as benefit with great savings. You will only be paying a fraction of the cost when you repair and use remanufactured parts instead of brand new motors.

It is not necessary to wait when the repairs are being carried out when one is using the exchange process. The remanufactured spare part is used to replace the malfunctioning part and help continue to run the facility smoothly. It is not necessary to maintain a huge inventory of various machine parts in case one of them does not function properly.

The advantage is that your facility continues to function with the backing of the industrial repair company. These types of servo motor exchange and repair companies enable people to avoid incurring huge costs for maintaining inventories by providing equipment from their inventory. They prefer to collaborate with companies that use the exchange facility for repair as well as delivery. Given below are some methods used by industrial repair companies in the exchange process

·         The website of the company can be visited and the exchange form filled

·         The full price for the remanufactured unit should be paid upfront

·         Downtime is eliminated as the item is quickly shipped

·         The malfunctioning motor is quickly returned to the repair company after boxing it up when the remanufactured item is received for efficient motion control

·         Once this item having malfunctions are received, the customer credit for the item is issued by the company

Make sure you collaborate with a company that offers and deals with equipment such as spindle, servo motor, servo amplifier, VFD drive, monitor, spindle amplifier, power supply and so on. This equipment should also work with electronic manufacturers such as Indramat, Allen Bradley, Yaskawa, Siemens, Fanuc and Xycom. These companies also serve as a one stop solution for every requirement and you can avoid running to different repair services every time you run into a problem.

What Is Motion Control?

Motion control is sub field of automation. This controls the position or the velocity of the machinery. To do this it uses device like a linear actuator, electric motor, hydraulic pump or generally a servo motor.  This is a very important part of robotics and CNC machine tools. This is a very complex system as the kinematics in these machines is usually very simple. Motion control is used greatly in packaging, textile, semi conductor, printing and assembly lines.

The basic design of the motion control is as follows. The control is set to generate set points for the desired outcome and to close positions or velocity (the feedback loop). The signal is then changed into an electrical current by a drive or an amplifier. This is then delivered to the actuator. (An actuator is for motion output and can be a hydraulic pump, electric motor or a linear actuator.)  Some newer models are more accurate because they can close the position internally. 

Feedback sensors such as Hall Effect devices or optical encoders are used to close the position of the actuator bring it back to the motion control. The mechanical components then change the motion into a required movement. This can include shifting, belts, ball screw, gears, and linkages linear or rotational bearings. When co-ordinated motion is required the interface between the motion controllers are critical. They have to provide tight synchronisation.

There are some common control features and these include position control (this is often based on the velocity profiles for example S-curve or triangular profile.), velocity, electronic gearing (also known as cam profiling) this is where the master axis and the position of the slave axis are mathematically linked. For example, when two rotating drums turn at a set ratio to one another, there is also electronic camming and this is where the slave axis abides by a profile that is the job of the master as this does not need to be salted but it has to be animated. There is also pressure and force control.

Motion controllers are used in an array of different industries to help produce and make most of the things we use every day. They help do the jobs that are hard labour for humans and assist in increasing productivity.  There are several companies that globally sell these controls. They develop, manufacture and market servo drives and systems. Their products are predominantly brushless controls; however they do provide drives for alternate motor types. They also provide standard products and can customize to suit your needs.

How does Windmills Work?

Everyone has seen all the moves towards clean energy in the past few years. Things like solar and wind energy have become the new standard for clean energy as they don’t seem to have the bi-product problems of things such as electricity. While electric engines burn more cleanly than your standard combustion engine runs off gasoline or petrol they still require an input system that is typically one built out of a dirty fuel such as coal. Windmills can produce and store more energy than solar cells and tend to be more efficient overall.

When you see windmills towering over the town below, it is easy to wonder how they know which way to face in order to catch the wind properly. One of the key components in the built in pitch control system. This uses hydraulics in order to adjust the way the blades face and even change the position of the head. This allows the windmill to turn more rapidly creating more stored energy as it travels down the base of the system.

The center of the windmill is wired to capture all the energy created by the spinning top. It then travels down the wires to the base of the windmill where a battery sits to capture the energy. Other wires go to the general power source. This means you can both draw power immediately and store it for future use. This gives you more freedom with this version of clean energy. While you can store solar power it does not have the same conversion rate and you lose much of the energy in the storage process.

As for the direction of the windmills, that is up to the person who sets up the farm. Some windmills can use the pitch control system to move the entire direction of the head, while other windmills are stationary. The stationary ones can still move the blades to better catch the wind but the windmill itself always faces the exact same direction. For those close to the water, this is often a great choice as the wind tends to only come from one way.

