Flux Vector AC Drive

Control VS
Servo Drive Control
Presented by:
Kevin Miller- Motion Automation Eng
Schaedler-Yesco
Darryl Jacobs- Technical Consultant
Rockwell Automation

Copyright 2005 Rockwell Automation, Inc. All rights reserved.

1

Todays Agenda

1.1.Flux
FluxVector
VectorAC
ACdrive
drivetheory
theory(FORCE)
(FORCE)
2.2.Servo
ServoDrive
DriveControl
Controltheory
theory
3.3.Application
ApplicationExamples
Examples
4.4.Technical
Technicalperformance
performancecomparisons
comparisons
5.5.Rockwell
RockwellAutomation
Automationsolutions
solutions

Basic Control Classes for AC drives

BasicVolts/Hertz
Volts/Hertz
Volts/Hertz
Control
Control
(V/Hz)
(V/Hz)

EnhancedV/Hz

VectorControl

V/Hzwithcurrent
V/Hzwithcurrent
limiting,boost,and
limiting,boost,and
slipcomp
slipcomp

SensorlessVector
SensorlessVector
Controlwith
Controlwith
slipcomp.
slipcomp.

I heard of space vector, sensorless vector, flux

vector and just about every under the sun
vector drive. What does all this mean?

FluxVectoror
FluxVectoror
FieldOriented
FieldOriented
Control
Control
w/outEncoder
w/outEncoder
FluxVectoror
FluxVectoror
FieldOriented
FieldOriented
Control
Control
w/EncoderFdbk
w/EncoderFdbk

Breaking through the vector messages

Older and less expensive drives were limited to a volts per hertz ratio
output. You could cap or limit the output current, add some boost start
voltage level and more advanced drives allowed recalculating the voltage
ratio to frequency or vector delta. Motor thermal protection was limited to
current levels and Klixon contacts.
More advance systems such as sensorless vector added I2T motor thermal
modeling, better processors to calculate for faster response to load
changes, takes into account the flux producing or magnetizing current that
develops motor torque. Essentially sensorless vector offered best
breakaway current torque performance across the entire speed range. Still
the flux producing current is set to a level but not controlled.
Adding encoder feedback options adds more finite samples in hard speed
reference to supplement speed control and shorten response time.

Vector Control vs Flux Vector

Vector Control
Acknowledges that motor current is the vector sum of
the torque and flux currents and uses this information
to provide better control of motor speed/torque.

Flux Vector Control

The ability to independently control the flux and
torque in a motor for the purpose of accurate torque
and power control.

What is Flux Vector Control ?

The ability to independently control the flux and torque producing
components of current in an motor for the purpose of accurate torque and
power control. The significance of this is now beyond simply controlling the
total current and voltage we can control the torque producing components
in the motor just as independently as we can control voltage and overall
current.
Now the need for slip compensation to make up for a calculated
torque slip factor of the motor is not needed as we now control what the
torque differential is. Standard NEMA type induction motors always have a
slip in design. This means we have control of production torque current
across the speed range, not exclusively dependent on the motor natural
torque curve.
Adding a feedback device enhances all control regulation.

What advantage does flux vector offer?

Offers pure torque control to not break shafts or hold a web tension.
Allows for holding torque at very low or zero speeds. Great for lifts or
momentary hold in place until a brake can be applied or released.
Maximizes with control how much torque can be produced out of a motor.
This becomes a DC drive displacer as faster current response and torque
control are equal to or better than DC drives. This does away with the
typical DC motor wear issues with more standard induction motors.
Flux vector offers a better bus regulation system as now more factors other
than simply reducing output frequency are used to keep the DC bus level in
check.

What is field oriented control?

In Allen Bradley its referred to as FORCE technology.
This kicks the flux vector control level up a notch by adding a voltage
component to the flux control feedback. Typically flux vector control
calculates this value where FORCE will control all components of the flux
producing magnetic field. Motor thermal calculations are now part of the
control, not reacting.
What this allows is even better bandwidth control, response and low speed
torque control. Improving the bandwidth now tightens positional reference
drift simply because the numbers are more finite. This means more torque
and better low speed response.
The same bandwidth improvement offers more advantages with high
resolution feedback and works high torque/high speed/low power motors
such as permanent magnet servo motors with low inertia.
With FORCE keeping tighter controls of all facets of the motor it permits
more servo like applications requiring tighter motor control.

