connected motion and robotics: systems, platforms and...

DARA O’SULLIVAN

ROGER YU

Connected Motion and Robotics:

Systems, Platforms and Solutions

for Industry 4.0

Analog Devices Confidential Information. ©2018 Analog Devices, Inc. All rights reserved.

NOV. 2019

MOTOR CONTROL SHENZHEN CONFERENCE

ASIA TECHNICAL SYMPOSIUM | DECEMBER 3-7,2018 | SHANGHAI, CHINA

What is Motor Control?

4

AC Motor

Electrical Energy Mechanical Work

Drive/ServoMotors convertCurrent into Torque

Drives control themotor current to meet the Machine Control demand for Torque, Speed or Position

Machines convert

raw materials into

useful products

current Torque

T =k.im

Process/Machine

Motor

Control

im

PLC

Vm

Power

Source

DC AC

Command

q Application

Impact

Analog Devices Confidential Information—Not

for External Distribution


Multi-Axis Synchronized Motor Control

5 Analog Devices Confidential Information.

©2018 Analog Devices, Inc. All rights reserved.

Paper Machine

AC

Motor

AC

Motor

AC

Motor AC

Motor

AC

Motor

y

x

WMachine

Tool

y

x

AC

Motor

AC

Motor

q1

q2

q3

q4

q5

(x,y,z)

► Sheet or Wire Production (paper, steel, plastics, rope, cables etc.)

▪ Synchronized speed of multiple rollers/drums.

▪ Variable electronic gearing to maintain tension

► Metal Processing (Turning, Milling, Grinding, Drilling)

▪ Continuous motion of cutting tool relative to work piece

▪ Synchronized control of tool position along multiple axes

► Electronic Assembly

(Circuit boards/wire

bonding)

▪ Rapid motion of tool in

Cartesian plane.

▪ Precision control of tool

(x,y) position and vertical

force

► Automotive and general

assembly (cars,

consumer goods etc.)

▪ Synchronized motion

control of multiple axes

▪ Flexible programming

and fast response


Motor Drives and Servos in Industrial Automation

► Process Automation

▪ Oil and Gas; Mining; Cement; Chemicals;

Steel; Paper; Food

and Bev; HVAC etc.

Assembly Automation

▪ Semiconductor;

Automotive;

Metal processing;

Molding; Textiles;

Packaging; etc.

► Process Industry focus on reducing

Energy consumption ($$) by

efficiently controlling fluid and material

flow.

▪ Connectivity supports plant optimization.

▪ Acoustic noise and smooth operation in

some applications

► Assembly Industry focus on

maximizing ROI by increasing quality

and throughput.

▪ Faster response and higher motion

precision (in space & time)

▪ Precise Machine synchronization

▪ Integrated safety functions for

operational efficiency

► General trends

▪ Maximize plant uptime

▪ Minimize cabinet size

▪ Maximize product flexibility

▪ Minimize installation cost etc.

Continuous Motion

Discontinuous Motion

AC

Motor

Current

feedback

Speed/Pos

feedback

Speed/

Position

Motor

Control

q

Servos

Single/

Multiple

Axes

AC

Motor

Current

feedback

Speed

feedback

Torque/

Speed

Motor

Control

q

Drives

Inverters

~ Speed

Motor

Control

AC

Motor

Open Loop

Volts/Hz

► Motor Drive Types




Control cabinet

space saving

Architecture trend: Integration of drive and motor to simplify wiring.

7

Analog Devices Confidential Information.


June 18-22, 2018

RT

Ne

two

rk

MC

AS

SP

RT

Ne

two

rk

MC

AS

SP

RT

Ne

two

rk

Mu

ltico

re

MP

U/D

SP

q Motor

q Motor

RT

Ne

two

rk

Mu

ltico

re

MP

U/D

SP

q Motor

RT

Ne

t

AS

SP

q Motor

RT

Ne

t

AS

SP

HV AC motor +

LV feedback Cable

Control Cabinet with

AC servo drives, Robot

/machine controller &

DC bus supply.