Helping Increase Safety with Computerized Motors

Car manufacturers and assembly lines have long relied on servo motors in order to increase productivity and consistency on the line. Now, these same AC servo motors are helping to increase safety levels both for the employees of the plants and for those who are driving the vehicles. Technicians have realized the increased parameter options allows for more control over the finished product. This means less variation so that the pieces fit together in a way making them more stable than ever before and increasing the overall safety of the vehicle.

The AC servo motors that control the line help prevent overheating. This type of condition can cause fires, meltdowns and other dangerous situations for those who are monitoring the line. By using a mechanism that makes adjustments immediately, like a servo, the problem never has a chance to develop. It takes much less time to make a correction from the beginning than undoing a problem scenario has blown out of control. Think of it along the lines of laying a drop cloth down when you are painting or trying to clean up the paint off the ground after you are done. One is a simple clean up job and the other is a protracted process.

For the output of the product, because a servo motor can monitor things so closely there are fewer problems with the end product. When bolts and pieces do not meet up exactly, vibrations and other processes can cause things to wiggle loose. This factor often results in tires falling off, seat belts failing, pieces of the engine getting knocked out or other disastrous scenarios. By ensuring everything is exactly uniform, there is less chance of this type of problem. Basically it was the next logical step in the development of motorized vehicle development and the assembly line. The companies had maxed out what could be done with just humans and found a way to utilize the computerized systems in order to increase safety and productivity at the same time. Helping to make life safer is a great side benefit of computerized advances.

How BLDC Motors Work

Before using BLDC motors, understand its mechanism.

You will be able to find BLDC motors or brushless DC motors in industrial equipment, appliances and medical instruments as they provide various advantages as compared to others like it.

However, before usingthese motors particularly for blade pitch control, you must first have a complete understanding of its mechanism which consequently results to a fast review of the construction of a DC motor.

A BLDC motor is particular type of servo motors which basically relies on wire coils on rotors and frames of rigid motors which on the other hand places permanent magnets all over the rotor.

Electric current passing through the windings make some magnetic field which either repels it from the magnet or attracts a winding to the magnet. Brushes placed on stators and contacts placed on rotors choose various windings as power while the rotors turn.

In BLDC motors, the coils make up the motors’ outsides and the rotors provide permanent magnets. Once again, the repulsions and attractions of the coils and the permanent magnets make the rotors spin. However, in BLDC motors, commutations do no occur on spinning shafts.

Even though these motors are more expensive than other brush-DC motors, they provide benefits. Their exterior coils dissipate heat better than those on rotors. BLDC motors do not have commutators or brushes to tire out or need maintenance regularly, thus they can function unattended for a very long period of time. Lastly, these motors don’t produce electromagnetic interference or EMI from machine-driven commutators.

Rather than utilizing mechanical commutators, servo motors like BLDC use automated commutation in switching the coils to on or to off. This kind of commutation is classified into two – the sensorless or the sensor-based.

The sensor-based motors, Hall-effect sensors are placed inside the coils of the motor to sense the position of the permanent magnets of the rotors. Microcontrollers or MCU read the states of the sensors and utilize a particular algorithm to know which of the coils to power as well as when.

On the other hand, sensorless motors require MCUs to measure the back electromotive force orr EMF produced across coils by spinning rotors’ magnets. The back EMF or BEMF defines the magnets’ positions.

However, the sensorless method is faced with a challenge because controller as well should power coils consequently to make the motors turn. Thus, how can one separate pulse-width signals of modulation which drive coils BEMF signals?

The answer is quite simple. Program MCUs to filter high-frequency PWM signals out as well as measure BEMF near the time when PWM signals pass through zero Voltage. The BEMF depends on various factors like coil resistance, number of coil windings, rotor magnets strengths and many others.

Taking a Closer Look at One of the Most Sought After Pitch Control Solutions

A servo driver serves as an effective moderator as it accepts command signals originating from control systems amplifies these signals and consequently transmits the current to motors in order to produce a kind of motion which is proportional to the received command signals.

Usually, the desired velocities are represented by these command signals. However, they as well represent the anticipated torque or position. With assistance from velocity sensors, servo motors report the actual velocities to their corresponding servo driver. The driver then changes the frequencies of the voltage to correct errors in the velocities.

Pitch control solutions are basically categorized into two important types of issues. The first type takes care of command tracking. It monitors whether commands are actually followed by motions. Generally, command in rotational wave controls are position, velocity, acceleration and torque. In the event of liner motion, a force, rather than torque, is applied.

The specific component of pitch control drive which handles it directly is usually identified as a “feed-forward” control. It aids in the determination of internal commands in order for the user’s motion commands to be performed in the absence of errors.