Sensorless Vector Encoderless

Separates current and voltage control

Flux Vector Encoderless

Flux Vector w/ Encoder

FOC w/ Encoder

Performance Comparison
Control Mode

Fan/Pump or
Custom
V/Hz with
slip comp

SVC with
slip comp

SVC with
feedback

FOC or Flux
Vector without
feedback

FOC or Flux
Vector with
feedback

Typical DC

Speed Regulation
(% of base
speed)

+/- 0.5%

+/- 0.5%

+/- 0.1%

+/- 0.1%

+/- 0.001%

+/- 0.001 %

Operating Speed
Range

40:1

80:1

80:1

120:1

1000:1

1000:1

Speed Bandwidth

10 rad/sec

20 rad/sec

20 rad/sec

50 rad/sec

250 rad/sec (VC)

300 rad/sec (S)

100 rad/sec

Torque Regulation

NA

NA

NA

+/10%

+/5%

+/5%

Torque Bandwidth

NA

NA

NA

600rad/sec

2500rad/sec

950rad/sec

What is ..
The Difference between Field Oriented Control (700S) and Flux
Vector Control (700VC)
No voltage feedback on 700VC, voltage fdbk is approximated

Both the Powerflex 70 Enhanced control and Powerflex 700

offer the setting options of sensorless vector or flux vector
control in the same drive.

Lets discuss what motion control is

So far with AC drives we have discussed speed and torque
control. What servo motion control adds to the mix:
*Maintaining position control
*Speed, torque and position adjustments on the fly
*Coordinating drive/motor running profiles or axis together
*Having velocity and acceleration independent
*Homing to a known start position
*Repeatable and concise steps
*Camming or following a pattern beyond just a speed ratio

The blurry line between drives and servos today.

The Powerflex 700 VC drive today can do:
Torque Proving with fast brake control
Indexing function with homing
Speed profile blending
all without a PLC, using a standard induction motor and
standard encoder feedback.
This offers an option to use standard like
parts across small and large HP ranges.

The blurry line between drives and servos today.

The Powerflex 700S with Drivelogix goes even further in offering:
*Electronic Gearing *Absolute Position Control
*High resolution feedback capable *Dual feedback device capable
*High speed Synchlink control (50 microsec) and co-orination
*Will run standard AC motors and servo motors
*Uses standard AC drive components and accessories
*Accepts 25 most common
RSLogix5000 motion commands.

Powerflex 700 applications

Powerflex 70 and 700 handle a wide
variety of VT and CT applications with
common AC induction motors.
Fans Pumps Conveyors
Palletizers
Lifts
Automated Storage and Retrieval
Food
Packaging
Machine Tool
virtually anywhere motor speed or
torque control is applied.

PowerFlex 700S / Applications

Backery Line
Coating Lines
Roll Grinding
Tenter Frames
Hoist
Bottling
Re-winder
Plaster board Line
Accelerator rolls
Stamping
Nip Rolls
Copper Line
Converting Lab Lines
Spline Rolling Machine
Coating Lab Line
Lay on Roll for Turret Winder
Turntable Transfer

Where do servo drives make more sense

Where speed regulation is precise.
Where positioning in precise and must be repeatable.
Where gearing and transmissions are required while maintaining position
accuracy.
Much easier to coordinate multiple axis operation.
Where many different move types with varying accel/decel profiles are
required.
When precise speed, torque, position and axis move coordination are all
required to perform the task.
Where getting the best match motor to match the load requires is essential
for best performance at the best cost.

In short something designed for the job.

