Industrial Motion Control Systems

Positioning Control
using PLC

Ho Chi Minh City

University of Technology 1 1
Basic on Positioning Control

• What is positioning control?

• Actuators for positioning
• Positioning method type

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What is positioning control?
The positioning controller, together with the programmable logic controller,
personal computer and operator interface, is one of the four main units of FA
(factory automation).

Positioning is all about motion, and motion often involves speed and precision.
And since speed can be directly related to productivity, positioning is an area of
much development.

“Positioning” refers to moving a moving body, such as a workpiece or tool at a

designated speed, and accurately stopping it at the target position.

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Actuators for positioning
The options available for positioning control depend on the type of actuator
driving the system. An actuator is a mechanical device that moves or controls a
specific element or a series of elements within a system.

In a mechanical system, an actuator is often used with a sensor to detect the

motion or position of a workpiece.

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Actuators for positioning
Pneumatic
Stepping motor

AC servo system

Brake motor

DC servo system

General purpose
inverter and
general purpose
motor
Clutch brake
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Actuators for positioning

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Actuators for positioning

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Actuators for positioning

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Actuators for positioning

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Actuators for positioning

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Actuators for positioning

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Actuators for positioning

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Positioning method type
• In general, there are two methods to control the movement of a
workpiece: speed control and position control.

• For basic, more rudimentary positioning, speed control can be

used with an inverter and general purpose motor. For systems
where precision is a must, servo systems are required for the
advanced handling of pulse commands.

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Positioning method type
❑ Speed control
Control
Description Schematic drawing
method
Two limit switches are provided
in places where a system’s
moving part passes. At the first
limit switch, the motor speed is
(1) reduced. At the second limit
Limit switch, the motor turns off and
switch the brake turns on to stop the
moving part.
method
In this method, because position
controllers are not required, the
system configuration can be
realized at reasonable cost.
Guideline of stopping precision: Approximately ±1.0 to 5.0 mm
(The stop precision shows a value in a case where the low speed is 10 to 100 mm/s.)
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Positioning method type
❑ Speed control
Control
Description Schematic drawing
method
A position detector (such as a
pulse encoder) is set up in a
motor or rotation axis. The pulse
number generated from the
(2) position detector is counted by a
Pulse high-speed counter. When the
count pulse number reaches the preset
method value, the moving part stops.
In this method, because limit
switches are not used, the stop
position can be easily changed.
Guideline of stopping precision: Approximately ±0.1 to 0.5 mm
(The stop precision shows a value in a case where the low speed is 10 to 100 mm/s.)
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Positioning method type
❑ Speed control
• With the limit switch method, a system operates without any
feedback to the controller to indicate the location of the
workpiece.
• With the pulse count method, the speed can be changed and the
stop command can be executed at specific distances (at specific
timings) according to the feedback from the pulse generator
connected to the motor.
• Both the limit switch method and the pulse count method,
however, are subject to a loss in stop precision due to the
dispersion of distance that occurs for workpieces at different
speeds.

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Positioning method type
❑ Speed control

The moving part continues by a coasting Dispersion in the stop distance changes,
distance until it completely stops affected by the speed and speed reduction
time delay after stop.

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Positioning method type
❑ Speed control

In actual operation to improve the stop precision, the motor speed can be
reduced from a high speed to a low speed before the motor is stopped, as shown
below.

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Positioning method type
❑ Position control

Control
Description Schematic drawing
method
An AC servo motor which
rotates in proportion to the
input pulse number is used as
the drive motor.
Pulse When the pulse number
command corresponding to the movement
method distance is input to the servo
amplifier of the AC servo motor,
positioning can be performed at
high speed in proportion to the
pulse frequency.

Guideline of stopping precision: Approximately ±0.01 to 0.05 mm (The stop

precision shows a value in a case where the low speed is 10 to 100 mm/s.)
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Positioning method type
❑ Position control

Using the pulse command method with a servo amplifier, the weak points described
above for speed control are improved.
A pulse encoder is attached to the servo motor to detect the motor rotation quantity
(workpiece movement distance) and feed the information directly to the servo
amplifier in order to continuously and directly control the high-speed positioning
operation to the target position.
This method allows the workpiece to stop with better precision and eliminates the
coasting and dispersion distance at stop.
Furthermore, limit switches to stop normal positioning operations, along with
counting methods from the PLC are not needed.

