Sensorless control strategies were first suggested well over a decade ago with the aim of reducing the size, weight and unit cost of electrically actuated servo systems. The resulting algorithms have been successfully applied to the induction and synchronous motor families in applications where control of armature speeds above approximately one hundred revolutions per minute is desired. However, sensorless position control remains problematic. This thesis provides an in depth investigation into sensorless motor control strategies for high precision motion control applications. Specifically, methods of achieving control of position and very low speed thresholds are investigated. The developed grey box identification techniques are shown to perform better than their traditional white or black box counterparts. Further, fuzzy model based sliding mode control is implemented and results demonstrate its improved robustness to certain classes of disturbance. Attempts to reject uncertainty within the developed models using the sliding mode are discussed. Novel controllers, which enhance the performance of the sliding mode are presented. Finally, algorithms that achieve control without a primary feedback sensor are successfully demonstrated. Sensorless position control is achieved with resolutions equivalent to those of existing stepper motor technology. The successful control of armature speeds below sixty revolutions per minute is achieved and problems typically associated with motor starting are circumvented.

A Read-While-Write (RWW) operation for tape and/or potentially disk applications is needed in the following three cases: 1. High reliability; 2. Data servo systems; 3. Buried servo systems. All these applications mean that the read (servo) head and write head are operative simultaneously. Consequently, RWW operation will require work to suppress the so-called crossfeed field radiation from the write head. Traditionally, write-read crossfeed has been reduced in conventional magnetic recording heads by a variety of screening methods, but the effectness of these methods is very limited. On the other hand, the early theoretical investigations of the crossfeed problem concentrating on the flux line pattern in front of a head structure based on a simplified model, may not be comprehensive. Today a growing number of magnetic recording equipment manufacturers employ thin-film technology to fabricate heads and thereby the size of the modern head is much smaller than in the past. The increasing use of thin-film metallic magnetic materials for heads, along with the appearance of other new technologies, such as the MR reproductive mode and keepered media, has stimulated the need for an increased understanding of the crossfeed problem by advanced analysis methods and a satisfactory practical solution to achieve the RWW operation. The work described in this thesis to suppress the crossfeed field involves both a novel reproductive mode of a Dual Magnetoresistive (DMR) head, which was originally designed to gain a large reproduce sensitivity at high linear recording densities exceeding 100 kFCI, playing the key role in suppressing the crossfeed (the corresponding signal-noise ratio is over 38 dB), and several other compensation schemes, giving further suppression. Advanced analytical and numerical methods of estimating crossfeed in single and multi track thin-film/MR heads under both DC and AC excitations can often help a head designer understand how the crossfeed field spreads and therefore how to suppress the crossfeed field from the standpoint of an overall head configuration. This work also assesses the scale of the crossfeed problem by making measurements on current and improved heads, thereby adapting the main contributors to crossfeed. The relevance of this work to the computer industry is clear for achieving simultaneous operation of the read head and write head, especially in a thin-film head assembly. This is because computer data rates must increase to meet the demands of storing more and more information in less time as computer graphics packages become more sophisticated.