Some basic servo motion control differences

Motion control typically runs in a very tight accuracy range for speed and
position. A feedback device is almost always used.
Servo tackles moving a load with high speed motors attached to low
gearing. This affords high accuracy at slow speeds, higher velocity points
and smallest possible hardware. Its the current that costs real money in
hardware.
Servo motors and drives are designed to handle very quick acceleration and
deceleration ramps. This high velocity ramp affords tremendous torque.
Zero speed for holding torque is common with motor brakes just for parking.
Motion controllers have the ability to adjust to maintain a positional
reference, can maintain a home position reference via tracking and/or
absolute feedback.
Servo motors typically can produce 2 to 2.5 times their rated torque in peak
delivery. As such most servo drives peak at 200%

Comparing Performance
PF700S with
Drivelogix

Ultra3000

Ultra5000

Kinetix 6000

Position Loop Task

Update Time

1msec

1msec

500 usec

125 usec

Velocity Loop Task

Update Time

250 usec

250 usec

250 usec

125 usec

Sercos Minimum
Cycle Time

N/A

1 msec

N/A

500 usec

Registration input
time

8msec

4-8 usec

4-8 usec

3usec

Torque Control
Task Update Time

125 - 250 usec

125 usec

250 usec

125 usec

Across the board servo drives are design for much faster
control update rates.

Some basic servo motion control differences

Servo motor permanent magnet design
is high torque delivery, low inertia, high
speed with quick acceleration to fit in
tight spaces. Mountings and shafts are
design for plum direct mounting. The
longer case design is to maximize torque
at all speeds with great heat dissipation
for quick speed changes over a very
wide speed range. This same design
offers very incremental concise moves.

Same no blower design to 7250RPM

A fast response drive to control this type

of motor.
Standard round frame AC motors are
designed with gaps in 2 to 8 pole
configurations more suitable speed and
torque regulation, not positioning. The motor
itself is really a transformer with the stator to
rotor pull being the secondary.
The exception is a true laminated motor.

More poles means more torque

but usually more slip.

Motion Control via Servo

Closed Loop Position Servo Motion Control
Definition
Standard Drives -vs- Closed Loop Position Servo Motion Control
Position control with the ability to stay on track. Typical drive application will
allow position to slip with no means of recovery without manual homing.
Applications include:

Converting Industry Example

Packaging Industry Example
Food & Beverage Example
Assembly Example
Metal Forming Example

Servo Motion Control

Define Closed Loop Position Servo Motion Control

Motion Control is the process of managing or
directing the movement of machinery or
equipment.
Automated equipment employing Closed
Loop Position Servo Motion Control will
provide machine movement that is:
Accurate- Capable of moving to a
precise position!
Repeatable- Capable of moving to
the same precise position every time
the machine is commanded to do so!

Servo Motion Control

Define Closed Loop Position Servo Motion Control
The Pick & Place motion application on the right is used in a
variety of industries. Application examples include product
transfer lines, component insertion, etc.. The Pick & Place
example further clarifies the concept of Accurate and
Repeatable.
Accurate: The Pick & Place unit is typically commanded to
precise locations to assure that packages or components are
inserted to specification. Precision is determined by the
application requirements. Position accuracy of XX.0010
(accurate to 1 thousandth of an inch) are common.
Pick and Place

Position 2

Position 1

Servo Motion Control

Define Closed Loop Position Servo Motion Control

Repeatable: Closed Loop Position Servos

are frequently applied in a production
environment where thousands of identical
assemblies are manufactured daily. To
assure product quality and reliability,
components must be assembled to tight
tolerances (identical). Motion Controllers
typically move to multiple positions each time
a part is manufactured. It must be capable of
repeating those exact movements for each
part. Pick and Place

Position 2

Position 1

Servo Motion Control

Define Closed Loop Position Servo Motion Control
Standard Drives vs-Closed Loop Position Servo
Frequently, people ask, What is the
difference between a Standard Drive and
a Closed Loop Position Servo?
Speed controlled by
a Standard Drive

Typically, In Standard Drive applications,

speed (velocity) is the main control
parameter.

Rotary Knives are frequently used in industry to cut material to

specified lengths. In this Rotary Knife example a Standard
Drive is used to control the speed of the Material(aka Web)
feed.

Rotary Knife

Servo Motion Control

Define Closed Loop Position Servo Motion Control
Standard Drives vs-Closed Loop Position Servo

In Closed Loop Position Servo applications

position is the main control parameter. Velocity
can vary to maintain position.

