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FRONIUS controller refers to converting predetermined control schemes and planning instructions into desired mechanical motion under complex conditions, achieving precise position control, speed control, acceleration control, and torque or force control of mechanical motion. A motion controller is a specialized controller that controls the operating mode of an electric motor: for example, a motor drives an object upward to a specified position via a limit switch controlling an AC contactor, then moves downward; or a time relay controls the motor's forward and reverse rotation, or intermittent operation. Motion control applications in robotics and CNC machine tools are more complex than those in dedicated machines, because the latter have simpler motion forms, often referred to as general motion control (GMC).

FRONIUS controller introduction

Motion control typically involves converting predetermined control schemes and planning instructions into desired mechanical motion under complex conditions, achieving precise position control, speed control, acceleration control, and torque or force control of mechanical motion. Depending on the power source used, motion control is mainly divided into electrical motion control using electric motors as the power source, pneumatic/hydraulic control using gas and fluids as the power source, and heat engine motion control using fuels (coal, oil, etc.) as the power source. According to statistical data, more than 90% of all power sources come from electric motors. Electric motors play a very important role in modern production and daily life, so among these types of motion control, electrical motion control is the most widely used. Electrical motion control evolved from electric drive systems; electric drive or electrical transmission is a general term for control systems targeting electric motors. Motion control systems vary, but in terms of basic structure, the hardware of a typical modern motion control system mainly consists of a host computer, motion controller, power drive unit, motor, actuator, and sensor feedback detection device. The motion controller is a control device with a central logic control unit as the core, sensors as signal sensing elements, and motors or power devices and execution units as control objects. [A motion controller is a specialized controller that controls the operating mode of an electric motor: for example, a motor drives an object upward to a specified position via a limit switch controlling an AC contactor, then moves downward; or a time relay controls the motor's forward and reverse rotation, or intermittent operation. Motion control applications in robotics and CNC machine tools are more complex than those in dedicated machines, because the latter have simpler motion forms, often referred to as general motion control (GMC). The motion controller is the main component determining the performance of an automatic control system. For the Mitsubishi series, the motion CPU is the motion controller. For simple motion control systems, a motion controller designed with a microcontroller can meet requirements and offers high cost-performance ratio.

FRONIUS controller functions

1) Motion planning function: This essentially forms the reference values for motion speed and position. Suitable reference values not only improve trajectory accuracy but also reduce requirements for the rotation system and mechanical transmission components. General motion controllers usually provide motion planning methods that limit values affecting dynamic trajectory accuracy, such as jerk, acceleration, and speed, allowing users to call corresponding functions directly. Motion planning with acceleration limits produces a trapezoidal velocity curve; motion planning with jerk limits produces an S-shaped velocity curve. Generally, for CNC machine tools, motion planning methods limiting acceleration and speed reference values already yield excellent dynamic characteristics. For fast positioning systems with high acceleration and short strokes, strict requirements exist for positioning time and overshoot, often requiring motion planning methods with continuous higher-order derivatives. 2) Multi-axis interpolation and continuous interpolation functions: The multi-axis interpolation function provided by general motion controllers is widely used in the CNC machinery industry. In recent years, the rapid development of the engraving market, especially the mold engraving machine market, has driven the development of continuous interpolation functions in motion controllers. Mold engraving involves processing many short line segments, requiring minimal fluctuation in machining speed between segments and smooth transitions at speed change inflection points. This requires motion controllers to have look-ahead speed and continuous interpolation functions. Googol Technology has launched a continuous interpolation motion controller specifically for small line segment processing technologies, which has been well applied in mold engraving, laser engraving, and planar cutting. 3) Electronic gear and electronic cam functions: Electronic gears and electronic cams can greatly simplify mechanical design and achieve functions difficult to realize with mechanical gears and cams. Electronic gears allow multiple motion axes to move synchronously according to set gear ratios, making motion controllers well-suited for fixed-length shearing and shaftless register printing. Additionally, the electronic gear function allows one motion axis to follow a function defined by the motion of several other axes at a set gear ratio; one axis can also follow the combined speed of two other axes at a set proportion. The electronic cam function allows changing the cam shape via programming without grinding mechanical cams, greatly simplifying processing technology. This function makes motion controllers well-suited for quenching processing of mechanical cams, irregular glass cutting, and all-electric spring driving. 4) Compare output function: This refers to the motion controller outputting one or more digital signals when the position reaches a set coordinate point during motion, without affecting the motion process. For example, in AOI fly-by inspection, the compare output function of the motion controller triggers CCD high-speed imaging when the system reaches the set position, without affecting motion, which greatly improves efficiency and image quality. Additionally, this function of Googol Technology's general motion controller has been well applied in laser engraving applications. 5) Probe signal latch function: This can latch the moment a probe signal is generated and the positions of each motion axis. Its accuracy depends only on hardware circuits, unaffected by software and system inertia, making it well-suited for the CCM measurement industry. Furthermore, more and more OEM manufacturers wish to integrate their rich industry application experience into motion control systems, designing personalized motion controller functions for different application scenarios and control objects. Googol Technology has developed a general motion controller application development platform, giving general motion controllers a truly object-oriented open control structure and system reconfiguration capability. Users can load their own control algorithms into the motion controller's memory without changing the control system's structural design, thereby reconstructing a special-purpose dedicated motion controller.

FRONIUS controller composition

A motion controller is used to generate trajectory points (desired output) and close the position feedback loop. Many controllers can also close a velocity loop internally. A drive or amplifier is used to convert the motion controller's control signals (usually velocity or torque signals) into higher-power current or voltage signals. More advanced intelligent drives can close position and velocity loops themselves to achieve more precise control. An actuator, such as a hydraulic pump, cylinder, linear actuator, or motor, is used to output motion. A feedback sensor, such as an optical encoder, resolver, or Hall effect device, is used to feedback the actuator's position to the position controller to close the position control loop. Numerous mechanical components are used to convert the actuator's motion form into the desired motion form, including gearboxes, shafts, ball screws, timing belts, couplings, and linear and rotary bearings. Typically, the functions of a motion control system include speed control and point-to-point control. There are many methods to calculate a motion trajectory, usually based on a motion velocity curve such as a triangular velocity curve, trapezoidal velocity curve, or S-shaped velocity curve. Such as electronic gear (or electronic cam). This means the slave axis position mechanically follows the position changes of the master axis. A simple example is a system containing two turntables rotating according to a given relative angular relationship. Electronic cams are more complex than electronic gears, making the follow relationship curve between the master and slave axes a function. This curve can be nonlinear but must be a functional relationship.

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