Traditional methods for mechatronics design are often based on a sequential approach, where the mechanical structure is designed first, and then fitted with off-the-shelf electric motors, drive electronics, gearheads and sensors. Finally a control system is designed and optimized for the already existing physical system. Such a design method, that doesn’t consider aspects from a control point of view during the design of the physical system, is unlikely to result in a system with optimal control performance. Furthermore, to separately design and optimize each of the physical components will, from a global perspective, generally not result in a system that is optimal from a weight, size or cost perspective. In order to reach the optimal design of an integrated mechatronic system (mechatronic module) it is necessary to treat the system as a whole, considering aspects from all involved engineering domains concurrently. In this thesis such an approach to integrated design of mechatronic servo systems is presented. A design methodology that considers the simultaneous design of the electric machine, gearhead, machine driver and control system, and therefore enables global optimization, has been developed. The target of the design methodology is conceptual design and evaluation. It is assumed that the load to be driven by the servo system is known and well defined, a load profile describing the wanted load motion and the corresponding torque, is required as input. The methodology can then be used to derive the lightest or smallest possible system that can drive the specified load. Furthermore, the control performance is evaluated and optimized, such that the physical system design and the controller design are integrated. The methodology is based on modelling and simulation. Two types of component models have been developed, static and dynamic models. The static models describe relations between the parameters of the physical components, for example a component’s torque rating as function of its size. The static models are based on traditional design rules and are used to optimize the physical parts of the system. The dynamic models describe the behaviour of the components and are used for control system design and performance optimization. The gear ratio is identified to be the most central design variable when designing and optimizing electromechanical servo systems. The gear ratio directly affects the required size of the gearhead, electric machine and the machine driver. But it has also large influences on the system’s control performance. It is concluded that high gear ratios generally are better from a control point of view than low ratios. A consequence of this is that it is possible, without compromising the control performance, to use less expensive (less accurate) sensors and microprocessors in high gear ratio servo systems, while low gear ratio systems require more expensive hardware. It is also concluded that it is essential to include all performance limiting phenomena, linear as well as non-linear, in this type of integrated analysis. Using for example a linearized system description for controller design, means that many of the most important couplings between control system and physical system design are overlooked. / QC 20100816

<p>The number of electric powered sub-systems in road-vehicles is increasing fast. This development is primarily driven by the new and improved functionality that can be implemented with electro-mechanical sub-systems, but it is also necessary for the transition to electric and hybrid-electric drive trains.</p><p>An electromechanical sub-system can be implemented as a physically integrated mechatronic module: controller, power electronics, electric motor, transmission and sensors, all integrated into one component. A mechatronic module, spans, as all mechatronic systems, over several closely coupled engineering disciplines: mechanics, electronics, electro-mechanics, control theory and computer science. In order to design and optimize a mechatronic system it is therefore desirable to design the system within all domains concurrently. Optimizing each domain or component separately will not result in the optimal system design. Furthermore, the very large production volumes of automotive sub-systems increase the freedom in the mechatronics design process. Instead of being limited to the selection from off-the shelf components, application specific components may be designed.</p><p>The research presented in this thesis aims at development of an integrated design and optimization methodology for mechatronic modules. The target of the methodology is the conceptual design phase, where the number of design parameters is relatively small. So far, the focus has been on design methods for the electric motor and gearhead, two of the most important components in an actuation module. The thesis presents two methods for design and optimization of motor and gearhead in mechatronic applications. One discrete method, intended for the selection of off-the-shelf components, and one method mainly intended for high volume applications where new application specific components may be designed. Both methods can handle any type of load combination, which is important in mechatronic systems, where the load seldom can be classified as pure inertial or constant speed.</p><p>Furthermore, design models relating spur gear weight, size and inertia to output torque and gear ratio are presented. It is shown that a gearhead has significantly lower inertia and weight than a motor. The results indicate that it almost always is favorable from a weight and size perspective to use a gearhead. A direct drive configuration may only be lighter for very high speed applications. The main contribution of this thesis is however the motor/gear ratio sizing methods that can be applied to any electromechanical actuation system that requires rotational motion.</p>

