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Servo TuningTuning a Servo SystemAny closed-loop servo system, whether analog ordigital, will require some tuning. This is the processof adjusting the characteristics of the servo so thatit follows the input signal as closely as possible.

Why is tuning necessary?A servo system is error-driven, in other words, theremust be a difference between the input and theoutput before the servo will begin moving to reducethe error. The “gain” of the system determines howhard the servo tries to reduce the error. A high-gainsystem can produce large correcting torques whenthe error is very small. A high gain is required if theoutput is to follow the input faithfully with minimalerror.

Now a servo motor and its load both have inertia,which the servo amplifier must accelerate anddecelerate while attempting to follow a change atthe input. The presence of the inertia will tend toresult in over-correction, with the system oscillatingor “ringing” beyond either side of its target (Fig. 3.1).This ringing must be damped, but too muchdamping will cause the response to be sluggish.When we tune a servo, we are trying to achieve thefastest response with little or no overshoot.

Fig. 3.1 System response characteristics

In practice, tuning a servo means adjustingpotentiometers in an analog drive or changing gainvalues numerically in a digital system. To carry outthis process effectively, it helps to understandwhat’s going on in the drive. Unfortunately, thetheory behind servo system behavior, though wellunderstood, does not reveal itself to most of uswithout a struggle. So we’ll use a simplifiedapproach to explain the tuning process in a typicalanalog velocity servo. Bear in mind that thissimplified approach does not necessarily accountfor all aspects of servo behavior.

A Brief Look at Servo TheoryA servo is a closed-loop system with negativefeedback. If you make the feedback positive, youwill have an oscillator. So for the servo to workproperly, the feedback must always remainnegative, otherwise the servo becomes unstable. Inpractice, it’s not as clear-cut as this. The servo canalmost become an oscillator, in which case itovershoots and rings following a rapid change atthe input.

So why doesn’t the feedback stay negative all thetime?To answer this, we need to clarify what we mean by“negative”. In this context, it means that the inputand feedback signals are in antiphase. If the input isdriven with a low frequency sinewave, the feedbacksignal (which will also be a sinewave) is displaced inphase by 180°. The 180°-phase displacement isachieved by an inversion at the input of theamplifier. (In practice it’s achieved simply byconnecting the tach the right way round – connectit the wrong way and the motor runs away.)

The very nature of a servo system is such that itscharacteristics vary with frequency, and thisincludes phase characteristics. So feedback thatstarts out negative at low frequencies can turnpositive at high frequencies. The result can beovershoot, ringing or ultimately continuousoscillation.

We’ve said that the purpose of servo tuning is toget the best possible performance from the systemwithout running into instability. We need tocompensate for the characteristics of the servocomponents and maintain an adequate stabilitymargin.

What determines whether the system will be stableor not?Closed-loop systems can be difficult to analyzebecause everything is interactive. The output getsfed back to the input in antiphase and virtuallycancels it out, so there seems to be nothing left tomeasure. The best way to determine what’s goingon is to open the loop and then see what happens.

Fig. 3.2 Closed-loop velocity servo

Fig. 3.3A Measuring open-loop characteristics

Critical Damping

Underdamped ResponseOutput

Time

Overdamped Response

Motor

Tach

+-

Oscillator

Scope

Motor

Tach

+-

Servo Amplifier

Feedback Signal

Velocity Input

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AE

ngin

eeri

ng R

efe

rence

Servo TuningMeasuring the open-loop characteristic allows us tofind out what the output (and therefore thefeedback) signal will be in response to a particularinput. We need to measure the gain and phaseshift at different frequencies, and we can plot theresults graphically. For a typical servo system, theresults might look like this:

Fig. 3.3B Open-loop gain and phase characteristics

The gain scale is in decibels (dB), which is alogarithmic scale (a 6dB decrease corresponds to areduction in amplitude of about 50%). The 0dB linerepresents an open-loop gain of one (unity), so atthis frequency the input and output signals will havethe same amplitude. The falling response in the gaincharacteristics is mainly due to the inertia of themotor itself.

