基于工业以太网的总线型交流伺服系统关键技术研究
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摘要
交流永磁同步伺服系统在现代数控加工和机器人等运动控制领域具有无可替代的地位,然而由于国内伺服行业起步晚、经验少、技术水平低等原因,高端伺服驱动系统仍然被国外所垄断。为促进我国产业升级,提升民族制造业水平,本文对总线型交流伺服驱动系统的关键技术进行了深入研究。通过对伺服系统总线接口技术的研究,将工业以太网技术应用于交流伺服驱动系统,立足实现伺服驱动系统网络化控制；通过分析和研究模型参考自适应系统(Model Reference Adaptive System, MRAS)和卡尔曼滤波器(Kalman Filter, KF)等相关理论,实现了伺服系统控制参数在线自整定以及超低速下的平稳控制。
首先,研究了实时工业以太网在伺服驱动系统中的应用。对课题组自主研发的以太网总线技术EtherMAC (Ethernet for Manufacturing Automation Control)进行了改进和完善,针对伺服驱动装置对总线控制接口的特殊要求,设计了EtherMAC伺服驱动从站的物理层、数据链路层和应用层。规划了用于伺服驱动系统的以太网数据帧协议标准,其中包括通讯控制指令、伺服控制指令及运行状态反馈数据。实验结果表明,在不使用强实时操作系统和专用网卡条件下,本文所设计的总线型伺服驱动从站可以满足伺服系统对实时性和同步性的要求。
其次,依据现代控制理论分析了伺服驱动系统各环节的传递函数,为实现被控对象参数辨识、闭环控制参数自整定以及超低速平稳控制等研究提供良好的理论依据,并依此建立了电流环、速度环和位置环三环串级控制结构中各环路的数学模型。为提高内埋式永磁同步电机(Interior Permanent Magnet Synchronous Motor, IPMSM)的驱动效率,改善调速性能,本文针对其特殊的磁路结构,研究了最大转矩电流比(Maximum Torque Per Ampere, MTPA)的电流矢量控制策略,提出了一种适于工程应用的近似实现方法。
然后,对伺服驱动系统控制参数自整定策略进行了研究。通过对伺服系统中的被控对象进行特征分析,提出了基于模型参考自适应理论的被控对象特征参量的在线辨识方法。建立了永磁同步电动机(Permanent MagnetSynchronous Motor, PMSM)电枢绕组电阻、等效同步电感、永磁体磁链和系统转动惯量在线辨识的可调参数模型,并依据Popov超稳定理论设计了自适应规则。通过分析各控制环节的数学模型,依据二阶最佳系统、三阶最佳系统等系统矫正理论,推导出伺服驱动系统电流环、速度环和位置环中控制参数的整定规则,并利用在线辨识出的特征参数实现控制参数的在线自整定。仿真和实验表明,本文提出的参数在线辨识方法收敛速度快、辨识精度高且具有良好的适应性,可在需要更新被控对象特征参数时随时执行；控制参数经自整定后有效地改善了伺服系统的动态性能,增强了伺服驱动系统的鲁棒性。
此外,研究了交流永磁同步伺服系统超低速控制策略。针对伺服驱动系统中低速和超低速平稳控制这一难点问题,提出了一种基于(扩展)卡尔曼滤波器(Extended Kalman Filter, EKF)最优估计理论,适用于宽转速、高噪声环境下的电机瞬时转速、角位移和等效负载转矩的在线估计方法。并利用MRAS在线辨识出的系统转动惯量对估计器的状态矩阵进行实时更新,实现转动惯量自适应状态估计。依据估计出的等效负载转矩设计了转矩前馈环节,用以提高伺服驱动系统的转矩响应速度,降低负载变化率。同时,对常规M/T速度检测方法进行改进,以消除非完整编码器脉冲周期造成的测速误差。根据伺服驱动系统在不同速度区间的运行特性,提出了一种伺服驱动系统变结构优化控制方案。该方案根据当前电机转速的不同,动态调整电流环和速度环的控制周期,并配置最优的控制和参量反馈策略。实验结果表明,该优化配置策略可以提高伺服系统中、高速区域的动态响应,且保证电机在低速和超低速区域的平稳运行,使得伺服驱动系统在较宽的速度范围内均可获得良好的控制性能。
最后,研发了基于实时工业以太网的总线型交流伺服驱动系统。设计了总线型伺服驱动硬件平台,开发了基于STM32F4系列ARM (Advanced RISC Machines)控制器的PMSM矢量控制算法库和以太网应用层程序,并设计了上位机图形化用户应用程序用于伺服控制和调试。实验结果表明,所设计的总线型伺服驱动系统具有良好的电流环、速度环和位置环动、静态性能。
本研究的成功实施为工业以太网总线在伺服驱动领域的广泛应用提供了一条有效的途径,为解决伺服驱动系统中控制参数在线自整定、超低速平稳控制等难点问题提供了一套可行的方案。
AC permanent magnet synchronous motor (PMSM) servo system plays an irreplaceable role in the field of motion control such as the modern numerical control machining and robotics. However, because of the late beginning, insufficient experience and low technological level for the domestic servo industry, most of high-end servo drive systems are monopolized by foreign countries. In order to promote Chinese manufacturing industry upgrading and raise the level of national manufacturing, the key technologies of bus-type servo system were further researched in this dissertation. Industrial Ethernet technology was applied to the AC servo system to realize a networked control servo drive system by means of research on bus interface technology for the servo system. On-line self-tuning for servo system control parameters and high-performance speed control in ultra-low speed range were realized by means of analyzing and studying the related theories which include model reference adaptive system (MRAS) and Kalman filter (KF).
First of all, the study was focused on the application of real-time industrial Ethernet in the servo drive system. The EtherMAC (Ethernet for Manufacturing Automation), which was developed by our research group, was improved and perfected. According to the special requirements of bus control interface for servo drivers, the physical layer, data link layer and application layer of EtherMAC based servo driver slave station were designed. And the communication protocol, which includes communication commands, servo commands and data feedback in Ethernet data frames, was planned for bus-type servo drive system. The experimental results show that, without the hard real-time operating system and special equipments, the designed bus-type servo drive slave station can meet the requirements of real-time and synchronism for servo system.
