Servo Controller - The AC Servo Controller is a closed loop tracking system which is used for mechanical movement. Anaheim Automation offers two different models of the AC Servo Controller, the EDC and EDB series. These AC Servo Controller products are a great value for anyone who requires high precision at a low cost. Anaheim Automation provides great customer service/support with a no-nonsense approach. Our ESView software offers an easy to use, and easy to maintain alternative to other complicated AC Servo Controller.
• High-Speed, High-Precision AC Servo Controller products
• Power Rating from 200 to 5,000 Watts
• Industrial-Grade Intelligent Power Modules
• High Overload and Disturbance Rejection
• Higher Start-Up Torque than Most Servos
• Modbus for Networking up to 32 Motors
Fundamentals of Servo Controller
- Servo Controller - Basics
- Servo Controller - Customization
- Servo Controller - Mounting
- Servo Controller - Environmental Considerations
- Servo Controller - Wiring
- Servo Controller - Applications
- Servo Controller - Feedback
- Servo Controller - History
Servo Controller is an electronic amplifier used to power servo motors. The Servo Controller monitors the feedback signals from a servo motor and continually adjusts for deviations in speed, position, and torque from its expected behavior. There are two different ways that a Servo Controller achieves its desired motion. First, a "PID" (Proportional, Integral, and derivative position loop) and a "PIV" (Proportional position loop, Integral and proportional Velocity loop) is used to detect and correct any disturbance on the Servo Controller speed, position, or torque. Second, "Feed forward control," which is used to track how well the actual motion follows what is being commanded on the servo drive. A Servo Controller will incorporate both types of control to achieve the best performance.
Servo Controller PID loop consists of the proportional, the integral, and the derivative values. The proportional value checks for the reaction to the current error, the integral value determines the reaction based on the sum of recent errors, and the derivative value determines the reaction based on the rate at which the error has been changing.
Servo Controller Proportional gain - For a quicker response time, increase the servo drives proportional gain. Excessively large value of proportional gain will lead to instability and oscillation.
Servo Controller Integral gain - The larger the Servo Controller integral gain value, the quicker the steady state errors are eliminated, which also creates a larger overshoot.
Servo Controller Derivative gain - The larger the value of the Servo Controller derivative gain decreases overshoot, but slows down transient response and may lead to instability due to signal noise amplification in the differentiation of error.
Anaheim Automation was established in 1966 as a manufacturer of "turnkey" motion control systems. Its' emphasis on R&D has insured the continued introduction of advanced motor drive/controller, such as the Servo Controller product line. Today, Anaheim Automation ranks among the leading manufacturers and distributor of motion control products, a position enhanced by its excellent reputation for quality products at competitive prices. The Servo Controller product line is no exception to the Company's goal.
Anaheim Automation offers a wide variety of standard Servo Controller products. Occasionally, OEM customers with mid to large quantity requirements prefer to have Servo Controller that is custom or modified to meet their exact design requirements. Sometimes the customization is as simple as a packaging modification, mounting dimensions, or a label. Other times, a customer might require that a Servo Controller meet an ideal specification such as, speed, torque, and/or voltage.
Engineers appreciate that Anaheim Automation's Servo Controller product line can answer their desire for creativity, flexibility and system efficiency. Buyers appreciate the simplicity of the "one-stop shop," and the cost savings of a custom Servo Controller design, while engineers are pleased with Anaheim Automation's dedicated involvement in their specific Servo Controller and motor system.
Anaheim Automation's standard Servo Controller product line is a cost-effective solution, in that they are known for their rugged construction and excellent performance. A considerable size of its sales growth has resulted from dedicated engineering, friendly customer service and professional application assistance, often surpassing the customer's expectations for fulfilling their custom requirements. While a good portion of Anaheim Automation's Servo Controller sales involves special, custom, or private-labeling requirements, the company takes pride in its standard stock base located in Anaheim, California, USA. To make customization of a Servo Controller affordable, a minimum quantity and/or a Non-Recurring Engineering (NRE) fee is required. Contact the factory for details, should you require a custom Servo Controller in your design.
All Sales for a customized or modified Servo Controller are Non-Cancelable-Non-Returnable, and a NCNR Agreement must be signed by the customer, per each request. All Sales, including a customized servo drive, are made pursuant to Anaheim Automation's standard Terms and Conditions, and are in lieu of any other expressed or implied terms, including but not limited to any implied warranties.
Anaheim Automation's customers for the Servo Controller product line is diverse: companies operating or designing automated machinery or processes that involve food, cosmetics or medical packaging, labeling or tamper-evident requirements, cut-to-length applications, assembly, conveyor, material handling, robotics, special filming and projection effects, medical diagnostics, inspection and security devices, pump flow control, metal fabrication (CNC machinery), and equipment upgrades. Many OEM customers request that we "private-label" the Servo Controller used in their system or machinery, so that their customers stay loyal to them for servicing, replacements and repairs.