AC motor-sensor

embedded in the

Robot /machine

Integrated drive-

motor-sensor

embedded in the

Robot /machine

HV DC bus +

Network Cable

20-100m

One cable set

per motor-sensor

► Integrated Drive Motor (IDM)

▪ Save on control cabinet space

▪ Save on motor cables

▪ Minimize cable EMI

Need small efficient

power converters

and control circuits.

► Traditional drive architecture

AC HV DC


Architecture Trend: Reference- vs. I/O Synchronization

8



June 18-22, 2018

Motor1

q1

MotionControl

vq1*

Machine &Application

Control

Co

m

Vdc

Drive 1

Machine

PLC/CNC

SD

MotionControl

Co

m

SD

Motor2

q2

i

q2*v i

Drive 2

Motor1

q1

MotionControl

v(v,i,q)1

Motion, Machine & Application

Control C

om

Vdc

Drive 1

Machine

PLC/CNC

SD

MotionControl

Co

mSD

Motor2

q2

i

v i

Drive 2

(v,i,q)2

TDr1

TDr2

Synchronized command

TPLCTPLC

Synchronized control I/O

Deterministic Ethernet with synchronized I/ODeterministic Ethernet with synchronized

commands only

Independent processing and clock domains Common clock domain. Scalable processing within PLC or drive

nodes.

~1kHz Update ~10kHz Update ~10kHz Update

Typical Machine

Tools and General

Automation

High Speed

Assembly &

Robots

ADI Solutions for the CMR Market

Analog Devices Confidential Information. ©2018 Analog Devices, Inc. All rights reserved.9

June 18-22, 2018


Drives and Servos Signal Chain

June 18-22, 2018Analog Devices Confidential Information. ©2018 Analog Devices, Inc. All rights reserved.10

AC

Motor

Current

feedback

Speed/Pos

feedback

Speed/

Position

Motor

Control

q

Servos

Single/

Multiple

Axes

AC

Motor

Current

feedback

Speed

feedback

Torque/

Speed

Motor

Control

q

Drives

Inverters

~ Speed

Motor

Control

AC

Motor

Open Loop

Volts/Hz

► Motor Drive Types

Inverters

Drives

Servos

AC

Motor

IE Protocols/App

Motor Control

Application

ASSP

PWM SINC

SAR

- +

SA

R

SD

ENC

q

- +

SA

R

SA

R

- +

SPI

SMC

IE S

witc

h/

Pro

ce

sso

r

MII

MII

LDOVi Vo

+

-

XL

Power Conversion

and Isolation

Current

Feedback Position

Feedback

Signal ProcessingReal Time

Ethernet ConnectivityInterface




MCMC

iu iviw

idc

+- +-+-+-

AD

C

AD

C

AD

C

AD

C

AD

C

iuL ivL iwL

MC

SIN

C

SIN

C+ -

SD

+ -

SD

MC

AD

C

AD

C

MC

+- +-

AD

C

AD

C

MC

AD

C

AD

C

+-

+-

AC

Motor

U

V

W

11

Non isolated

current

feedback:

1. dc link shunt

2. inverter leg

shunts

3. HV current

diff amps

HV

Isolated current feedback:

4. Current shunt with isolation

amplifier

5. Isolating magnetic current

sensor

6. Current shunt with isolating

sigma delta modulator

4 5 6

1 2 3

Performance

Linearity, gain match, offset [esp.drift] and

noise immunity are critical parameters

driving Torque quality

Current feedback for Torque control

and inverter switch protection

current Torque

Isolated and non Isolated Current Feedback Architectures




Feedback Signal Scaling requires Dynamic Range

► Significant trend towards Shunt current measurement vs. CT/Hall.

▪ Dynamic range required to measure both Peak and Nominal currents. Rated currents

may be fraction of ADC dynamic range.

▪ Same drive services range of motor sizes. Dynamic range lost in lowest rated motor.

► Demand for lower shunt values requires even higher DR. ~+/-250mV->+/-50mV

► Offset Drift and Gain Drift contribute directly to torque ripple on the motor shaft.