Position of Knife
controlled by
Closed Loop
Position Servo

The Closed Loop Position Servo ( AKA Servo) is

used to position the cutter to cut the material to the
desired length.
Rotary Knife

Servo Motion Control

Application Examples of Motion Control in Industry
In packaging applications, Servo Driven Smart
Belts are used to position randomly spaced
packages into evenly spaced packages. The
evenly spaced packages are fed to downstream
equipment for further processing. Smart Belts
typically use photo-eyes to detect product. These
Photo-eyes are typically wired to a special motion
controller high speed input called a Registration
Input.

Smart Belt

Photo-eye wired to
Motion Controllers
Registration Input

Servo Motion Control

Application Examples of Motion Control in Industry
Vertical Form, Fill & Seal machines are used in the
food industry for a wide variety of packaging
applications. Applications include high speed
candy packaging and low speed coffee packaging.
Typically, product is fed into a pouch and sealed
on both ends. Servos are used to feed the
packaging material and to seal/cut the pouch on
both ends of the package. Servos eliminate waste
by feeding the packaging material to the proper
length while synchronizing the cutter.

Vertical

Servo driven
packaging material
feed.
Servo driven cutter in
synchronization with
material feed.

Servo Motion Control

Application Examples of Motion Control in Industry

In the semiconductor industry, the Wet Bench
is used for transferring sliced semiconductor
wafers through a series of chemical baths to
clean and remove residue left from the slicing
of the semiconductor wafer.
A servo driven mechanical actuator is used to
lift the boat of wafers out of the dip tank. A
longer horizontal servo driven actuator is used
to shuttle the load from one tank to another.
Ball Screw Actuator
converts rotary motion
to linear motion.
Wet Bench

Belt Actuator converts

rotary motion to linear
motion

Servo Motion Control

Application Examples of Motion Control in Industry
Press feeds are used to feed sheet steel in to a
mechanical press. Press machinery is used in a
variety of industries including automotive and
motor manufacturing.
Servos are used to feed material into the press in
correct lengths. In this application, the servo
motors rotates pinch rolls( apply pressure and pull
material). Product lengths can be modified in the
motion controller.

Press Feed

Basics of Motion Hardware and Factors

Basic Motion Hardware
These are some of the basic hardware items involved in motion.

Servo Motor
Servo Drive
Actuator
Transmission Stage
Motor Current
Motor Voltage

Motion Controller
Motion Controller Software
Overtravel Switch
Home Switch
Brake
Control, feedback, brake and power cables.

Basic Motion Application Sizing and Operation

*Total and Mismatch Inertia

*Bus Utilization

*Cycle Profile or Indexing

*Registration

*Gearing

*Shunt Requirements

*Rotary or Linear load

*Absolute Feedback

Peak Torque/Velocity/Current

*Continuous and Peak Stall Torque

Basics of Motion Hardware

Basic Motion Hardware

The Pick and Place example is an interesting
linear application to study in greater detail. It
employs the basic motion components.

Motor
with
Feedback
Transmission Stage

Negative
Overtravel Limit
Switch

Movement

Home Limit
Switch

Load
Table

Ballscrew

Machinery

Positive
Overtravel Limit
Switch

Basics of Motion Hardware

Basic Motion Hardware

The shaded area below identifies the major controller components of a motion control
system. In the next series of slides, well define the basic operation of each component and
explain how they interact with each other to function as a system.
Transmission Stage

Motor
with
Feedback

Negative
Overtravel Limit
Switch

Movement

Home Limit
Switch

Load
Table

Motor
Power

Machinery

Positive
Overtravel Limit
Switch

Ballscrew

Position
Feedback
Command Signal
Servo
Drive
Position Feedback

Motion
Controller

Motion
Software

Basics of Motion Control in Operation

Basic Motion Hardware

Motion Controller Functions
Control the Motion
When executing motion programs, motion controllers provide precise control of:
Position
Velocity
Acceleration

In a typical AC drive application the acceleration rate

is a constant 0 to maximum speed value unless set
by another action such as a digital input.

