March 2018
Linear Motion from non-Linear Robots
Galil Motion Control
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Overview of Galil Motion Control:
- Found in 1983 – 1st to introduce motion control by μP
- Introduced Ethernet based motion controller in 1999
- Over 750,000 controllers operating around the world
- AC / DC Servo, Step motor, Piezo motor & Hydraulic
Galil Motion Control
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Robot – Two classes of Robots:
- Linear axes with Cartesian coordinates
- Non-linear topology with Cartesian coordinates
Galil Motion Control
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Samples of Non-Linear Robotic solutions implemented
- SCARA robot
- Two axes manipulator arm for X-Y motion
- Two axes concentric linkage (Frog leg)
- Parallel axes system (Also known as H or T gantry)
- Delta Robot (four axes)
- Hybrid XY with Tripod and Rotary (six axes)
- Stewart Platform (six axes)
- Multi-joint articulated arm in semiconductor fab
- Bevel control on motion path for Edge polishing applications
Galil Motion Control
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Process flow and Topics of discussion
- Select Topology for the requirements
- Design of each joint with inertia / load calculations
- Motor / gear box selection – Inertia matching
- Selection of Power Drivers
- Forward Kinematics Equations for calculation of the Cartesian space from motor position
- Inverse Kinematics Equations for calculation of motor position from the Cartesian space
- Selection of Motion Controller – Centralized vs EtherCAT
- Tuning of each motor for optimum performance
Galil Motion Control
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Process flow and Topics of discussion
- Vibration detection and isolation – Is it detected via the Feedback sensor?
- Accelerometer can be used at the end-effector to measure the vibration frequency
- Optimize PID Filters along with Notch / Pole to address higher frequency vibrations
- Lower frequency addressed from the input Profile with smoothing filter
- Dynamic change of system variables such as inertia, friction, natural frequencies, etc.
- Piece wise linearization or continuous adjustment as function of position(s)
- Example of Gravity as arm length change
- Change of Mass or Inertia
- Working against Spring (Linear device) results in non-linear system response
Galil Motion Control
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Vibration Reduction
- Smooth motion along with speed are important
- Motion profile using high acceleration / deceleration with low pass to filter
discontinuity on velocity
- Notch filter on profile to suppress natural frequency at the end-effector
- Dynamic speed change to improve smoothness along with cycle time
Galil Motion Control
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Example of SCARA robot
- Forward transformation using absolute encoders on the motor
- Commands given as target position with X, Y, Z and Theta (Q ) orientation in
the Cartesian space
- Inverse Kinematics to command each motor on target path via calculating
Shoulder Q1, Elbow Q2, End-Effector Q4 and Vertical displacement d3
- Lets simplify and call motor at the shoulder (S), at the elbow (E), Vertical
position (V) and end-effector (W) to differentiate from the Cartesian space
reference
Galil Motion Control
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SCARA robot – Simplified Drawing
- The Forward Kinematic Equations are:
Shoulder (S), Elbow (E), Vertical position (V) and End-Effector (W) are read
X = L1 COS (S) + L2 COS (S + E)
Y = L1 SIN (S) + L2 SIN (S + E)
Tool Orientation Q = S + E + W
Vertical position Z = V + Z0 where Z0 is offset at home
Based on the motor positions of S, E, W and V absolute reference in Cartesian space is calculated
during initialization
Galil Motion Control
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SCARA robot – Simplified Drawing
- The Inverse Kinematic Equations are:
Tool Orientation W = Q - S – E where Q is the end-effector tip orientation
Vertical position V = Z - Z0 where Z0 is offset at home
Motors S, E, W and V are commanded to reach target position.
Galil Motion Control
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Digital Filter
Galil Motion Control
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Amplifiers or Drivers for Step motors
- Amplifiers provide 16-bit PWM for motor current (Torque ripple from switching)
- High bandwidth amplifiers with up to 6 kHz current loop bandwidth
- Stepper drivers – delivery of 256 microsteps/step resulting 51,200 microsteps per rev
- Special step motor smoothing filter available on the controller (filter on frequency
generation)
Galil Motion Control
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Galil Motion Control
Internal Drive EtherCAT Drive
• Instantaneous communications
• Encoder feedback from motor to controller
• Common ground between all components
• Centralized cabling
• Axes coupling – decoupling for isolation
• Cost advantage for centralized single processor
solution
• Ideal for less than 2 meters between drives
• Single CAT5 Ethernet Cable reduces cabling costs
• Loop closed on the drive
• Position data is sent to the drive via digital signal
• Encoder feedback sent to drive and relayed to
controller
• Increased total cost with a dedicated processor
per node
• Possible option for more than 3 meters to drives
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Product Life Cycle considerations
- Product life cycle greater than 20 years
- Average repair / service of product for 25+ years
- Obsolescence of parts does not effect customer’s production cycle
- Galil is committed to provide plug-in replacement with Form-Fit-&-Functional equivalent
- 18 months warranty on the controllers and amplifiers
Galil Motion Control
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Product Life Cycle considerations
- Over 100 man years of experience to help solve your complex motion control problems
to support from initial design stage through the production process
- Best value – anywhere : guaranteed by the Chairman and Co-Founder, Jacob Tal
http://www.galil.com/order/price-guarantee
- Customization with fast turn around
- Firmware changes (Mechanical systems – Kinematics)
- Hardware changes (Feedback sensors, motors)
- Software (OS, SCADA systems, development platforms)
Galil Motion Control
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Thank You!
- Question? Send the questions to support@galil.com or call (916) 626-0101
Galil Motion Control
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