Advances in Industrial Control Forothertitlespublishedinthisseries,goto www.springer.com/series/1412 Othertitlespublishedinthisseries: DigitalControllerImplementation ModellingandControlofMini-Flying andFragility Machines RobertS.H.IstepanianandJamesF. PedroCastillo,RogelioLozanoand Whidborne(Eds.) AlejandroDzul OptimisationofIndustrialProcesses ShipMotionControl atSupervisoryLevel TristanPerez DorisSáez,AldoCiprianoandAndrzejW. HardDiskDriveServoSystems(2ndEd.) Ordys BenM.Chen,TongH.Lee,KemaoPeng RobustControlofDieselShipPropulsion andVenkatakrishnanVenkataramanan NikolaosXiros Measurement,Control,and HydraulicServo-systems CommunicationUsingIEEE1588 MohieddineMaliandAndreasKroll JohnC.Eidson Model-basedFaultDiagnosisinDynamic PiezoelectricTransducersforVibration SystemsUsingIdentificationTechniques ControlandDamping SilvioSimani,CesareFantuzziandRonJ. S.O.RezaMoheimaniandAndrewJ. Patton Fleming StrategiesforFeedbackLinearisation ManufacturingSystemsControlDesign FreddyGarces,VictorM.Becerra, StjepanBogdan,FrankL.Lewis,Zdenko ChandrasekharKambhampatiandKevin Kovacˇic´andJoséMirelesJr. Warwick WindupinControl RobustAutonomousGuidance PeterHippe AlbertoIsidori,LorenzoMarconi andAndreaSerrani NonlinearH2/H∞,ConstrainedFeedback Control DynamicModellingofGasTurbines MuradAbu-Khalaf,JieHuang GennadyG.KulikovandHaydnA. andFrankL.Lewis Thompson(Eds.) PracticalGrey-boxProcessIdentification ControlofFuelCellPowerSystems TorstenBohlin JayT.Pukrushpan,AnnaG.Stefanopoulou andHueiPeng ControlofTrafficSystemsinBuildings SandorMarkon,HajimeKita,HiroshiKise FuzzyLogic,IdentificationandPredictive andThomasBartz-Beielstein Control JairoEspinosa,JoosVandewalle WindTurbineControlSystems andVincentWertz FernandoD.Bianchi,HernánDeBattista andRicardoJ.Mantz OptimalReal-timeControlofSewer Networks AdvancedFuzzyLogicTechnologies MagdaleneMarinakiandMarkos inIndustrialApplications Papageorgiou YingBai,HanqiZhuangandDaliWang (Eds.) ProcessModellingforControl BenoîtCodrons PracticalPIDControl ComputationalIntelligenceinTimeSeries AntonioVisioli Forecasting AjoyK.PalitandDobrivojePopovic (continuedafterIndex) Tan Kok Kiong (cid:2) Andi Sudjana Putra Drives and Control for Industrial Automation TanKokKiong,Ph.D. AndiSudjanaPutra DepartmentofElectricalandComputer EngineeringDean’sOffice Engineering NationalUniversityofSingapore NationalUniversityofSingapore 9EngineeringDrive1 4EngineeringDrive3 Singapore117576 117576Singapore Singapore Singapore [email protected] [email protected] ISSN1430-9491 ISBN978-1-84882-424-9 e-ISBN978-1-84882-425-6 DOI10.1007/978-1-84882-425-6 SpringerLondonDordrechtHeidelbergNewYork BritishLibraryCataloguinginPublicationData AcataloguerecordforthisbookisavailablefromtheBritishLibrary ©Springer-VerlagLondonLimited2011 Matlab®andSimulink®areregisteredtrademarksofTheMathWorks,Inc.,3AppleHillDrive,Natick, MA01760-2098,USA.http://www.mathworks.com Apartfromanyfairdealingforthepurposesofresearchorprivatestudy,orcriticismorreview,asper- mittedundertheCopyright,DesignsandPatentsAct1988,thispublicationmayonlybereproduced, storedortransmitted,inanyformorbyanymeans,withthepriorpermissioninwritingofthepublish- ers,orinthecaseofreprographicreproductioninaccordancewiththetermsoflicensesissuedbythe CopyrightLicensingAgency.Enquiriesconcerningreproductionoutsidethosetermsshouldbesentto thepublishers. 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Coverdesign:eStudioCalamar Printedonacid-freepaper SpringerispartofSpringerScience+BusinessMedia(www.springer.com) AdvancesinIndustrial Control SeriesEditors ProfessorMichaelJ.Grimble,ProfessorofIndustrialSystemsandDirector ProfessorMichaelA.Johnson,Professor(Emeritus)ofControlSystemsandDeputyDirector IndustrialControlCentre DepartmentofElectronicandElectricalEngineering UniversityofStrathclyde GrahamHillsBuilding 50GeorgeStreet GlasgowGl1QE UK SeriesAdvisoryBoard ProfessorE.F.Camacho EscuelaSuperiordeIngenieros UniversidaddeSevilla CaminodelosDescubrimientoss/n 41092Sevilla Spain ProfessorS.Engell