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Positioning by AC Servo System

• Advantages for using an AC

servo system
• Example of AC Servo System

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Advantages for using an AC servo system

With an AC servo system, positioning can be performed by many

diversified methods. Typically, a position controller, servo amplifier
and servo motor are required for positioning with an AC servo
system.
The top advantages to using an AC servo system:
Good cost
Compact and light Robust servo
Easy servo system performance servo
servo system system
system
In accordance
An AC servo
In the FA workplace, with severe AC servo systems are
system with good
a downsized AC operation easier to handle than
cost performance
servo system conditions, a hydraulic equipment.
saves a company in
occupying less tougher AC servo Easy systems are also
overall engineering
space is beneficial. system is often flexible for new staff
costs.
required.

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Advantages for using an AC servo system

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Example of AC Servo System

Positioning indicates the operation to move an object, such as a workpiece or tool

(drill or cutter), from one point to another point and to stop it with efficiency and
precision.

In other words, the principle of positioning is the control of speed in accordance

with the position, performed to promptly eliminate the remaining distance to the
target position. The flexibility to change the target position electrically and easily
is an important requirement.

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Example of AC Servo System

Type of
Description Schematic drawing
machine

In order to tap a workpiece, “1.

(1) Quick feed”, “2. Cutting feed”
Tapping and “3. Quick return” are
performed repeatedly.

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Example of AC Servo System

Type of
Description Schematic drawing
machine

The position of the circular table

(2) is indexed. The index position is
set on the outside (digital
Index switch) or the inside (program).
table Shortcut drive is performed
depending on the index position.

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Example of AC Servo System

Type of
Description Schematic drawing
machine
• To punch insulation material or
leather, etc., as the same shape at
a high yield, positioning is carried
out with the X axis and Y axis
servos.
(3) • After positioning the table with
the X axis servo, the press head is
Punch positioned with the Y axis servo,
press and is then punched with the
press.
• When the material type or
shape changes, the press head die
is changed, and the positioning
pattern is changed.

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Example of AC Servo System

Type of
Description Schematic drawing
machine
• The ATC tool magazine for a
compact machining center is
(4) positioned.
Auto • The relation of the magazine's
tool current value and target value is
changer calculated, and positioning is
carried out with forward run or
(ATC)
reverse run to achieve the
shortest access time.

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Example of AC Servo System

Type of
Description Schematic drawing
machine
• During the aging process of
Braun tubes, storage onto the
rack is carried out by
positioning with the AC servo.
(5) • The up/down positioning of
Lifter the lifter is carried out with the
1-axis servo, and the horizontal
position of the aging rack is
positioned with the 2-axis
servo.

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Example of AC Servo System

Type of
Description Schematic drawing
machine

• Using the servo for one axis,

the palletizer is positioned at a
(6) high accuracy.
Palletizer • The amount to lower the
palletizer according to the
material thickness is saved.

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Components of Positioning
Control and their Roles

• Positioning controller
• Servo amplifier
• Servo motor
• Drive mechanism

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Components of Postioning Control

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Positioning controller

Positioning controllers use programs and parameters to send

positioning commands to the servo amplifier.

❑ Command pulse control method

There are three types of control formats (Common) used for
outputting command pulses from a positioning controller:
• PLS/DIR (Pulse/Direction) method.
• FP/RP (Forward Pulse/Reverse Pulse) method.
• A phase/B phase mode.

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Positioning controller
❑ Command pulse control method

PLS/DIR (Pulse/Direction) method.

Positive logic Negative logic
Forward run and reverse run are Forward run and reverse run are
controlled with the ON/OFF controlled with the ON/OFF
of the direction sign (SIGN). of the direction sign (SIGN).
• The motor will forward run when the • The motor will forward run when the
direction sign is HIGH. direction sign is LOW.
• The motor will reverse run when the • The motor will reverse run when the
direction sign is LOW. direction sign is HIGH.

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Positioning controller
❑ Command pulse control method

FP/RP (Forward Pulse/Reverse Pulse) method.

Positive logic Negative logic

• During forward run, the forward run feed pulse (PULSE F) will be output.
• During reverse run, the reverse run feed pulse (PULSE R) will be output.

