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A hybrid current and acceleration control is presented and shown to improve the load disturbance behavior of servo drives significantly without additional sensor effort. The feedback signal of the acceleration control loop is calculated from the position data of the motor encoder. Hence, position measuring errors influence this control loop and lead to speed ripple. Therefore, the presented design of the acceleration control loop considers both load sensitivity and position measuring errors.
Position measuring devices with sinusoidal measuring signals are widely used in position-controlled servo drives in industrial automation, e.g., for machine tools or semiconductor production machines. Usually, the feedback signal for the speed or velocity controller is calculated from the measured position. Therefore, position measuring errors affect these control loops. This study presents an analytic error model that considers non-ideal sinusoidal measuring signals with basic deviations (amplitude differences, offset errors, and phase shift) as well as signal harmonics. The model was used to systematically investigate the influence of signal quality and the number of signal periods from position measuring devices on speed ripple, across a wide range of speeds. A test stand with a high-resolution reference angle measuring device was used to confirm the results.