LehrstuhlfürAnlagensteuerungstechnik FachbereichChemietechnik UniversitätDortmund 44221Dortmund Germany ProfessorG.Goodwin DepartmentofElectricalandComputerEngineering TheUniversityofNewcastle CallaghanNSW2308 Australia ProfessorT.J.Harris DepartmentofChemicalEngineering Queen’sUniversity Kingston,Ontario K7L3N6 Canada ProfessorT.H.Lee DepartmentofElectricalandComputerEngineering NationalUniversityofSingapore 4EngineeringDrive3 Singapore117576 Singapore Professor(Emeritus)O.P.Malik DepartmentofElectricalandComputerEngineering UniversityofCalgary 2500,UniversityDrive,NW Calgary,Alberta T2N1N4 Canada ProfessorK.-F.Man ElectronicEngineeringDepartment CityUniversityofHongKong TatCheeAvenue Kowloon HongKong ProfessorG.Olsson DepartmentofIndustrialElectricalEngineeringandAutomation LundInstituteofTechnology Box118 22100Lund Sweden ProfessorA.Ray DepartmentofMechanicalEngineering PennsylvaniaStateUniversity 0329ReberBuilding UniversityPark PA16802 USA ProfessorD.E.Seborg ChemicalEngineering UniversityofCaliforniaSantaBarbara 3335EngineeringII SantaBarbara CA93106 USA DoctorK.K.Tan DepartmentofElectricalandComputerEngineering NationalUniversityofSingapore 4EngineeringDrive3 Singapore117576 Singapore ProfessorI.Yamamoto DepartmentofMechanicalSystemsandEnvironmentalEngineering FacultyofEnvironmentalEngineering TheUniversityofKitakyushu 1-1,Hibikino,Wakamatsu-ku,Kitakyushu,Fukuoka,808-0135 Japan Series Editors’ Foreword The series Advances in Industrial Control aims to report and encourage technol- ogy transfer in control engineering. The rapid development of control technology has an impact on all areas of the control discipline. New theory, new controllers, actuators, sensors, new industrial processes, computer methods, new applications, new philosophies, ..., new challenges. Much of this development work resides in industrialreports,feasibilitystudypapersandthereportsofadvancedcollaborative projects.Theseriesoffersanopportunityforresearcherstopresentanextendedex- position of such new work in all aspects of industrial control for wider and rapid dissemination. Monographsfromtheacademiccontrolcommunitycommonlyhaveastrongfo- cusoncontrolsystemdesign,butthisisonlyoneaspectofindustrialcontrol,soitis pleasingtobeabletointroduceamonographintotheAdvancesinIndustrialCon- trolseriesthatisconcernedwithatopicfromtheequallyimportantareaofcontrol technology. Kok Kiong Tan and Andi Sudjani Putra from the National University ofSingaporehaveworkedforseveralyearswithindustrialengineersanduniversity studentsonthetechnologyofdrivesandtheirapplications.Theirworkhascovered teaching,research,andapplications,andnowtheirexperiencehasbeencapturedin thiscomprehensivemonographDrivesandControlforIndustrialAutomation.One focus of the book is to describe the hardware and working principles of hydraulic and pneumatic servo-drives, electric drives, and piezoelectric drives, all of which arepresentedandreviewedinonechaptereach(Chapters2–4,respectively).Agen- eral control system structure for these drives is then given in Chapter 5, where, being an industrially-oriented monograph, the control focus and discussion is on proportional-integral-derivative(PID)control.Theuseofagenericcontrolsystem structure across the differing drive technologies reinforces the authors’ approach totheindustrialservo-driveasapackagedunitintegratingsensors,actuators(prime mover),powermoderation,andcontrolsystem.Toincorporatesuchadriveunitinto aprocessapplicationleadsnaturallytoaconsiderationofindustrialprocesscommu- nicationtechnologyandcommunicationprotocols;thesearedescribedinChapter6, wherethefocusisonfieldbustechnology.Thefinalchapterofthebookreportson recentandfuturetrendsinmotioncontrol.Thekeydevelopmentsidentifiedarean vii viii SeriesEditors’Foreword industrial demand for miniaturisation and the growth of applications in the nano- andbio-technologyfields. Readers seeking an entry and introduction to the prevalent devices and current methodsforservo-drivetechnologywillfindthismonographquiteaccessible.Such