The second component addresses all of the system’s rejection traits of disturbance. Disturbances may range from erroneous motor parameter estimations employed in the feed-forward controls to torque troubles in the shafts of motors. These issues are resolved by utilizing the widely-known Proportional Integral and Derivative Position Loop or PID and the Proportional Integral and Velocity Position Loop or PIV.

Servo controls are designed efficiently to resolve all issues that machines may encounter and prevent chances of such mishaps effectively.

Learn more about wind turbine pitch control http://www.servotronix.com/clean-tech.html

Servo Drivers: The Prime Mover of Automated Devices

A servo driver is developed to regulate the position and velocity of various automated devices such as industrial machines, medical equipment and robots. Electromechanical elements such as servo motors help these devices to achieve their desired motion and servo drivers work as electronic amplifiers to these motors.

Servo control systems are pitch control solutions that monitor feedback signals of servo motors and constantly regulate motions to prevent any deviation from the anticipated behavior of machines. They address a lot of mechanical requirements for reducing voltage fluctuations, diminishing loading parameters sensitivity, decreasing steady state errors as well as enhancing the transitory response timing.

Servo systems upturn the bandwidth of the system. Faster response times enable higher machine productivity. Decreasing steady state errors result in high accuracy of servo systems. Lastly, reducing loading parameters sensitivity guarantees that servo systems withstand fluctuations in the output as well as the input parameters.

Servo amplifier

Servo is the name of the motor used to control and manage the mechanical performance of particular machines. In engineering terms it refers to an automatic device and applies this control theory to provide the actual power for the whole mechanism to work. These electric motors have inbuilt motion sensors to control applications for highly controlled motion.

Servo motor control is focused at sensing errors in the mechanism which will then send instant negative feedback or signals to correct this error and enable smooth uninterrupted functioning. These signals can correct multiple parameters from speed to mechanical position.

Controlling a mechanical position with servo amplifier –

Servo mainly uses electric motor to create mechanical force. The concept of servo motor control lies on two factors – there is an actual position and there is a desired position within the mechanism. The difference is sensed and an error signal is then amplified and then converted to reduce or completely erase the error. Other than electric force some servos also use magnetic, pneumatics or hydraulic force to correct position. They are widely used in military and marine navigation systems, satellite tracking.

Controlling a mechanical speed with servo amplifier –

The use of servo in controlling speed has seen many earlier applications like the steam engine. Today the application of servo motor control is found in trains, airplanes as well as ships. But that’s not all. These are also integral part of machine which run huge industrial functions and run the complex industrial motions. The applications of speed control can be seen from complex airplane navigation, to the cruise control function of a car, to a hard disk drive in the laptop, in both cases focusing in error free and precise performance.

Servo motor control is one of the key components of robotic functioning. Constant error sensing feedback keeps all parts of a robotic function in check. They also need very little power to run on and are ideal of machine like robots which run on batteries. They are also essential parts of any remote controlled device. These range from remotes for a child’s toy to a complex one to manage a submarine or an aircraft. Basically they are keys to any application which needs precise mechanical functioning and where error would mean malfunction with serious ramifications. This is why it is so important for the defense industry. Servo mechanism can make smooth functioning through unfriendly terrains as well as hard weather conditions.

The use of servo mechanism is the basis for mechanical accuracy.

AC Servo Drives

AC servo drives use alternating current to match and meet the varying industrial status and rise up to any occasion to meet machine deviations. AC motors have an outside stationary stator which has coils to produce a rotating magnetic field with the alternating current and an interior rotor which attached to this external shaft creating the precise torque for the machine function.

AC servo drives are widely used in industrial settings. They can be single phased or poly-phased (two-phased, three-phased or hysteresis synchronous). The single phase induction AC servo motor is connected to a single voltage line while the others take up more than one as their nomenclatures suggest. Of all these, the two phase ones most common as servo systems.

The two phase AC motors are more sensitive to voltage fluctuations and changes in the control system. They successfully create a rotating magnetic field. AC servo drives therefore offers better control with high torque, high speed and better application of velocity control.  Their high ability to start power allows lower levels of overall power to be transmitted. The alternating power function determines how much power is needed by the system and gives off only that amount thus managing power efficiency and industrial automation control superbly.

AC servo drives are intrinsic to electronic assembly because they can fill in gaps with alternating current and thereby ensure smooth uninterrupted flow of industrial performance. They come with interactive magnetic fields – the wound and the electrified which are used to synchronize with the frequency of the alternating current. An integrated feedback device that continuously monitors the shaft motion, and in combination with a servo drive regulates the commanded motion very precisely.