Affects many applications, surface effect on milling/etching; vibration effects etc.

MCMCMCMCMC

iuiviw

idc

+- +-+-+-

AC

Motor

U

V

W

AD

C

AD

C

AD

C

AD

C

AD

C

AD

C

AD

C

AD

C

AD

C

+-

+-

SIN

C

SIN

C

+ -

SD

+ -

SD

▪ Thermal losses

▪ Power transfer efficiency

▪ Integration densities

▪ Self heating effects and solder joint stress

▪ Desire to extend power rating of shunt based systems, further reducing

CT usage.




2nd Iso-ADCGen

1st Iso-ADC Gen

3rd Iso-ADC Gen

Isolated SD Modulator Roadmap

13

<2014

Inte

rface T

yp

e

► 12.5-bit ENOB

► VIORM 565 Vpeak

► 16-pin

Availability

Released

Development

Concept

AD7400

LV

DS

CM

OS

: E

xt

CL

KC

MO

S:

Int

CL

K

► 13-bit ENOB

► VIORM 565 Vpeak

► 16-pin

AD7401

2015 2018

► 14-bit ENOB

► VIORM 1250 Vpeak

► 16-pin

AD7403

► 13.5-bit ENOB

► VIORM 1250Vpeak

► 8-pin

AD7402-8

► 14-bit ENOB

► VIORM 1250Vpeak

► 8-pin

AD7403-8

► 14-bit ENOB

► VIORM 1250 Vpeak

► 16-pin

► LVDS

AD7405

Reduced Power

Improved Offset & Gain Drift

Increased DR, VIORM and CMTI

Lower EMI emissions

Integrated LDO

Manchester Encoded Option

Higher Performance

Increased Isolation VIORM

Additional Package

Options

VDD1 V DD2

ADuM770x CMOS + LDO

G ND 1 G ND 2

MCLKIN

(5 MHz to 25 MHz)

MDAT

CLK

DECODERCLK

ENCODER

DATA

ENCODERDATA

DECODER

V IN +

V IN–

B UF

Σ -Δ ADCGAIN

REF

LDO

(4.5 V to 20 V)




MCMC

iu iviw

idc

+- +-+-+-

AD

C

AD

C

AD

C

AD

C

AD

C

iuL ivL iwL

MC

SIN

C

SIN

C+ -

SD

+ -

SD

MC

AD

C

AD

C

MC

+- +-

AD

C

AD

C

MC

AD

C

AD

C

+-

+-

AC

Motor

U

V

W

14Analog Devices Confidential Information.


Non isolated

current

feedback:

1. dc link shunt

2. inverter leg

shunts

3. HV current

diff amps

HV

Isolated current feedback:

4. Current shunt with isolation

amplifier

5. Isolating magnetic current

sensor

6. Current shunt with isolating

sigma delta modulator

4 5 6

1 2 3

Performance

Linearity, gain match, offset [esp.drift] and

noise immunity are critical parameters

driving Torque quality

Current feedback for Torque control

and inverter switch protection

current Torque

Discrete/

Embedded

ADC

Isolated and non Isolated Current Feedback Architectures


8-Ch DAQ

8-Ch DAQ

16-Ch,

Dual Sim-Sampling

8-Ch DAQ Subsystem

Simultaneous Sampling, SAR ADC Roadmap (18 to 12-Bits)