The number of electric powered sub-systems in road-vehicles is increasing fast. This development is primarily driven by the new and improved functionality that can be implemented with electro-mechanical sub-systems, but it is also necessary for the transition to electric and hybrid-electric drive trains. An electromechanical sub-system can be implemented as a physically integrated mechatronic module: controller, power electronics, electric motor, transmission and sensors, all integrated into one component. A mechatronic module, spans, as all mechatronic systems, over several closely coupled engineering disciplines: mechanics, electronics, electro-mechanics, control theory and computer science. In order to design and optimize a mechatronic system it is therefore desirable to design the system within all domains concurrently. Optimizing each domain or component separately will not result in the optimal system design. Furthermore, the very large production volumes of automotive sub-systems increase the freedom in the mechatronics design process. Instead of being limited to the selection from off-the shelf components, application specific components may be designed. The research presented in this thesis aims at development of an integrated design and optimization methodology for mechatronic modules. The target of the methodology is the conceptual design phase, where the number of design parameters is relatively small. So far, the focus has been on design methods for the electric motor and gearhead, two of the most important components in an actuation module. The thesis presents two methods for design and optimization of motor and gearhead in mechatronic applications. One discrete method, intended for the selection of off-the-shelf components, and one method mainly intended for high volume applications where new application specific components may be designed. Both methods can handle any type of load combination, which is important in mechatronic systems, where the load seldom can be classified as pure inertial or constant speed. Furthermore, design models relating spur gear weight, size and inertia to output torque and gear ratio are presented. It is shown that a gearhead has significantly lower inertia and weight than a motor. The results indicate that it almost always is favorable from a weight and size perspective to use a gearhead. A direct drive configuration may only be lighter for very high speed applications. The main contribution of this thesis is however the motor/gear ratio sizing methods that can be applied to any electromechanical actuation system that requires rotational motion. / QC 20101220

Nessa pesquisa é apresentada uma inovação tecnológica em aplicações de controle de posição em máquinas e/ou dispositivos: o Controlador de Posição Linear Hidro- Pneumático. Para os casos nos quais têm-se grandes esforços combinados com pequenos deslocamentos, normalmente esse trabalho é feito com o uso de Sistemas Servo-Hidráulcos nos quais, devido às características mencionadas do nicho de mercado visado pela presente proposta, representam um custo elevado quando comparado com a solução Hidro-Pneumática aqui descrita. Salienta-se a simplicidade da infra-estrutura requerida para a instalação dessa alternativa, e também a redução do desperdício energético com relação à tecnologia tradicional com a Servo-Hidráulica. Observou-se nos testes com o protótipo, um excelente desempenho do sistema em termos de rapidez de resposta, como ainda no quesito resolução de posicionamento cujos valores encontrados apresentam-se na casa de 0,05 segundos e 0,01 mm, respectivamente. O pequeno tamanho físico obtido com essa nova tecnologia é outro item relevante, permitindo-se o seu emprego em locais de reduzido espaço disponível. . Resultados de simulações numéricas e de testes experimentais são apresentadas, bem como perspectivas de desenvolvimentos futuros. / This research presents a technological innovation for applications in machine / device position control: the Hydro-Pneumatic Linear Position controller. In cases where great efforts are combined with small dislocations, this task is normally accomplished by means of Servo Hydraulic Systems that, due to particular characteristics of the market envisaged by the present proposition, represent elevated costs, when compared to those of the hydro-pneumatic solution described here. This work presents an analytical numerical model for the devise as well as an experimental prototype. It worth noting the infra-structure simplicity required for this alternative implementation, and also the reduction in energy waste when compared to the traditional servo-hydraulic technology. The prototype experimental tests demonstrated the system excellent behavior in what concerns answer speed and position resolution whose values were respectively in range 0.05 s and 0,01 mm. The small physical size obtained with this technology is another relevant item, which allows the device use in places of reduced available space. Numerical simulation and experimental test results are presented as well as perspectives of future developments