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Positioning controller
❑ Command pulse control method

A phase/B phase mode

Forward run and reverse run are controlled with the phase difference of the A phase
(A ) and B phase (B ).
• When the B phase is 90° behind the A phase, the motor will forward run.
• When the B phase is 90° ahead of the A phase, the motor will reverse run

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Positioning controller
❑ Command pulse control method

A phase/B phase mode.

Positive logic Negative logic

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 Positioning controller
❑ Basic parameter settings
To send a series of pulses (a pulse train) to a servo amplifier, positioning
controllers use a specified feed quantity, which is proportional to the number of
pulses. A feed speed must also be specified to control the number of pulses
output per second.
a) Feed quantity
The feed quantity determined by the target address tells the servo system how
far to move the workpiece. So, for example, if a servo motor encoder generates
8,192 pulses for one rotation, the command pulse number “8,192” can be output
to rotate the servo motor by 1 rotation.

b) Feed speed
The feed speed defines the amount of travel per unit of time for the workpiece.
When a servo motor encoder generates 8,192 pulses for one rotation, the
command pulse frequency (speed) “8,192 pulses/s” should be output to rotate
the servo motor by 1 rotation per second. Decrease the pulse frequency to rotate
the servo motor at a lower speed. Increase the pulse frequency to rotate the
servo motor at a higher speed. 40
 Positioning controller
❑ Basic parameter settings

c) Acceleration/deceleration time
When the start command is given, acceleration, operation at constant speed, and
deceleration are performed for positioning. Set the acceleration time and the
deceleration time in the controller’s parameters

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 Positioning controller
❑ Zero point return function

Many positioning systems include a “home position” to where a workpiece may

need to return after performing various operations. For this reason, positioning
controllers include a built-in function to return a workpiece to a defined position
by using a mechanical DOG switch.

To understand how this works, it is necessary to first understand when the

function is needed according to the parameter setting of the servo amplifier and
the type of servo motor encoder.

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 Positioning controller
❑ Zero point return function

a) Incremental type servo motor encoder (pulse count method)

When the servo system uses an incremental or relative type encoder, the current
value of the address stored in the position controller is not “remembered” or
maintained when the power is turned off. This means that the address is set to
zero every time the power is cycled, which can be disadvantageous in an
application.

Accordingly, every time the system is re-powered, it must be calibrated to the

correct zero-point location by executing the zero point return function.

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 Positioning controller
❑ Zero point return function

b) Absolute type servo motor encoder (absolute position detection system)

The absolute position detection system requires an absolute position motor

encoder, a backup battery on the servo amplifier, and a parameter specification
setting. It is constructed so that the current value stored in the positioning
controller is always assured, regardless of power outages or movement while the
power is turned off. The advantage to using this method is that after executing
the zero point return function once, zero point return it is not needed again.

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 Positioning controller
❑ Zero point return function

The zero point return function does not actuate movement to a physical zero
address. Instead, the zero point return function causes movement in a specified
direction (positive or negative) in order to define the physical zero address after
contact with a DOG switch.

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 Positioning controller
❑ Zero point return function

• With an incremental encoder, there are many different methods for

establishing a "zero point" by a machine zero point return differs according
to the method supported by positioning controller.
• In general, the "zero point" input signals can be:
+ One-pulse signal output per each motor revolution (Z-phase signal
output from drive unit, etc.)
+ Signal output upon detection of contact with stopper (Supplied from
an external device)
• In some cases the "zero point“ can be established without "zero point"
input signals.

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 Positioning controller
❑ Zero point return function
❖ NOTE:
• Creep speed: The stopping accuracy is poor when the machine suddenly
stops from high speeds. To improve the machine's stopping accuracy, its
must change over to a low speed before stopping.
• Dog signal: The near-point dog of the machine zero point return.

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 Positioning controller
❑ Zero point return function
❖ NOTE:
• Dwell time: This is the time taken immediately after the positioning is
completed to adjust for the droop pulses in the deviation counter. The
positioning will not be accurate if this time is too short.