Benefits of the AC servo drives –

·         Lower maintenance

·         High starting power potential

·         Less wastage of power

·         Accurate performance for machines

·         Cost effective

·         Provides better industrial automation control for better turnover

Applications of AC servo drives –

·         Electric clocks and timer motors in appliances.

·         Home usage in appliances refrigerator, air conditioners, washing machines, dryers and fans.

·         Industrial usage is manifested in CNC machining, in electronic assembly, in factory automation and very widely in robotics industry.

More and more industries are switching to AC servo drives so that they can perform better, save assembly line costs, create a more economical process all the while making sure that there is optimum energy saving without compromising the level of performance and industrial automation control.

Servo Motor Control & Its Uses. Part 2

Servo controls are widely used as wind turbine pitch control too. The wind turbine pitch control system are used for changing the frequency of the rotor blades in a wind power system or a wind mill that works with the real wind speed in order to adjust the output power attaining the highest utilization efficiency of the wind power and thus providing a protection for the rotor blades. The servomotors are used as the pitch control for the wind turbines.  

There are three different types of servo motors that are normally used in the modern servo systems. These are:

• AC servo motors – These motors are based on the induction motor designs
• DC servo motors – These are based on the DC motor design
• AC brushless servo motors – These are based on the synchronous motor designs

  

The servo motors provide a motion profile that is a set of commands programmed in a controller which defines the operation of the servo motors in regards to velocity, position and time. Servo motion control makes the robotic devices and other such devices work with utmost precision.  





            

Servo Motor Control & Its Uses. Part 1

The Servo motor is in use for quite some time now. Because of its diverse functionality, the servo motor has gained popularity. The easy to use applications mostly in RC electronics and other devices make it a popular and widely used thing.   The Servo motor control refers to the error sensing the feedback control that is used for correcting the performance of a particular system. The RC servo motors are actually DC motors that are fitted with a servo mechanism in order to have accurate control of angular position. The RC servo motor control generally has a 90° to 180° rotation limit. But there other servo motors that come with 360° rotation limit. However, the servo motors do not need to rotate on a continuous basis. It will only rotate between its defined angles. 

The servo motors are majorly used for their precision positioning. These motors are widely used in robotic legs and arms, RC toys, sensor scanners, RC helicopters, cars and airplanes too.  The servo motors that are manufactured nowadays offer cost effective solutions for the users. These servo controls have efficient power saving technology and they can take up high inertial loads too. The servo motion control is exceptionally useful for robotics and thus they are made in small sizes but are very powerful and efficient.   

Mechanics of a Servo Control System

A servomotor is an essential component of a servo control system or servomechanism. It is usually paired with an encoding device to accurately provide the speed or position feedback detail. However, not all servomechanisms require a servomotor. A domestic furnace is a good example of a servo control device that does not use a servomotor. The thermostat in a domestic furnace acts as a servomechanism in the sense that it depends on feedback and error-control; however, no motor is directly controlled by it for performing this task.  

Classification of Servos

Servo amplifiers can be further classified based on the type of their performances and their feedback control:

·         Type 0- This type of servos typically generate a constant output value when the error signal remains constant under steady state

·         Type 1- These produce a constant output value when the error signal is null under steady state conditions. However, a constant change of reference would imply a constant error in reference tracking

·         Type 2 – These are capable of providing a steady output value with a null error signal under a steady state. Here a constant change in the reference provides zero error in reference tracking but a steady rate of acceleration of the reference would mean there is a constant error in reference tracking

Here, the bandwidth of the servo control systems, indicate their ability to respond to the rapidly changing input commands.

Servo Control System - What You Should Know

A servomechanism also commonly referred to as servo is a high-end device that works by using feedback and error sensing to automatically correct the performance of any mechanism. Typically, a servo control system is used to help control the speed, or the position but it may also be used in error correction of other parameters. For instance, the cruise control device in your automobile is a good example of a servomechanism. On the other hand, the automatic windows in your vehicle are not. This is because there is no error-correction or negative feedback involved in this process.

Uses of Servo Control Systems

Servomechanism has been commonly used in speed control for a very long time. Some of the early examples include the use of servomotors in steam engines, in the mechanism that governed the speed of the water wheels, in gas turbines for efficient fuel control, and in the aircraft speed propellers used during World War II for steady maneuvering. Servo controlsystems for positioning were first used in military navigation equipment and in fire-control devices.

Today, servo control devices are used in almost every field. Starting from satellite tracking devices, aircraft gun control, automatic machines, to remote controlled boats and airplanes all contain some kind of servo amplifiers. In addition, many cameras using auto-focus also make use of servomotors to simultaneously focus as well as accurately move the lens. It is also found in modern computer hard-disk-drives, and used commonly in industrial devices that require complex motion.