The phase scale is in degrees and shows the phaselag between input and output. Remember that thefeedback loop is arranged to give negativefeedback at low frequencies, (i.e., 180° phasedifference). If the additional phase lag introduced bythe system components reaches 180°, thefeedback signal is now shifted by 360° andtherefore back in phase with the input. We need tomake sure that at no point do we get a feedbacksignal larger than the original input and in phasewith it. This would amount to positive feedback,producing an ever-increasing output leading tooscillation.

Fortunately, it is possible to predict quite accuratelythe gain and phase characteristics of most servosystems, provided that you have the necessarymathematical expertise and sufficient data aboutthe system. So in practice, it is seldom necessary tomeasure these characteristics unless you have aparticular stability problem that persists.

Frequency

Phase Shift

Gain

+30

db 0

+10

+20

-10

0

-90

-180

We’ve said that a problem can occur when there isa phase shift of 180° round the loop. When thishappens, the open-loop gain must be less than one(1) so that the signal fed back is smaller than theinput. So here is a basic requirement for a stablesystem:

The open-loop gain must be less than unitywhen the phase shift is 180°.When this condition is only just met (i.e., the phaseshift is near to180° at unity gain) the system will ringafter a fast change on the input.

Fig. 3.4 Underdamped response

Characteristics of a PracticalServo SystemTypical open-loop gain and phase characteristics ofan unloaded drive-motor-tach system will looksomething like Fig. 3.5.

Fig. 3.5 Characteristics of a practical system

Input Output

Ringing at unity-gain frequency

Gain

Phase

+dB

0

-dB

-180°

0

-360°

B

Shaft resonance 2 kHz typical

Crossover frequency 40–300 Hz typical

The first thing we notice is the pronounced spike inthe gain plot at a frequency of around 2kHz. This iscaused by shaft resonance, torsional oscillation inthe shaft between the motor and the tach. Observethat the phase plot drive dramatically through thecritical 180° line at this point. This means that theloop gain at this frequency must be less than unity(0dB), otherwise the system will oscillate.

The TIME CONSTANT control determines thefrequency at which the gain of the amplifier starts toroll off. You can think of it rather like the treblecontrol on an audio amplifier. When we adjust thetime constant control, we are changing the high-frequency gain to keep the gain spike at 2kHz justbelow 0dB. With too high a gain (time constant toolow) the motor will whistle at about 2kHz.

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Servo TuningThe second point of interest is the CROSSOVERFREQUENCY, which is the frequency at which thegain curve passes through 0dB (unity gain). Thisfrequency is typically between 40 and 300Hz. Onthe phase plot, ß (beta) is the phase margin at thecrossover frequency. If ß is very small, the systemwill overshoot and ring at the crossover frequency.So ß represents the degree of damping – thesystem will be heavily damped if ß is large.

The DAMPING control increases the phase marginat the crossover frequency. It operates by applyinglead compensation, sometimes called accelerationfeedback. The compensation network creates aphase lead in the region of the crossover frequency,which increases the phase margin and thereforeimproves the stability.

Increasing the damping also tends to reduce thegain at the 2kHz peak, allowing a higher gain to beused before instability occurs. Therefore, the timeconstant should be re-adjusted after the dampinghas been set up.

What’s the effect of adding load inertia?An external load will alter both the gain and phasecharacteristics. Not only will the overall gain bereduced owing to the larger inertia, but anadditional gain spike will be introduced due totorsional oscillation between the motor and theload. This gain spike may well be larger than theoriginal 2kHz spike, in which case the motor willstart to buzz at a lower frequency when the timeconstant is adjusted.

The amplitude of this second spike will depend onthe compliance or stiffness of the couplingbetween motor and load. A springy coupling willproduce a large gain spike; this means having toreduce the gain to prevent oscillation, resulting inpoorer system stiffness and slower response. So,if you’re after a snappy performance, it’s importantto use a torsionally-stiff coupling between themotor and the load.

Gain

Phase

+dB

0

-dB

-180°

0

-360°

Motor plus load

Motor alone (no load)

Fig. 3.6 Characteristics of a system with inertial load