15

<2017

Resis

tiv

e In

pu

t

High Sampling Rate, High density

125kSPS/Ch

ADAS3023

200kSPS/Ch

AD7606 1MSPS/Ch

AD7606B

Bu

ffere

d I

np

ut

125kSPS/Ch

AD7616

AD7380 AD7380-4

1MSPS/ChAD4606

Dual ADCs

► 14, 12-Bit

4.2MSPSAD7357

► Bandwidth 400kHz ► Bandwidth 22kHz

► Dual ADC ► Quad ADC

SC

In

pu

t

8/4/2-Ch DAQ

200/350/550

kSPS/Ch

LTC2358/7/3

2018 2019

Direct interface to low impedance sensors

Direct interface to high and low impedance sensors

8/4/2-Ch ADCs

200/400/666

kSPS/ChLTC2345/4/1

► 18-Bit

>2020

Availability

Released

Development

Concept




Machine

AC

Motor

IE Protocols/App

Motor Control

Application

PWM SINC

SAR

- +

SA

R

SD

ENC

q

- +

SA

R

SA

R

- +

eMAC

SPI

MII

isolation

barrier Functional

safety

EMI/

EMC



Mixed Signal MicrocontrollerIndustrial

Communications

Digital

Isolation

Current

Feedback

Position

Feedback

I/O

Motion Control High Level Signal Chain


Position Feedback Architectures and sensors

Lowest cost/performance – simple drives only

Resolver selected for robustness and absolute

angle on power up

AMR for cost and absolute position - emerging

Incremental selected for ease of use and

cost/performance – needs simple absolute

sensor support (HE) at power up

Performance

Preferred sensor in high end automation

Absolute angle, high precision supports

low speed control – but expensive.

Proprietary serial interface to drive

Shaft angle sensor:

▪ Commutation and

drive shaft control

▪ Enables precision

in automation

I/O

ADC

ADC

q w

q, w

Motor

Control(Algorithms

and drivers)

serial

PDZVEx

qr

Vsin

Vcos

N S

AMR/HE

Magnetic Coupled Optical

Hall

Effect

3b Abs

0.5o An Abs

12b/rev Inc

RS48516 – 24b Abs

QEP

Count

ASIC

Position

Feedback

ENDAT or Hyperface

iv

iw

Power Inverter

q,w

vdc

AC

Motor

AMR

RES

RD

C

INC

ENC

RS485

ABS

ENC

ASIC

AD

C

AD

C

mux10 – 16b Abs

Shaft

Angle

Sensor

ADC

ADC

Sine

Cos

ADCs required to interpolate. High

precision supports low speed control.

High end automation.




8-Ch DAQ

8-Ch DAQ

16-Ch,

Dual Sim-Sampling

8-Ch DAQ Subsystem

Simultaneous Sampling, SAR ADC Roadmap (18 to 12-Bits)

18

<2017

Resis

tiv

e In

pu

t

High Sampling Rate, High density

125kSPS/Ch

ADAS3023

200kSPS/Ch

AD7606 1MSPS/Ch

AD7606B

Bu

ffere

d I

np

ut

125kSPS/Ch

AD7616

AD7380 AD7380-4

1MSPS/ChAD4606

Dual ADCs

► 14, 12-Bit

4.2MSPSAD7357

► Bandwidth 400kHz ► Bandwidth 22kHz

► Dual ADC ► Quad ADC

SC

In

pu

t

8/4/2-Ch DAQ

200/350/550

kSPS/Ch

LTC2358/7/3

2018 2019

Direct interface to low impedance sensors

Direct interface to high and low impedance sensors

8/4/2-Ch ADCs

200/400/666

kSPS/ChLTC2345/4/1

► 18-Bit

>2020

Availability

Released

Development

Concept

Facilitates existing

Analog/ Digital ASIC usage

Ease of Adoption




xMR Sensors for Position Feedback

► AMR with 180°absolute position is a released product (ADA4571)

► GMR and TMR (both 360°absolute) are being qualified and sampled▪ 0.1°-0.5°accuracy

► AMR off-shaft length sensor for industrial applications

► Accuracies of 0.05°and lower achievable -> mechanical construction tolerance▪ Different measurement principle to standard AMR

► Zero power multiturn sensor

► Potential fit for mid-precision machines, collaborative robots, high

speed machines such as spindles

▪ Robust, high speed, 10-14bit precision

▪ Zero power multi-turn for shutdown position awareness

▪ Will customers be willing to design and integrate position sensing?