Secondly, in order to provide a good theoretical basis for controlled object parameters identification, system control parameters self-tuning and ultra-low speed stable control, the transfer functions of each link were analyzed and the mathematical models of current loop, speed loop and position loop were built correspondingly. Besides, in order to improve the efficiency and speed adjusting performance of interior permanent magnet synchronous motors (IPMSM), an engineering approximate algorithm for maximum torque per ampere (MTPA) control was given to facilitate engineering application.
Thirdly, the self-tuning strategy for servo system control parameters was studied. The MRAS based on-line controlled object parameters identification was presented by means of analyzing the controlled object of servo system. The adjustable parameter models of permanent magnet synchronous motor (PMSM) winding resistance, equivalent inductance, permanent magnet flux linkage and system total inertia were built. Then the corresponding adaptive laws were designed according to Popov hyperstability theory. Based on the deep research on each control loop mathematical model, self-tuning rules for current loop, speed loop and position loop were derived according to two-rank optimum system and three-rank optimum system theories. And the identified parameters were used to realize the self-tuning of control parameters. The simulation and experimental results show a good adaptability of the proposed on-line identification method. The varying parameters can be identified with enough response time and identification precision. The dynamic performance and robustness of servo system are improved with the self-tuning control parameters.
Then, the ultra-low speed control strategies for PMSM servo system were studied. According to the difficulty of low and ultra-low speed control for servo drive system, an optimal state estimator based on the extended Kalman filter (EKF) was used to provide exact estimation for instantaneous speed, position and equivalent disturbance load torque in a random noisy environment. The MRAS was incorporated to identify the variations of inertia moment real-timely, and the identified inertia was used to adapt the EKF for better dynamic performance. The estimated equivalent load torque was used for feedforward control which can decrease the torque ripple of the motor effectively. Meanwhile, the conventional M/T speed detection method was improved so as to eliminate the error from non-complete pulse period. With analyzing the servo system operation characteristics in different speed ranges. a variable structure optimization for servo drive system was designed. This optimization method adjusts the sampling periods of current loop and speed loop dynamically and configures the optimized speed feedback method according to the current speed. The experimental results show that the optimization method can improve the dynamic response of medium and high speed region, and confirm stable in low and ultra-low speed range. The presented strategy provides a precise speed control over a wide range of speeds and the proposed system is robust to modeling error and system noise.