Motion Controllers maintain precision by continually comparing the machines actual

position (Position Feedback) to where it should be (Commanded position). The
Command Signal to the machine corrects errors very quickly.

Machine
Motion

Command Signal
Position Feedback

Motion
Controller

Basics of Motion Hardware

Basic Motion Hardware

The Motion Controller is the Brains of the system. Motion controllers serve (3) primary
functions:

Motion Controller Functions

Motor
with
Feedback

Store and Execute Motion Programs

Motor
Power

Store Configuration Parameters

Control the Motion

Position
Feedback
Command Signal
Servo
Drive
Position Feedback

Motion
Controller

Motion
Software

Basics of Motion

Basic Motion Hardware

Servo Drives interpret the Motion Controller command signal
and control the amount of speed and torque delivered by the
motor. Drives accomplish this task by converting plant power to
the voltage and current levels required by the motor to control
the application. The commands can be analog, digital, networks
or fiber interface. One thing to take notice of here is were
getting into more control cabling and addition
programming than a typical drive application.

Motor
with
Feedback

Motor
Power

Plant
Power

Position
Feedback
Command Signal
Servo
Drive
Position Feedback

Motion
Controller

Motion
Software

This sounds complicatedany way to simplify?

Selecting the best solution has
never been easier. It starts with a
good machine concept and hard
mechanical load data. Rockwell
Automation Motion Analyzer
software can walk through the
moves, offer hardware choices and
show all possible solutions in
graphic detail. Best part is its a
free download.
Most important is consult with your
Schaedler-Yesco motion specialist.

That sure looks like a lot of wires

For applications where a single axis,
simple digital, analog or pulse reference
control is required, Allen Bradley offers:
Ultra 1500 (115V & 230V)
Ultra 3000 (230V and 460V)
Ultra 3000 Indexer
Ultra 3000 Devicenet (w/Indexer too)
Ultra 5000 stand alone controller
Ultraware drive set up software
A huge variety of pre-molded control and
feedback cables and breakout terminal
boards
Micrologix with pulse output control
Contrologix 2 axis analog servo control
card

but there is a better way

Motion in Integrated Architecture

A motion control system that allows
you to connect over a SERCOS
fiber optic ring to the following
drives:

Kinetix 6000
Kinetix 7000
Ultra3000
1394

A combination of
architecture, world class A-B
motion products, and motion
application expertise.
Kinetix motion is part of
Integrated Architecture.

A cost effective integrated solution that provides you with

everything you need to be cost-effective and competitive.

Where does Kinetix fit?

pick and place robotics

Any application that requires:

accurate positioning of product

rapid acceleration/deceleration
precise speed control with varying loads
repeatability, accuracy, cycle timing,
maintenance of mechanical clutches/brakes
an entire Rockwell Automation machine system
solution

case packing
positioning conveyors

canning
pharmaceutical
packaging

wrapping
automated assembly

tire assembly

cartoning

metal forming
food processing
palletizing

press feed

electronic line shafting

flow wrapping

laminating

labeling
bottling

pouch filling

Motion control already in RSLogix5000

components are eliminated
one integrated sequential and motion controller
one software package

2 Software
Packages
2
Programming
Languages
Extra
Communication
Logic
Extra
Coordinati
on
Logic

1
Processor
1 Software
Package
1
Programming
Language

Time is money
less expensive and easier to wire
fewer axis module cards required
two fiber connections replace 18 discrete wires per drive, eliminating 36
terminations per axis
fewer components to wire
Completely digital interface

analog terminal block

less time required to implement

already integrated
plug and play modules
easy to add axes
faster to start up
easier to troubleshoot

only one software package to purchase and learn

fiber optic connection

Less connections, faster uptime, lower total cost

smaller enclosure panel requirements
saves money and floor space
Eliminates lots of cabling for each axis
All motion controller function resides in the Contrologix

ControlLogix SERCOS Interface Motion Modules

M16SE and PM16SE
16 axes SERCOS Module/Card with one fiber cable
M08SE M03SE
8 and 3 axes SERCOS Module and 1756-L60M03SE
Compactlogix 1768-M04SE 4 axis module

Overall Wiring Reduction With

Kinetix Integrated Motion Using The Kinetix 6000

Kinetix

Traditional

The
Thenew
newscience
scienceofofintegrated
integratedmotion
motion

Motion
Controller

8 axis system example

Overall Wire Terminations Reduction

Same 8 axis example
showing control and power
wiring comparison.

