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When a load under control must follow a specific path to get from its starting point to its stopping point, the movements of the axes must be coordinated or interpolated. There are three kinds of interpolation: linear, circular, and contouring. Linear interpolation is the ability of a motion control system having two or more axes to move the load from one point to another in a straight line. The motion controller must determine the speed of each axis so that it can coordinate their movements. True linear interpolation requires that the motion controller modify axis acceleration, but some controllers approximate true linear interpolation with programmed acceleration profiles. The path can lie in one plane or be three dimensional. Circular interpolation is the ability of a motion control system having two or more axes to move the load around a circular trajectory. It requires that the motion controller modify load acceleration while it is in transit. Again the circle can lie in one plane or be three dimensional. Contouring is the path followed by the load, tool, or end- effector under the coordinated control of two or more axes. It requires that the motion controller change the speeds on different axes so that their trajectories pass through a set of predefined points. Load speed is determined along the trajectory, and it can be constant except during starting and stopping.
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Several important types of programmed computer-aided motion control can emulate mechanical motion and eliminate the need for actual gears
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or cams. Electronic gearing is the control by software of one or more axes to impart motion to a load, tool, or end effector that simulates the speed changes that can be performed by actual gears. Electronic camming is the control by software of one or more axes to impart a motion to a load, tool, or end effector that simulates the motion changes that are typically performed by actual cams.
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The mechanical components in a motion control system can be more influential in the design of the system than the electronic circuitry used to control it. Product flow and throughput, human operator requirements, and maintenance issues help to determine the mechanics, which in turn influence the motion controller and software requirements. Mechanical actuators convert a motor s rotary motion into linear motion. Mechanical methods for accomplishing this include the use of leadscrews, shown in Figure 1-10, ballscrews, shown in Figure 1-11, worm-drive gearing, shown in Figure 1-12, and belt, cable, or chain drives. Method selection is based on the relative costs of the alternatives and consideration for the possible effects of backlash. All actuators have finite levels of torsional and axial stiffness that can affect the system s frequency response characteristics.
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Figure 1-10 Leadscrew drive: As the leadscrew rotates, the load is translated in the axial direction of the screw.
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Motor and Motion Control Systems
Figure 1-11 Ballscrew drive: Ballscrews use recirculating balls to reduce friction and gain higher efficiency than conventional leadscrews.
Figure 1-12 Worm-drive systems can provide high speed and high torque.
Linear guides or stages constrain a translating load to a single degree of freedom. The linear stage supports the mass of the load to be actuated and assures smooth, straight-line motion while minimizing friction. A common example of a linear stage is a ballscrew-driven single-axis stage, illustrated in Figure 1-13. The motor turns the ballscrew, and its rotary motion is translated into the linear motion that moves the carriage and load by the stage s bolt nut. The bearing ways act as linear guides. As shown in Figure 1-7, these stages can be equipped with sensors such as a rotary or linear encoder or a laser interferometer for feedback. A ballscrew-driven single-axis stage with a rotary encoder coupled to the motor shaft provides an indirect measurement. This method ignores
Figure 1-13 Ballscrew-driven single-axis slide mechanism translates rotary motion into linear motion.
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