19 Analog Devices Confidential Information—Not


11/5/2019

End of shaft

Off-shaft length sensor


Machine

AC

Motor

IE Protocols/App

Motor Control

Application

PWM SINC

SAR

- +

SA

R

SD

ENC

q

- +

SA

R

SA

R

- +

eMAC

SPI

MII

isolation

barrier Functional

safety

EMI/

EMC




Communications

Digital

Isolation

Current

Feedback

Position

Feedback



► Advanced Gate drivers (ADuM4135/4136)▪ Support the most common industrial working voltage and

higher power range (<100kW)▪ Also very suited to driving new & faster GaN/SiC switches

▪ Includes embedded SC protection and other features▪ DESAT function detects short circuit fault without current

measurement

▪ Fault reporting and reset pins

▪ Roadmap▪ Over temperature monitor of the power switch

▪ Flyback controller for gate drive power supply

▪ Full gate power supply integration for IGBT/SiC

▪ Fast short circuit fault detection for GaN/SiC

▪ Programmable slew rate

Isolated Gate Driver for Industrial Motor drives

► Basic Gate Drivers (ADuM4120/4121)▪ Support the most common industrial working voltage and

power range (400V <50kW)▪ Miller clamp to prevent spurious turn on

▪ 5 kV isolation, working voltage 600 V rms

▪ 6 and 8 pin version with 8 mm creepage

▪ Very suited to driving new & faster GaN/SiC switches▪ CMTI: 150 kV/µs

▪ Prop delay 38 ns typical, prop delay skew <15 ns

▪ Roadmap▪ Slew rate selection to manage EMI/efficiency trade-off

▪ Insulation and packages for 690V and higher power

▪ Integrated Gate drive supply for GaN switches

21



June 18-22, 2018


Slew Rate Controlled Gate Drive

► Some customers looking to use faster IGBTs in new designs

▪ Faster switching transitions -> reduced switching loss -> smaller heat sink size

▪ Faster switching transitions -> increased EMI problems -> larger EMI filter

► EMI worst-case is at light load/motor standstill

► Lower Gate Drive Impedance minimises losses

► Higher Gate Drive Impedance slows the switching transitions reducing emissions

Switching loss area

CM current

Heat Sink

Proportional to dv/dt




Machine

AC

Motor

IE Protocols/App

Motor Control

Application

PWM SINC

SAR

- +

SA

R

SD

ENC

q

- +

SA

R

SA

R

- +

eMAC

SPI

MII

isolation

barrier Functional

safety

EMI/

EMC




Communications

Digital

Isolation

Current

Feedback

Position

Feedback



S-D Current

Feedback & OCP

UP TO 2M BYTE

FLASH

(EXECUTABLE)

L1 CACHE

16K BYTE

L1 INSTRUCTION

CACHE

SYSTEM CONTROL BLOCKS

PERIPHERALS

HARDWARE FUNCTIONS

L3 MEMORY

SYSTEM FABRIC

1×EMAC WITH

IEEE 1588

(OPTIONAL)

2x SPORT

2×CAN

STATIC MEMORY

CONTROLLERASYNC INTERFACE

2×SPI

4×QUADRATURE

ENCODER

8×TIMER

12×PWM PAIRS

1×TWI / I2C

USB FS OTG

(OPTIONAL)

L1 MEMORY

UP TO 384K BYTE

PARITY-ENABLED

ZERO-WAIT-STATE SRAM

JTAG, SWD,

CoreSight™TRACE

EVENT

CONTROL

SYSTEM

WATCHDOGS

PLL & POWER

MANAGEMENT

FAULT

MANAGEMENT

3×UART

ADCC DACC

HARMONIC ANALYSIS ENGINE

(HAE)

ANALOG

FRONT END

GP

IO(4

0O

R91)

2×ADC 2×DAC

UP TO 240 MHz

SINC FILTERS

SECURITY

Cortex-M4

(16 BIT)

ADSP-CM40x Overview: ‘Slater’