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 Positioning controller
❑ Zero point return function
❖ NOTE:
• Home offset (Zero point shift amount): This function offsets the position by
the designated distance from the machine zero point and set that position as
the zero point address

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 Positioning controller
❑ Zero point return function
❖ NOTE:
• Zero point return retry: This function retries
the machine zero point return with the
upper/lower limit switches during machine
zero point return. This allows machine zero
point return to be carried out even if the
axis is not returned to before the near point
dog with JOG operation, etc.
[Operation for zero point return retry function]
1) Movement in the designated zero point return direction starts with the machine
zero point return start.
2) The axis decelerates when the limit switch is detected.
3) After stopping with the limit switch detection, the axis moves in the opposite
direction of the designated zero point return direction at the zero point return
speed.
4) The axis decelerates when the near point dog signal turns OFF.
5),6) After stopping with the near-point dog signal OFF, carries out machine zero
point return in the designated zero point return direction. 50
 Positioning controller
❑ Zero point return function
Example 1: Near-point dog method.

(1) Start machine zero point

return.
(2) Detect the near-point dog
ON, and start deceleration.
(3) Decelerate to Creep speed,
and move with the creep speed
(4) At the first zero point signal
after the near-point dog OFF,
the machine zero point return is
completed.

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 Positioning controller
❑ Zero point return function
Example 2: Stopper stop method 1.
(1) Start machine zero point return.
(2) Detect the near-point dog ON,
and start deceleration.
(3) Decelerate to Creep speed, and
move with the creep speed. Torque
limit is required. If the torque is not
limited, the servomotor could be
damaged in step (4)
(4) The axis contacts against the
stopper at the Creep speed, and
then stops.
(5) When the near-point dog turns
ON and the dwell time is passed, the
machine zero point return is
completed.

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 Positioning controller
❑ Zero point return function
Example 3: Stopper stop method 2.
(1) Start machine zero point return.
(2) Detect the near-point dog ON, and
start deceleration.
(3) Decelerate to Creep speed, and
move with the creep speed. Torque
limit is required. If the torque is not
limited, the servomotor could be
damaged in step (4)
(4) The axis contacts against the
stopper at the Creep speed, and then
stops.
(5) After stopping with the zero point
signal (a signal issued from an external
device upon detection of contact with
the stopper), the machine zero point
return is completed.

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 Positioning controller
❑ Zero point return function
Example 4: Stopper stop method 3.

(1) Start machine zero point

return at the creep speed.
(2) The axis contacts against the
stopper at the Creep speed, and
then stops.
(3) After stopping with the zero
point signal (a signal issued from
an external device upon detection
of contact with the stopper), the
machine zero point return is
completed.

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 Positioning controller
❑ Zero point return function
Example 5: Count method 1.
(1) Start machine zero point
return.
(2) Detect the near-point dog
ON, and start deceleration.
(3) Decelerate to Creep speed,
and move with the creep speed.
(4) After the near-point dog
turns ON and the movement
amount after near-point dog ON
has passed with the first zero
point signal. The machine zero
point return is completed.

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 Positioning controller
❑ Zero point return function
Example 6: Count method 2.
(1) Start machine zero point
return.
(2) Detect the near-point dog
ON, and start deceleration.
(3) Decelerate to Creep speed,
and move with the creep speed.
(4) After the near-point dog
turns ON and the movement
amount after near-point dog
ON" has passed. The machine
zero point return is completed.

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Positioning controller
❑ Manual control

"Manual control" refers to control in which positioning data is not used, and a
positioning operation is carried out in response to signal input from an
external source.
• JOG operation
• Manual pulse generator operation

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Positioning controller
❑ Manual control
❖ JOG operation

"JOG operation" is a control method in which the machine is moved by only a

movement amount (pulses are continuously transmitted while the JOG START
signal is ON).

Use the hardware stroke limit function when carrying out JOG operation near
the upper or lower limits.
* If not use, the workpiece may exceed the operating range, causing an accident.

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Positioning controller
❑ Manual control
❖ Manual pulse generator operation

"Manual pulse generator operation" is a control method in which positioning is

carried out in response to the No. of pulses input from a manual pulse
generator (the No. of input pulses is output). This operation is used for manual
fine adjustment, etc., when carrying out accurate positioning to obtain the
positioning address.

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 Servo amplifier and servo motor
The servo amplifier controls the movement quantity and the speed according to
the commands given by the positioning controller. The servo motor then transmits
rotation to the drive mechanism after receiving signals from the servo amplifier.

