Designing Robust and Fault-Tolerant Motion-Control Feedback Systems


Posted on Feb 6, 2014

This article reviews basic servo systems and development of the fault-tolerant feedback systems for servo systems. Controller receiver circuit design, proper PC-board receiver circuit layout, and the encoder`s signal cable and termination are discussed. Additionally, various types of industrial feedback encoders are presented, along with


Designing Robust and Fault-Tolerant Motion-Control Feedback Systems
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the various types of faults that can develop in a servo feedback system. The key to robust operation in a system lies in the way it handles mechanical and electrical faults. This article discusses the design of a robust and fault-tolerant motion-control system whose feedback paths incorporate quadrature encoders. Modern automated systems incorporate closed-loop feedback for motion control. They typically include a servo system that consists of a motor driver and feedback elements combined in a manner that gives accurate and stable control over speed and position. The various system-level components of a typical servo system are illustrated in Figure 1. DC brushless motors are preferred for high-performance and high-speed applications. DC brush and stepper motors are suitable for low-speed and less-demanding applications. Brushless motors are assumed throughout this article. Such motors typically include a quadrature encoder on the end shaft that determines the shaft velocity and commutation point for controlling the motor`s coil-switching sequences (see sidebar, Feedback encoder types). A second quadrature encoder on the machine`s rotating shaft provides position data for that shaft, which generally differs from the motor-shaft position due to inaccuracies caused by backlash in the gearhead and lead-screw assemblies. Typical motion-controller cards and modules include a motion-control IC, a microprocessor, and a DSP or...




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