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Table 1-1 Stepping and Permanent-Magnet DC Servomotors Compared.
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required from a linear motor, the existing motor must be replaced with a larger one. Linear motors must operate in closed feedback loops, and they typically require more costly feedback sensors than rotary motors. In addition, space must be allowed for the free movement of the motor s power cable as it tracks back and forth along a linear path. Moreover, their applications are also limited because of their inability to dissipate heat as readily as rotary motors with metal frames and cooling fins, and the exposed magnetic fields of some models can attract loose ferrous objects, creating a safety hazard.
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Motor drivers or amplifiers must be capable of driving their associated motors stepper, brush, brushless, or linear. A drive circuit for a stepper motor can be fairly simple because it needs only several power transistors to sequentially energize the motor phases according to the number of digital step pulses received from the motion controller. However, more advanced stepping motor drivers can control phase current to permit microstepping, a technique that allows the motor to position the load more precisely. Servodrive amplifiers for brush and brushless motors typically receive analog voltages of 10-VDC signals from the motion controller. These signals correspond to current or voltage commands. When amplified, the signals control both the direction and magnitude of the current in the
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motor windings. Two types of amplifiers are generally used in closedloop servosystems: linear and pulse-width modulated (PWM). Pulse-width modulated amplifiers predominate because they are more efficient than linear amplifiers and can provide up to 100 W. The transistors in PWM amplifiers (as in PWM power supplies) are optimized for switchmode operation, and they are capable of switching amplifier output voltage at frequencies up to 20 kHz. When the power transistors are switched on (on state), they saturate, but when they are off, no current is drawn. This operating mode reduces transistor power dissipation and boosts amplifier efficiency. Because of their higher operating frequencies, the magnetic components in PWM amplifiers can be smaller and lighter than those in linear amplifiers. Thus the entire drive module can be packaged in a smaller, lighter case. By contrast, the power transistors in linear amplifiers are continuously in the on state although output power requirements can be varied. This operating mode wastes power, resulting in lower amplifier efficiency while subjecting the power transistors to thermal stress. However, linear amplifiers permit smoother motor operation, a requirement for some sensitive motion control systems. In addition linear amplifiers are better at driving low-inductance motors. Moreover, these amplifiers generate less EMI than PWM amplifiers, so they do not require the same degree of filtering. By contrast, linear amplifiers typically have lower maxi-mum power ratings than PWM amplifiers.
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Position feedback is the most common requirement in closed-loop motion control systems, and the most popular sensor for providing this information is the rotary optical encoder. The axial shafts of these encoders are mechanically coupled to the drive shafts of the motor. They generate either sine waves or pulses that can be counted by the motion controller to determine the motor or load position and direction of travel at any time to permit precise positioning. Analog encoders produce sine waves that must be conditioned by external circuitry for counting, but digital encoders include circuitry for translating sine waves into pulses. Absolute rotary optical encoders produce binary words for the motion controller that provide precise position information. If they are stopped accidentally due to power failure, these encoders preserve the binary word because the last position of the encoder code wheel acts as a memory. Linear optical encoders, by contrast, produce pulses that are proportional to the actual linear distance of load movement. They work on the
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