PLEASE NOTE: Technical assistance regarding its Servo Controller product line, as well as all the products manufactured or distributed by Anaheim Automation, is available at no charge. This assistance is offered to help the customer in choosing Anaheim Automation products for a specific application. However, any selection, quotation, or application suggestion for a servo drive, or any other product, offered from Anaheim Automation's staff, its' representatives or distributors, are only to assist the customer. In all cases, determination of fitness of the custom Servo Controller in a specific system design, is solely the customers' responsibility. While every effort is made to offer solid advice regarding the Servo Controller product line, as well as other motion control products, and to produce technical data and illustrations accurately, such advice and documents are for reference only, and subject to change without notice.
The following information is intended as a general guideline for the installation and mounting of the servo drive. WARNING - Dangerous voltages capable of causing injury or death may be present in the Servo Controller system. Use extreme caution when handling, testing, and adjusting during installation, set-up, tuning, and operation. It is very important that the wiring of the Servo Controller be taken into consideration upon installation and mounting.
Subpanels installed inside the enclosure for mounting Servo Controller and motor system components, must be a flat, rigid surface that will be free from shock, vibration, moisture, oil, vapors, or dust. Remember that the Servo Controller and motor will produce heat during work, therefore, heat dissipation should be considered in designing the system layout. Size the enclosure so as not to exceed the maximum ambient temperature rating. It is recommended that the Servo Controller be mounted in an upright position, providing adequate airflow. The Servo Controller and motor should be mounted in a stable fashion, secured tightly. NOTE: There should be a minimum of 10mm between the Servo Controller and any other devices mounted in the system/electric panel or cabinet. There should be at least 10mm space in the lateral direction and 50mm space in the longitudinal direction, between the Servo Controller and other electronic/electrical devices. For multi-axis systems, mount in the panel left to right according to power utilization (highest to lowest). If power utilization is unknown, mount from left to right based on Amp rating.
NOTE: In order to comply with UL and CE requirements, the Servo Controller must be grounded in a grounded conducive enclosure offering protection as defined in standard EN 60529 (IEC 529) to IP55 such that they are not accessible to the operator or unskilled person. As with any moving part in a system, the servo motor should be kept out of the reach of the operator. A NEMA 4X enclosure exceeds those requirements providing protection to IP66. To improve the bond between the power rail and the subpanel, construct your subpanel out of a zinc-plated (paint-free) steel. Additionally, it is strongly recommended that the Servo Controller be protected against electrical noise interferences. Noise from signal wires can cause mechanical vibration and malfunctions.
The following environmental and safety considerations must be observed during all phases of operation, service and repair of a Servo Controller and motor system. Failure to comply with these precautions violates safety standards of design, manufacture and intended use of the drive and motor. Please note that even a well-built Servo Controller and motor products operated and installed improperly, can be hazardous. Precaution must be observed by the user with respect to the load and operating environment. The customer is ultimately responsible for the proper selection, installation, and operation of the Servo Controller and motor system.
The atmosphere in which a Servo Controller and motor is used must be conducive to good general practices of electrical/electronic equipment. Do not operate the Servo Controller and motor in the presence of flammable gases, dust, oil, vapor or moisture. For outdoor use, the Servo Controller and motor must be protected from the elements by an adequate cover, while still providing adequate air flow and cooling. Moisture may cause an electrical shock hazard and/or induce system breakdown. Due consideration should be given to the avoidance of liquids and vapors of any kind. Contact the factory should your application require specific IP ratings. It is wise to install the Servo Controller and motor in an environment which is free from condensation, electrical noise, vibration and shock.
Additionally, it is preferable to work with the Servo Controller in a non-static protective environment. Exposed circuitry should always be properly guarded and/or enclosed to prevent unauthorized human contact with live circuitry. No work should be performed while power is applied. Don't plug in or unplug the connectors when power is ON. Wait for at least 5 minutes before doing inspection work on the Servo Controller and motor system after turning power OFF, because even after the power is turned off, there will still be some electrical energy remaining in the capacitors of the internal circuit of the servo drive.
Plan the installation of the Servo Controller and motor in a system design that is free from debris, such as metal debris from cutting, drilling, tapping, and welding, or any other foreign material that could come in contact with circuitry. Failure to prevent debris from entering the Servo Controller and motor system can result in damage and/or shock.
NOTE: Meeting CE Requirements requires a ground system, and the method of grounding the ac line filter and the Servo Controller must match. Failure to do this renders the filter ineffective and may damage.