Finally, a real-time industrial Ethernet based bus-type AC servo system was developed, which includes the bus-type servo driver hardware platform, the field oriented control library, application layer software based on STM32F4ARM processor and graphical user application for servo control and debugging. The experimental results show that the designed bus-type servo drive system has good dynamic and static performance of current, speed and position loop.
The successful implementation of this research provides an effective way to apply industrial Ethernet in servo drive system. It also gives a solution to solve the key problems of control parameters self-tuning and ultra-low speed stable control.
首先,研究了实时工业以太网在伺服驱动系统中的应用。对课题组自主研发的以太网总线技术EtherMAC (Ethernet for Manufacturing Automation Control)进行了改进和完善,针对伺服驱动装置对总线控制接口的特殊要求,设计了EtherMAC伺服驱动从站的物理层、数据链路层和应用层。规划了用于伺服驱动系统的以太网数据帧协议标准,其中包括通讯控制指令、伺服控制指令及运行状态反馈数据。实验结果表明,在不使用强实时操作系统和专用网卡条件下,本文所设计的总线型伺服驱动从站可以满足伺服系统对实时性和同步性的要求。
其次,依据现代控制理论分析了伺服驱动系统各环节的传递函数,为实现被控对象参数辨识、闭环控制参数自整定以及超低速平稳控制等研究提供良好的理论依据,并依此建立了电流环、速度环和位置环三环串级控制结构中各环路的数学模型。为提高内埋式永磁同步电机(Interior Permanent Magnet Synchronous Motor, IPMSM)的驱动效率,改善调速性能,本文针对其特殊的磁路结构,研究了最大转矩电流比(Maximum Torque Per Ampere, MTPA)的电流矢量控制策略,提出了一种适于工程应用的近似实现方法。
然后,对伺服驱动系统控制参数自整定策略进行了研究。通过对伺服系统中的被控对象进行特征分析,提出了基于模型参考自适应理论的被控对象特征参量的在线辨识方法。建立了永磁同步电动机(Permanent MagnetSynchronous Motor, PMSM)电枢绕组电阻、等效同步电感、永磁体磁链和系统转动惯量在线辨识的可调参数模型,并依据Popov超稳定理论设计了自适应规则。通过分析各控制环节的数学模型,依据二阶最佳系统、三阶最佳系统等系统矫正理论,推导出伺服驱动系统电流环、速度环和位置环中控制参数的整定规则,并利用在线辨识出的特征参数实现控制参数的在线自整定。仿真和实验表明,本文提出的参数在线辨识方法收敛速度快、辨识精度高且具有良好的适应性,可在需要更新被控对象特征参数时随时执行；控制参数经自整定后有效地改善了伺服系统的动态性能,增强了伺服驱动系统的鲁棒性。
此外,研究了交流永磁同步伺服系统超低速控制策略。针对伺服驱动系统中低速和超低速平稳控制这一难点问题,提出了一种基于(扩展)卡尔曼滤波器(Extended Kalman Filter, EKF)最优估计理论,适用于宽转速、高噪声环境下的电机瞬时转速、角位移和等效负载转矩的在线估计方法。并利用MRAS在线辨识出的系统转动惯量对估计器的状态矩阵进行实时更新,实现转动惯量自适应状态估计。依据估计出的等效负载转矩设计了转矩前馈环节,用以提高伺服驱动系统的转矩响应速度,降低负载变化率。同时,对常规M/T速度检测方法进行改进,以消除非完整编码器脉冲周期造成的测速误差。根据伺服驱动系统在不同速度区间的运行特性,提出了一种伺服驱动系统变结构优化控制方案。该方案根据当前电机转速的不同,动态调整电流环和速度环的控制周期,并配置最优的控制和参量反馈策略。实验结果表明,该优化配置策略可以提高伺服系统中、高速区域的动态响应,且保证电机在低速和超低速区域的平稳运行,使得伺服驱动系统在较宽的速度范围内均可获得良好的控制性能。
最后,研发了基于实时工业以太网的总线型交流伺服驱动系统。设计了总线型伺服驱动硬件平台,开发了基于STM32F4系列ARM (Advanced RISC Machines)控制器的PMSM矢量控制算法库和以太网应用层程序,并设计了上位机图形化用户应用程序用于伺服控制和调试。实验结果表明,所设计的总线型伺服驱动系统具有良好的电流环、速度环和位置环动、静态性能。
本研究的成功实施为工业以太网总线在伺服驱动领域的广泛应用提供了一条有效的途径,为解决伺服驱动系统中控制参数在线自整定、超低速平稳控制等难点问题提供了一套可行的方案。
AC permanent magnet synchronous motor (PMSM) servo system plays an irreplaceable role in the field of motion control such as the modern numerical control machining and robotics. However, because of the late beginning, insufficient experience and low technological level for the domestic servo industry, most of high-end servo drive systems are monopolized by foreign countries. In order to promote Chinese manufacturing industry upgrading and raise the level of national manufacturing, the key technologies of bus-type servo system were further researched in this dissertation. Industrial Ethernet technology was applied to the AC servo system to realize a networked control servo drive system by means of research on bus interface technology for the servo system. On-line self-tuning for servo system control parameters and high-performance speed control in ultra-low speed range were realized by means of analyzing and studying the related theories which include model reference adaptive system (MRAS) and Kalman filter (KF).
