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same principles as the rotary encoders, but the graduations are engraved on a stationary glass or metal scale while the read head moves along the scale. Tachometers are generators that provide analog signals that are directly proportional to motor shaft speed. They are mechanically coupled to the motor shaft and can be located within the motor frame. After tachometer output is converted to a digital format by the motion controller, a feedback signal is generated for the driver to keep motor speed within preset limits. Other common feedback sensors include resolvers, linear variable differential transformers (LVDTs), Inductosyns, and potentiometers. Less common are the more accurate laser interferometers. Feedback sensor selection is based on an evaluation of the sensor s accuracy, repeatability, ruggedness, temperature limits, size, weight, mounting requirements, and cost, with the relative importance of each determined by the application.
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The design and implementation of a cost-effective motion-control system require a high degree of expertise on the part of the person or persons responsible for system integration. It is rare that a diverse group of components can be removed from their boxes, installed, and interconnected to form an instantly effective system. Each servosystem (and many stepper systems) must be tuned (stabilized) to the load and environmental conditions. However, installation and development time can be minimized if the customer s requirements are accurately defined, optimum components are selected, and the tuning and debugging tools are applied correctly. Moreover, operators must be properly trained in formal classes or, at the very least, must have a clear understanding of the information in the manufacturers technical manuals gained by careful reading.
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SERVOMOTORS, STEPPER MOTORS, AND ACTUATORS FOR MOTION CONTROL
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Many different kinds of electric motors have been adapted for use in motion control systems because of their linear characteristics. These include both conventional rotary and linear alternating current (AC) and direct current (DC) motors. These motors can be further classified into
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those that must be operated in closed-loop servosystems and those that can be operated open-loop. The most popular servomotors are permanent magnet (PM) rotary DC servomotors that have been adapted from conventional PM DC motors. These servomotors are typically classified as brush-type and brushless. The brush-type PM DC servomotors include those with wound rotors and those with lighter weight, lower inertia cup- and disk coil-type armatures. Brushless servomotors have PM rotors and wound stators. Some motion control systems are driven by two-part linear servomotors that move along tracks or ways. They are popular in applications where errors introduced by mechanical coupling between the rotary motors and the load can introduce unwanted errors in positioning. Linear motors require closed loops for their operation, and provision must be made to accommodate the back-and-forth movement of the attached data and power cable. Stepper or stepping motors are generally used in less demanding motion control systems, where positioning the load by stepper motors is not critical for the application. Increased position accuracy can be obtained by enclosing the motors in control loops.
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Permanent-Magnet DC Servomotors
Permanent-magnet (PM) field DC rotary motors have proven to be reliable drives for motion control applications where high efficiency, high starting torque, and linear speed torque curves are desirable characteristics. While they share many of the characteristics of conventional rotary series, shunt, and compound-wound brush-type DC motors, PM DC servomotors increased in popularity with the introduction of stronger ceramic and rare-earth magnets made from such materials as neodymium iron boron and the fact that these motors can be driven easily by microprocessor-based controllers. The replacement of a wound field with permanent magnets eliminates both the need for separate field excitation and the electrical losses that occur in those field windings. Because there are both brush-type and brushless DC servomotors, the term DC motor implies that it is brushtype or requires mechanical commutation unless it is modified by the term brushless. Permanent-magnet DC brush-type servomotors can also have armatures formed as laminated coils in disk or cup shapes. They are lightweight, low-inertia armatures that permit the motors to accelerate faster than the heavier conventional wound armatures. The increased field strength of the ceramic and rare-earth magnets permitted the construction of DC motors that are both smaller and lighter
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