5 Digital Position Control

In this chapter, position control and its role within motion-control systems
is introduced and discussed. Single-axis position controllers are explained
and modeled. Analytical design of the position controller structure is given,
along with procedures for setting the adjustable feedback parameters.
The speed and torque system limits are explained at the end of the chapter,
along with the analysis of nonlinear operating modes. Nonlinear control
laws, capable of securing a robust large step response, are considered.
In the succeeding sections, the structure and parameter setting of linear
discrete time position controllers are discussed, analyzed and designed.
Within motion-control systems, the position controller may assume differ-
ent roles and forms. Its basic purpose is to provide for the corrective action
that drives the mechanical load, work piece, or tool along a predefined tra-
jectory in space. Position trajectories are created by a superior controller,
such as the production-cell computer, and they depend on specific opera-
tions to be performed within a desired production cycle.
At the output, position controllers have to provide the reference values,
calculated in such a way that any position error caused by the load distur-
bance or a reference change, is suppressed and driven to zero. In a number
of motion-control applications, position controllers provide the reference
of the driving torque and feed this reference to the torque actuator. In other
cases, the position controller calculates the speed the system ought to as-
sume in order that the position error is dissipated. In such cases, the output
of the position controller is fed to the reference input of the speed controller.
Eventually, the torque commands are calculated so as to correct the speed
error, assisting the position control task in an indirect way. The physical
location of position controllers varies with the application.
The host computer in traditional motion control systems, known as the
CNC (Computerized Numerical Control), generates the reference profiles
for a number of motors that have to effectuate a coordinated motion. In
most cases, the CNC comprises individual position controllers. Position
control functions are often implemented by relying on dedicated hardware
units called the axis cards, located within the CNC. The host computer
may control the individual drives by sending them the speed reference. In
this case, the speed control function is performed by digital drive controllers,
148 5 Digital Position Control

associated with drive power converters, and thus controlling the current
torque, flux, and speed of individual motors. Control functions are shared
between the CNC and the digital drive controllers. The two controllers
may be separated spatially, and the overall performance may largely de-
pend upon the quality of the signal transmission between the CNC and the
drive.
In many applications, the host computer executes the position control
algorithm and generates the torque reference. This reference is fed to indi-
vidual drives in the form of an analog signal, or by means of a high-speed
digital serial link. The signal integrity issues are less pronounced than in
the case when the speed reference is transferred. Individual drive control-
lers perform the current, torque, and flux control.
With the position control functions distributed between the CNC and the
digital drive controller, the accuracy and bandwidth of the position loop is
compromised by the delay and degradation of the reference and feedback
signals communicated between the control nodes. Therefore, contemporary
drive controllers include single-axis positioners, capable of keeping the
position of the motor at the reference. The reference trajectory can be
stored within the internal memory of the drive controller, or received in
real time from the host computer by means of a high-speed digital serial
link.
In this chapter, single-axis discrete-time position controllers with posi-
tion error at the input and torque reference at their output are discussed,
analyzed, and designed.

5.1 The role and desired performance of single-axis

positioners

Industrial motion-control systems utilize the electromagnetic torque or force

generated by servo motors in order to effectuate controlled motion of work
pieces, tools, or machine parts. Within a production cell, several motors need
to move in coordination in order to provide for the desired motion. Each
production cycle consists of several motion sequences. Fast motion leads
to a reduced cycle time and increased productivity. On the other hand, pre-
cision in following the position reference profiles affects production quality.
Fast tracking of the reference trajectory has detrimental effects on posi-
tion accuracy. Therefore, productivity and production quality impose con-
flicting requirements on the position controller. For that reason, there is a
perpetual requirement to increase the closed-loop bandwidth of position
controllers, providing, in such a way, the desired accuracy at elevated speeds.