Magistro darbo tema yra aktuali, nes tai naujas ir efektyvus žingsnis tobulinant elektros pavaras ir pagerinant daugelio mechanizmų valdymo kokybę. Adaptyvios pavarų valdymo sistemos sudaromos taikant parametrinės arba signalinės adaptacijos principą. Parametriškai adaptyvioje valdymo sistemoje, kintant valdymo objekto parametrams, keičiami reguliatorių parametrai taip, kad valdymo kokybė nepakistų. Naudojant signalinės adaptacijos principą, adaptacijos blokas formuoja papildomą valdymo signalą, kuris veikia reguliatoriaus įėjime ir garantuoja pastovią valdymo kokybę kintant valdymo objekto parametrams. Tyrimų metu nustatyta, kad parametrinė adaptacija turi trūkumų – adaptuojamasi tik po kelių ciklų, pajungus apkrovą gaunamas statinis greičio nuokrypis. Taigi parametrinės adaptacijos metu yra kompensuojamas inercijos momento pokytis, tačiau nėra kompensuojama apkrovos momento įtaka. Signalinės adaptacijos principo taikymo elektromechanėse sistemose tyrimo rezultatai rodo, kad adaptuojamasi iš karto to paties ciklo metu. Statinės apkrovos įtaka yra pašalinama tuo išvengiant greičio statinio nuokrypio bei užtikrinant pageidaujamą pereinamąjį procesą. Taigi taikant signalinę adaptaciją kompensuojami tiek inercijos, tiek ir apkrovos momentų pokyčiai. Nustatyta, kad taikant P-PI kintamos struktūros reguliatorių yra kompensuojamas tik statinės apkrovos momento pokytis, tuo išvengiant greičio statinio nuokrypio. Signalinės adaptacijos ir P-PI kintamos struktūros reguliatoriaus... [toliau žr. visą tekstą] / The theme of this Master project is actual, because it is new and effective step to elevate electrical drives, and also improves the quality of mechanism control. Adaptive speed control system allows the application of the parametric and the signal adaptation principle. In an adaptive control system, which is consist of parametric adaptation principle the change of the controlled object parameters causes the change of the controller settings so that control quality of the system remains constant. Using the signal adaptation principle, the adaptation block forms additional control signal, which acts in a regulator input and guarantees a constant quality of system control, when the object parameters are changing. There has been made research of the parametric adaptation principle application in the electromechanical servo drives. It has been determined that this adaptation principle has disadvantages – adaptation is not instantaneously, but after few cycles. Static load causes the static deviation of the speed. So using the parametric adaptation the moment of inertia is compensated, but load torque can‘t be compensated. The results of the investigation of the signal adaptation principle application in the electromechanical servo drives demonstrate that this adaptation is instantaneously and it does not affected by the load. The signal adaptation compensates the change of the moment of inertia and load torque. The P-PI variable structure controller compensates only the change of... [to full text]

Nessa pesquisa é apresentada uma inovação tecnológica em aplicações de controle de posição em máquinas e/ou dispositivos: o Controlador de Posição Linear Hidro- Pneumático. Para os casos nos quais têm-se grandes esforços combinados com pequenos deslocamentos, normalmente esse trabalho é feito com o uso de Sistemas Servo-Hidráulcos nos quais, devido às características mencionadas do nicho de mercado visado pela presente proposta, representam um custo elevado quando comparado com a solução Hidro-Pneumática aqui descrita. Salienta-se a simplicidade da infra-estrutura requerida para a instalação dessa alternativa, e também a redução do desperdício energético com relação à tecnologia tradicional com a Servo-Hidráulica. Observou-se nos testes com o protótipo, um excelente desempenho do sistema em termos de rapidez de resposta, como ainda no quesito resolução de posicionamento cujos valores encontrados apresentam-se na casa de 0,05 segundos e 0,01 mm, respectivamente. O pequeno tamanho físico obtido com essa nova tecnologia é outro item relevante, permitindo-se o seu emprego em locais de reduzido espaço disponível. . Resultados de simulações numéricas e de testes experimentais são apresentadas, bem como perspectivas de desenvolvimentos futuros. / This research presents a technological innovation for applications in machine / device position control: the Hydro-Pneumatic Linear Position controller. In cases where great efforts are combined with small dislocations, this task is normally accomplished by means of Servo Hydraulic Systems that, due to particular characteristics of the market envisaged by the present proposition, represent elevated costs, when compared to those of the hydro-pneumatic solution described here. This work presents an analytical numerical model for the devise as well as an experimental prototype. It worth noting the infra-structure simplicity required for this alternative implementation, and also the reduction in energy waste when compared to the traditional servo-hydraulic technology. The prototype experimental tests demonstrated the system excellent behavior in what concerns answer speed and position resolution whose values were respectively in range 0.05 s and 0,01 mm. The small physical size obtained with this technology is another relevant item, which allows the device use in places of reduced available space. Numerical simulation and experimental test results are presented as well as perspectives of future developments