❑ Positioning control in accordance with command pulse

In accordance with speed and position command pulses from the positioning
controller, PWM (pulse width modulation) control is performed by the main circuit
of the servo amplifier in order to drive the motor. The rotation speed and the
rotation quantity are fed back to the amplifier from the encoder attached to the
servo motor.

❑ Deviation counter function

• The difference between the command pulses and the feedback pulses counted
by the deviation counter in the servo amplifier is called accumulated pulses.
• While the machine is operating at a constant speed, the accumulated pulse
quantity is almost constant. During acceleration and deceleration, the
accumulated pulse quantity changes more dramatically.

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Servo amplifier and servo motor
❑ Deviation counter function
• When the accumulated pulse quantity becomes equivalent to or less than a
specified quantity (in-position set value) after command pulses have stopped,
the servo amplifier outputs the positioning complete signal. The servo motor
continues operation even after that. Then, when the accumulated pulse quantity
becomes 0, the servo motor stops.
• The time after the servo motor outputs the positioning complete signal until it
stops is called the stop settling time.

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Servo amplifier and servo motor
❑ Servo lock function
• The servo motor is controlled so that the accumulated pulse quantity counted in
the deviation counter becomes 0.
• For example, if an external force for forward rotation is applied on the servo
motor, the servo motor performs the reverse rotation operation to eliminate the
accumulated pulses.

Accumulated pulses in deviation counter Servo motor

Minus pulses Reverse rotation operation
Plus pulses Forward rotation operation
0 (zero) Stop

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Servo amplifier and servo motor
❑ Regenerative brake function

• During deceleration, because the servo motor rotates by the load inertia of the
drive mechanism, it functions as a generator and electric power returns to the
servo amplifier. The regenerative resistor absorbs this electric power and
functions as a brake (called a regenerative brake.)
• A regenerative brake is required to prevent regenerative over voltage in the
servo amplifier when the load inertia is large and operations are frequently
performed.
• The regenerative resistor is required when the regenerative power generation
quantity during deceleration exceeds the allowable regenerative electric power
of the servo amplifier.

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Servo amplifier and servo motor
❑ Dynamic brake function

• When a circuit inside the servo amplifier is disabled by a power interruption in

the AC power of the main circuit or actuation of the protective circuit, the
terminals of the servo motor are short-circuited via resistors, the rotation
energy is consumed as heat, then the motor immediately stops without free
run.
• When the motor stops by elimination of the rotation energy, the brake is not
effective and the motor runs freely.

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Servo amplifier and servo motor

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Drive mechanism

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Drive mechanism
• The servo motor stops with the precision ±Δl , which is within ±1 pulse against
the command pulse.
• The movement quantity of the workpiece is:
[Output pulses from position controller] x [Δl ]
• The moving part speed is:
[f0] x [Δl]
• Either “mm,” “inch,” degree,” or pulse can be selected for the positioning
command unit. Accordingly, when data such as the movement quantity per
pulse, positioning speed, or the positioning address in accordance with the
positioning command unit are set, pulse trains are output for the target
address, and positioning is performed.

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Drive mechanism

❖ Useful equations:

To define the system illustrated above, Δl and v0 need to be

determined using a series of equations. The speed of the moving
part (v0) is constrained by the mechanical gearing system between
the servo motor and moving part, the pitch of the ball screw, and
the specification of the motor as shown through the following two
formulas.
• Transfer distance per rotation of motor:

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Drive mechanism

❖ Useful equations:
• Number of rotations of motor during quick feed:

Rated number
rev v0
N0 = ≤ of rotations
min ∆S of servo

• Transfer distance per pulse:

PLS ∆S
f0 = × (Electronic gear ratio)
S ∆l
During the process, the Electronic gear ratio and Speed reduction ratio can be
adjusted to fit the application’s needs

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Drive mechanism

❖ Useful equations:
• Number pulse frequency during quick feed:

PLS ∆S 1
f0 = × N0 ×
S ∆l 60

* Note: In each of the absolute and incremental positioning methods, the

entire movement distance of the machine should not exceed the maximum
allowable pulse output number from the positioning controller.

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Drive mechanism
a) Absolute method:

In this method, a point (absolute address) is specified for positioning while the
zero point is regarded as the reference. The start point is arbitrary.

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Drive mechanism
b) Incremental method:

In this method, positioning is performed through specification of the movement

direction and the movement quantity while the current stop position is
regarded as the start point.

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