90

Total
28
48
4
16
16

Kinetix

The
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newscience
scienceofofintegrated
integratedmotion
motion

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3 Phase Power Wiring

485
Total

Traditional

What was that box feeding the servo drives?

Line Interface Module (LIM)

How else is it easier to use?

Start up is easier
Drop down boxes and wizards
High resolution feedback eliminates the need to tune
servo drives in all but the most extreme cases

Drives located remote from the control

each segment (node-to-node) of a SERCOS ring can
be up to 32 meters in length using economical plastic
fiber, or up to 200 meters using glass fiber.

RSLogix 5000 Direct Commands

Online direct execution of motion commands -- no
application program needed

What are the facts on speed of commissioning?

One software package (RSLogix 5000)

Information enabled devices allow
configuration, tuning, programming
and monitoring out of one single
package. Plug and play from one
place.
Typical time savings
of 20% per axis
One example of 40%
total time saved

SERCOS allows drive replacement without reconfiguration

How else is it easier to use?

Simpler to Program

37 motion instructions
simple to add motion commands to the
application program.
No need to learn a cryptic motion programming
language.
Choice of three IEEE-61131-3 languages:
Ladder
Structured Text (ST)
Sequential Function Chart (SFC)

Extensive use of graphical tools simplifies creating

and implementing complex motion profile.
RSLogix5000 is the only programming package
required to completely configure, program, and
commission a motion system.

How can this help me?

High performance

high resolution feedback option improves positioning accuracy and

reduces cycle times
absolute feedback option eliminates time consuming homing cycles
super fast, up to 64s loop closure ensures
accurate load positioning
digital commands replace range limited
analog signals

Improved diagnostics
detailed drive and motor status information is available in RSLogix
5000 and the ControlLogix/Compactlogix/SoftLogix application
program
drive fault and status information is displayed in descriptive text,
eliminating the need to interpret cryptic codes
graphical trending allows important motion parameters to be collected
and viewed
All built in to RSLogix 5000

Where does Kinetix make more sense

Multiple axis set up and control start to finish is far quicker with Kinetix.
Coordinating axis is inherently easier.
Information enabled hardware enhances time to running. Configure, tune
and program all from the same software.
Widest offering of motor ranges and accessories.
SERCOS reduced connection count with outstanding performance.
Simpler code reuse
Better integration for monitoring and diagnostics
Kinetix space saving rack mount design
Reduced cabling time and cost
Single control connection system
Integral safety relay system
In short products designed to do the job with the best time to market.

So when do I use a standard drive or servo drive?

Evaluate your installed base of hardware, controllers and trained staff.

Evaluate how repeatable and accurate the application is.
Review what has to be mechanically interfaced.
Identify the required speed and power range.
Do you need to know where in the process you are if power fails.
Review how distributed the application control is.
Does the hardware configuration make more sense to connect via a
network or digital interface?
Review the needs of the application with which approach is best addressed
with standard hardware.

Discuss the application with your Schaedler-Yesco Allen Bradley

automation specialist.

Allen Bradley drives solutions

115V to 6190V
.5HP to 10,000HP
Standard NEMA1 to 4X
Configured boxed solutions
Application Solutions software
Common accessories, look and feel
Drives for simple and challenging
applications

Kinetix Family of Servo Drives

.1 KW

.25 KW

1.2 KW

6.6 KW

15 KW 18 KW 22 KW

93 KW

150 KW

Ultra3000
Kinetix 2000*
Kinetix 6000
CompactLogix
CompactLogixwith
with
SERCOS
SERCOSInterface
Interface
44axis
axiscontrol
control

* Available summer 2006

Highly integrated motion control SERCOS

over the entire power range with Kinetix

Kinetix 7000

Thanks for your attention!

Copyright 2005 Rockwell Automation, Inc. All rights reserved.

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