The following information is intended as a general guideline for wiring of the Anaheim Automation Servo Controller and motor product lines. See the individual product specification sheets for each model. Be aware that when you route power and signal wiring on a machine or system, radiated noise from the nearby relays, transformers, and other electronic devices can be induced into the servo motor and encoder signals, input/output communications, and other sensitive low voltage signals. This can cause systems faults and communication errors. WARNING - Dangerous voltages capable of causing injury or death, may be present in the servo drive. Use extreme caution when handling, wiring, testing, and adjusting during installation, set-up, tuning, and operation. Don't make extreme adjustments or changes to the Servo Controller and motor parameters, which can cause mechanical vibration and result in failure and/or loss. Once the servo motor is wired, do not run the Servo Controller by switching On/Off the power supply directly. Frequent power On/Off switching will cause fast aging of the internal components in the servo drive, which will reduce the lifetime of Servo Controller and motor system. It's required to use reference signals to control the running of the servo motor drive.
Strictly comply with the following rules:
- Route high-voltage power cables separately from low-voltage power cables.
- Segregate input power wiring and Servo Controller and motor power cables from control wiring and motor feedback cables as they leave the servo drive. Maintain this separation throughout the wire run.
- Use shielded cable for power wiring and provide a grounded 360 degree clamp termination to the enclosure wall. Allow room on the sub-panel for wire bends.
- Make all cable routes as short as possible.
- Single point grounding is required when mounting the servo motor and servo drive, and grounding resistance should be lower than 100Ω.
- It's prohibited to apply power input noise filter between Servo Controller and servo motor.
Factory made cables are recommended for use in our high Servo Controller and motor systems. These cables are purchased separately, and are designed to minimize EMI. These cables are recommended over customer-built cables to optimize system performance and to provide additional safety for the Servo Controller and motor system and the user.
NOTE: Meeting CE Requirements for a Servo Controller and motor system requires a ground system, and the method of grounding the ac line filter and the Servo Controller must match. Failure to do this renders the filter ineffective and may cause damage to the filter. For grounding and filter suggestions, please contact the factory.
WARNING - To avoid the possibility of electrical shock, perform all mounting and wiring of the Servo Controller and motor system prior to applying power. Once power is applied, connection terminals may have voltage present, even when the Servo Controller and motor are not in use.
Anaheim Automation's cost-effective Servo Controller and motor product lines are the wise choice for both OEM and user accounts. Anaheim Automation's customers for the Servo Controller and motor product lines are diverse: industrial companies operating or designing automated machinery or processes that involve food, cosmetics or medical packaging, labeling or tamper-evident requirements, cut-to-length applications, assembly, conveyor, material handling, robotics, special filming and projection effects, medical diagnostics, inspection and security devices, pump flow control, metal fabrication (CNC machinery), and equipment upgrades. A Servo Controller and motor are often found in motion systems that require position, velocity and/or torque control.
Anaheim Automation also offers a Servo Controller and motor product line that integrates a matched servo motor, Servo Controller and controller in one unit. This design concept makes selection easy, thus reducing errors and wiring time. With friendly customer service and professional application assistance, Anaheim Automation often surpasses the customer's expectations for fulfilling specific Servo Controller and motor requirements, as well as other motion control needs.
NOTE: Technical assistance regarding the Servo Controller product line is available at no charge. This assistance is offered to help the customer in choosing Anaheim Automation products for a specific application. However, any selection, quotation, or application suggestion for a servo drive, or any other product, offered from Anaheim Automation's staff, its' representatives or distributors, are only to assist the customer. In all cases, determination of fitness of the Servo Controller in a specific system application is solely the customers' responsibility. While every effort is made to offer solid advice regarding the Servo Controller and motor in a specific application, and to produce technical data and illustrations accurately, such advice and documents are for reference only, and subject to change without notice. Anaheim Automation is in no event responsible or liable for indirect or consequential damages resulting from the use or application of the Servo Controller and motor. Improper use of a high torque servo motor in an application can result in personal injury or death, property damage, and/or economic loss.
There are two options for Servo Controller feedback controls, either a Servo Controller encoder or a Servo Controller resolver. A Servo Controller encoder and a Servo Controller resolver provides the same solution in many applications, but are vastly different. They are both used to sense speed, direction, and position of the servo motor output shaft.
The resolver on the servo motor uses a second set of rotor and stator coils called the transformer to induce rotor voltages across an air gap. The resolver does not use any electronic components, therefore it's very robust with a high temperature range, and is inherently shock resistance due to its design. A resolver is mostly used in harsh environments.
The optical encoder on the servo motor uses a rotating shutter to interrupt a beam of light across an air gap between a light source and a photodetector, over time the wear associated with the rotating shutter reduces the longevity and reliability of the encoder.
The application will determine whether a resolver or an encoder is needed. Encoders are more accurate and are easier to implement so they should be the first choice for any application. The only reason to choose a resolver is if environmental and longevity requires it.
The steam engine governor is considered the first powered feedback system that used a gain value so it is considered the first servo mechanism. The word servo motor comes from the French phrase "Le Servomoteur" or the "slave motor". The first known record of its use was by JJL Farcot in 1868 to describe steam engines and hydraulics for use in steering a ship.
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