First of all, the study was focused on the application of real-time industrial Ethernet in the servo drive system. The EtherMAC (Ethernet for Manufacturing Automation), which was developed by our research group, was improved and perfected. According to the special requirements of bus control interface for servo drivers, the physical layer, data link layer and application layer of EtherMAC based servo driver slave station were designed. And the communication protocol, which includes communication commands, servo commands and data feedback in Ethernet data frames, was planned for bus-type servo drive system. The experimental results show that, without the hard real-time operating system and special equipments, the designed bus-type servo drive slave station can meet the requirements of real-time and synchronism for servo system.
Secondly, in order to provide a good theoretical basis for controlled object parameters identification, system control parameters self-tuning and ultra-low speed stable control, the transfer functions of each link were analyzed and the mathematical models of current loop, speed loop and position loop were built correspondingly. Besides, in order to improve the efficiency and speed adjusting performance of interior permanent magnet synchronous motors (IPMSM), an engineering approximate algorithm for maximum torque per ampere (MTPA) control was given to facilitate engineering application.
Thirdly, the self-tuning strategy for servo system control parameters was studied. The MRAS based on-line controlled object parameters identification was presented by means of analyzing the controlled object of servo system. The adjustable parameter models of permanent magnet synchronous motor (PMSM) winding resistance, equivalent inductance, permanent magnet flux linkage and system total inertia were built. Then the corresponding adaptive laws were designed according to Popov hyperstability theory. Based on the deep research on each control loop mathematical model, self-tuning rules for current loop, speed loop and position loop were derived according to two-rank optimum system and three-rank optimum system theories. And the identified parameters were used to realize the self-tuning of control parameters. The simulation and experimental results show a good adaptability of the proposed on-line identification method. The varying parameters can be identified with enough response time and identification precision. The dynamic performance and robustness of servo system are improved with the self-tuning control parameters.
Then, the ultra-low speed control strategies for PMSM servo system were studied. According to the difficulty of low and ultra-low speed control for servo drive system, an optimal state estimator based on the extended Kalman filter (EKF) was used to provide exact estimation for instantaneous speed, position and equivalent disturbance load torque in a random noisy environment. The MRAS was incorporated to identify the variations of inertia moment real-timely, and the identified inertia was used to adapt the EKF for better dynamic performance. The estimated equivalent load torque was used for feedforward control which can decrease the torque ripple of the motor effectively. Meanwhile, the conventional M/T speed detection method was improved so as to eliminate the error from non-complete pulse period. With analyzing the servo system operation characteristics in different speed ranges. a variable structure optimization for servo drive system was designed. This optimization method adjusts the sampling periods of current loop and speed loop dynamically and configures the optimized speed feedback method according to the current speed. The experimental results show that the optimization method can improve the dynamic response of medium and high speed region, and confirm stable in low and ultra-low speed range. The presented strategy provides a precise speed control over a wide range of speeds and the proposed system is robust to modeling error and system noise.
Finally, a real-time industrial Ethernet based bus-type AC servo system was developed, which includes the bus-type servo driver hardware platform, the field oriented control library, application layer software based on STM32F4ARM processor and graphical user application for servo control and debugging. The experimental results show that the designed bus-type servo drive system has good dynamic and static performance of current, speed and position loop.
The successful implementation of this research provides an effective way to apply industrial Ethernet in servo drive system. It also gives a solution to solve the key problems of control parameters self-tuning and ultra-low speed stable control.
引文
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