readersmightincludefinal-yearundergraduatestudents,engineeringpostgraduates, industrialengineers,controlengineers,andtechnologists,typicallyfrom thefields ofelectrical,mechanical,aviation,andprocessengineering.Thebreadthofthecon- tentsofthemonographmeansthatitcanalsobeusedasareferencetextforservo- drivetechnology. WhilstthismonographfromK.K.TanandA.S.Putrahastheadvantageofcom- prehensiveness,readersseekingfurtherspecialistknowledgemightfindthefollow- ing Advances in Industrial Control series monographs useful. In the field of hy- draulics, the monograph Hydraulic Servo-systems (ISBN 978-1-85233-692-9) by M. Jelali and A. Kroll, for electric motors, the new monograph Induction Motor ControlDesign(ISBN978-1-84996-283-4)byR.Marino,P.Tomei,andG.M.Ver- relli. In the field of piezoelectric devices, the monograph Piezoelectric Transduc- ersforVibrationControlandDamping(ISBN978-1-84628-331-4)byS.O.R.Mo- heimaniandA.J.Fleming,andfinallyincommunications,themonographMeasure- ment,ControlandCommunicationusingIEEE1588(ISBN978-1-84628-250-8)by J.C.Eidson.ForPIDcontrol,theAdvancesinIndustrialControlseriesoffersanum- berofseminaltextsincluding:AdvancesinPIDControl(ISBN978-1-85233-138-2) by K.K. Tan, Q.-G. Wang, and C.C. Hang with T.J. Hägglund; Precision Motion Control(ISBN978-1-84800-020-9)byK.K.Tan,T.H.Lee,andS.Huang;Practi- calPIDControl(ISBN978-1-84628-585-1)byA.Visioli,andfinallyforsomething alittledifferent,ModelPredictiveControlSystemDesignandImplementationwith MATLAB®(ISBN978-1-84882-330-3)byL.Wang. IndustrialControlCentre M.J.Grimble Glasgow M.A.Johnson Scotland,UK Preface Industrialautomationhasbecomeanimportantfeaturetoday,especiallyinthisage ofrapidproductionanhighprecision.Automationallowsindustriestoachievethe levelofspeedandqualityunattainablebylabourpower;withaffordablecost.While industrialautomationismostlyprofitableformassmanufacturingandhomogeneous products,thebulkofindustriesproducegoodsinlowquantity.Inthissituation,the challenge shifts into developing automation systems in industry that still justifies the installation cost. The knowledge and skill on this area has therefore become increasinglynecessary. This book recollects necessary materials related to servo control for industrial automation. It starts from a macroscopic view of servo control, especially for in- dustrial automation, treating drives and control systems as inseparable entities. It then continues with detail discussions of major types of drives for precision con- trol realization; namely servo hydraulic and pneumatic drives, electric drives, and piezoelectricdrives.Eachchaptercontainsdetaildiscussionsoftherespectivema- jorcomponents:actuators,sensors,andcontrollers—withoutgoingintothecontrol theory. The techniques and theory of motion control itself is discussed in a sepa- ratechapter,consideringthatthecontroltheoryforalloftheabovementioneddrives isidentical.Forthesamereason,digitalcommunicationprotocolisalsodiscussed in a separate chapter. This chapter is included as a recognition of the importance andgrowingtrendofdigitalizationinmotionandprecisioncontrol.Themoregen- eraltrendinmotioncontrolisdiscussedintheclosingchapter.Throughoutthedis- cussion,theintegrityandnuanceofmechatronics—asynergisticintegrationofthe abovementionedcomponents—aremaintained,reflectingtherealityoftheirsynergy intoday’sindustrialautomation. Despite its mechatronics nuance, the structure of this book allows traditional approach of step-by-step teaching to still be conducted should it be desired. Each chaptercontainsamaterialofitsownthatcanbestudiedseparatelywithoutcompro- mising the understanding of the readers. This book is written for wide readership, fromstudents,technicians,engineers,andresearchers.Thediscussionisthorough, with concise basics yet sufficient details. Equations are provided as means to ex- plain the certain concepts from the fundamentals such that it does not discourage inexperienced readers but is useful for those with prior knowledge. Readers who ix