Published on March 5, 2014
Encoders and Resolvers Series: The Benefits to Closed Loop Motion Feedback
Before We Start This webinar will be available afterwards at designworldonline.com & email Q&A at the end of the presentation Hashtag for this webinar: #DWwebinar
Moderator Presenter Miles Budimir Allen Chasey Design World Eastern U.S. Sales Manager, Dynapar Corp.
Allen Chasey is the Eastern U.S. Sales Manager for Dynapar Corp. and specializes in encoder and resolver motion feedback, with a concentrated focus in the Off-Highway Vehicle industry. Allen received his Bachelor of Science in Applied Physics from Jacksonville University, and has worked in the electronic/automation industry for twenty years.
Your customers want… Two more bells Five more whistles Infinite uptime Negative cost
Your boss wants… Faster installation Fewer failures Lower operating cost Better throughput
Work Smarter, Not Harder Closed-loop feedback increase throughput decrease downtime enhance safety boost performance long-term savings Paper Mill
“But I don’t build packaging machines.” Are you involved in industries like: Mining Logging Aerospace Steel manufacturing Tire manufacturing Dockside cranes Oil & Gas (drilling,exploration) Elevator Motor OEM
It ain't what you don't know that's the problem, it's what you know for sure that just ain't so. -- Mark Twain
HVAC Cooling Fans: Lesson Learned! The first engineering team to try it gained an enormous strategic advantage
Rotary Feedback 101 Speed feedback Position feedback Close the loop on the load or on the motor
Resolvers Tough--no onboard electronics Analog High resolution Resolver Applications: • Aerospace • Oil & Gas (down-hole drilling) • Formula One Racing (Kinetic Energy Recovery System)
Did We Mention TOUGH?
Encoders Speed or position Flexible Optical versus magnetic Incremental versus absolute High resolution Digital Did We Mention TOUGH?
Poll question #1 When should you close the loop on the motor rather than the load? a) Controlling speed, not displacement b) When there’s excessive backlash or “slop” in your system c) When tight speed tolerance (.01%) isn’t required
#1 Reduce downtime!!!
…and Downtime is Not. Another diagnostic for drives and controllers The canary in the coal mine Detect problems faster Encoders alert drives Drives and controllers alert HMI Shop floor to top floor Planned maintenance vs. unplanned faults
On The Bus Logging: if a branch catches a wire, how do you find the problem? Connected, closed-loop feedback
#2 Improve speed control
It’s not about going fast The slower you go, the more resolution you need If you’re controlling volume, you need to control speed
This matters in… Underground mining vehicles Better starting and stopping Elevator cars Fertilizer spreaders
What does it get you? Better quality product – paper, rolling metal, rubber and tires Better starting and stopping – elevators, mining vehicles Less wear Smaller motors can do the job
Poll question #2 When is high-resolution feedback most important? a) High-speed motion b) Low speed motion c) High-dynamic-range motion
#3 Prevent Damage
Stop Unsafe Motion Protect your system Your product Your personnel
In Lift Vehicles Short jacking – you need to restrict the arc of the boom
Potentiometers work… …for a while …if you don’t have EMI …or arc welding …and you don’t need intelligent feedback
Absolute encoders… …are noncontact …are CANbus compatible …deliver real-time diagnostics Did We Mention TOUGH?
#4 Bridge the Performance Gap
The Great Divide Smart excavators with GPS do a lot… Return-to-dig Inches of resolution …And cost a lot Manual excavators deliver a bargain… …What happens when your skilled operator is out sick?
Encoders… …pinpoint bucket location …pinpoint speed …deliver return-to-dig with greater accuracy And did we mention TOUGH?
#5 Make your equipment last
Entropy sucks. lack of order or predictability; gradual decline into disorder SOLUTION: Keep things in ORDER! Go Closed Loop!
Your equipment wears out a little more every day… Feedback Can Help!
Hydraulics Hard stops and starts = shock and vibration Damage seals Loosen connections Compromise welds and fasteners
Hi-Res Feedback Easy does
Mining--Variable Speed Flow (and don’t forget Oil & Gas mud pumps!) Fixed-speed pumps with valves to control flow. • Pressure jump creates heat • Any water vaporizes • Things go boom
Closed-Loop Feedback… Slows Motor BEFORE Valve Closes. No dead-heading No explosions Less wear, longer lifetime
Key Feedback Trends
Bus Communications Health monitoring Dynamically reprogrammable
Non-Contact Sensing Sensors separated from rotating equipment Easier to install More forgiving form factor Fewer wear points
Absolute Feedback Never lose track of your location Unless you want to reset home – once or many Bus connectivity Higher accuracy
Did we mention TOUGH? Stronger bearings Shaftless Potted electronics Chip-based array sensors bearingless potted electronics shaftless
And Budget-Friendly Performance? Semiconductor fabrication – more for less Cost of operations versus cost of acquisition Modest outlay, big boost
Conclusion (or back to your to-do list) Closed-loop feedback can give your product: More bells More whistles Faster throughput Better quality Less downtime Better cost/performance ratio
Explore What Closed-Loop Feedback Can Do For You
Questions? Design World Miles Budimir firstname.lastname@example.org Phone: 440.234.4531 Twitter: @DW_Motion Dynapar Allen Chasey Allen.email@example.com Phone: 1.678.817.4945 Twitter: @encoders
Thank You This webinar will be available at designworldonline.com & email Tweet with hashtag #DWwebinar Connect with Design World Discuss this on EngineeringExchange.com
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