>2x Motor

Position

Up to 3x3-ph

motor drive

Connectivity

Serial Encoder

Protocols

FPGA/FIDO

interface

User Interface

Current, Voltage,

Position

Feedback

Real-time

routines DMA, Interrupt, triggers

Real-time

execution at min

overhead

Cortex-M4F

240MHz

ARM Ecosystem


Machine

AC

Motor

IE Protocols/App

Motor Control

Application

PWM SINC

SAR

- +

SA

R

SD

ENC

q

- +

SA

R

SA

R

- +

eMAC

SPI

MII

isolation

barrier Functional

safety

EMI/

EMC




Communications

Digital

Isolation

Current

Feedback

Position

Feedback

I/O



SPI

SMC

Synchronized

Motion Control

Industrial

Ethernet Stack

IE S

witc

h/

Pro

ce

sso

r

MII

MII

Robot

Control

Motion Control

Field Bus

Protocol

UART

CAN



CAN/RS22/485

Transceivers

Real Time Industrial

Ethernet Switches

Real Time Industrial

Ethernet Switch

protocols

Robust Industrial PHY

Industrial Communications


FIDO5000 REM Switch Multiprotocol Real-Time Ethernet Switch Chip

27




Easy Evaluation with Complete Service and Support

The RapID Platform is a pre-tested Industrial Ethernet Network Interface

Card that processes the industrial protocol and network traffic

• Unique architecture with Innovasic's PriorityChannel® technology

eliminates the effects of network traffic

• Available as a card that plugs into your PCB or as schematics to

integrate circuit/chips into your PCB

• Common hardware interface supports all protocols

• Common software interface supports all protocols

• No licensing fees or royalties

• Guaranteed first-pass certification

Next Generation

RapID platform

release: ~Q2 2019




ADIN1200 / ADIN1300 Robust, Industrial, Low Latency, Low Power Ethernet

PHY

► ADIN1300 10/100/1000 Gigabit PHY

▪ Robust Temperature Range: -40 to 105C

▪ Robust EMI / EMC / ESD performance

▪ Small Footprint: 6x6mm 40-LFCSP

▪ Low Power: 365mW

▪ Low Latency: 290ns Tx & Rx (RGMII)

► ADIN1200 10/100 Fast Ethernet PHY

▪ Robust Temperature Range: -40 to 105C

▪ Robust EMI / EMC / ESD performance

▪ Small Footprint: 5x5mm 32-LFCSP

▪ Low Power : 175mW

▪ Low Latency : 300ns Tx & Rx (MII)

Generic Package Temp Range

ADIN1300 40 Lead LFCSP -40C to 105C

40 Lead LFCSP -40C to 85C

ADIN1301 64 Lead LGA -40C to 105C

64 Lead LGA -40C to 85C

ADIN1200 32 Lead LFCSP -40C to 105C

32 Lead LFCSP -40C to 85C

► PHY Samples

▪ ADIN1300 Dec 2018

▪ ADIN1200 Jan 2019

► PHY Production Release

▪ ADIN1300 Dec 2019

▪ ADIN1200 Jan 2020.



System Solutions

Analog Devices Confidential Information—Not for External Distribution30


220V 1kW AC Servo ADP with Option Cards

also supports general motor drive development (IM, BLDC)

► System demonstrations– To show what key ADI devices can

be used in a motor drive

– To show basic capabilities of ADI motor control solutions

► Key parts’ evaluation– Evaluation in a system

environment that is most similar to typical drive products

– ADI sigma delta ADC performance

– ADI isolation technologies

– ADI gate driver

► Flexible extensions– Generic interface to new

functionalities in motor drive systems

► Software development– A HW platform that can run almost

all motor control related software

Control Board

Option CardsEncoder & Pulse Interface

Power Board

LED/ Keypad

► 220V/400W PMSM

► 2500 line incremental encoder

Digital I/Os

RS485

Motor Power connectors

► 220V induction motorRS232 for IAP and debug

AC Power input

Break resistor


Bare Metal Ethercat Slave Solution

32



SMC

IRQ

sPHY PHY

MIIMII

MDIOMDIO

FIDO REM Driver

Network Stack

CiA402 profile

User Application

CM408 Peripherals

TwinCAT

ARM9 Core


Thank you!

33



connected motion and robotics: systems, platforms and...

Documents