Several Methods of High-accuracy Positioning Control Using TD3100 Frequency Converter
Abstract: This paper explores advanced methods for high-precision positioning control using the TD3100 elevator-specific vector control inverter, with a focus on its underlying principles and practical applications. Keywords: distance control, position control, inverter Abstract: This article presents techniques for achieving high-accuracy position control using the TD3100 inverter, emphasizing the theoretical framework and real-world implementation of these methods. Keywords: Distance control, Position control, Inverter I. Introduction In various industrial sectors, precise positioning is crucial for operations like machining and manufacturing. Traditionally, DC or AC servos have been used, but they come with high costs. This paper proposes an alternative by utilizing the TD3100 inverter from Emerson Network Power, which offers a cost-effective solution for high-precision positioning systems. II. Principle of TD3100 Distance Control The TD3100 is a specialized frequency inverter designed for elevators, built upon the high-performance TD3000 vector inverter. It features a distance control function that enables self-learning of floor heights and accurate docking. Users do not need to calculate deceleration points manually, reducing software design complexity. The inverter stores each floor's height information via an encoder. During operation, it automatically calculates the deceleration point when the destination floor is specified. When the FLE terminal is active, the system receives signals from F1 to F6. If the REQ signal is given, the inverter computes the deceleration point for each floor and sends a signal to the controller through Y1-Y4. After receiving the deceleration signal, if a stop is needed, the controller issues a REQ signal, and the inverter decelerates smoothly. The timing of the two distance control modes is illustrated in Figure 1. (a) Distance control for a given destination floor (b) Distance control for a given parking request Figure 1 TD3100 Frequency Converter Distance Control Timing III. Two Fixed Point Positioning Using TD3100 For two-point fixed positioning, the system behaves as if there are only two floors. Limit switches are installed at both ends, and after self-learning between the two points, the system can directly control positioning based on the parking request. 1. Self-Learning The self-learning connection is shown in Figure 2(a). UPL and DWL are shorted, and the left and right limits are connected in parallel. A flat layer signal is input to UPL and DWL. Self-learning should start from a position beyond the left or right limit. If the position cannot leave the limit, it can still be learned, and accuracy can be adjusted by setting F4.07 or F4.09 during normal operation. Set F4.00 to 2 and F4.01 according to the position width for automatic calculation of the frequency division factor. During self-learning, close FWD and SL terminals to initiate the process. After the limit switch activates, remove the FWD command and complete the learning. Check F4.08 and F4.09 to ensure correct logging. Adjust F3.11-F3.16 if acceleration/deceleration time is too long or too short. (a) Self-learning connection (b) Normal operation connection Fig. 2 Using TD3100 to Achieve Fixed Positioning with Two Points 2. Normal Operation Calculate and set F1.07 according to Formula 1, where D is the diameter of the roller at the control line speed, and R is the mechanical reduction ratio. Set F5.00=15, select the X1 terminal as the distance control enable function, and adjust the S curve according to the process requirements. Finally, adjust F3.02 and F3.21 to achieve the desired parking accuracy. According to Figure 2(b), the FWD, REV, and INS commands are controlled. During normal operation, only the FWD/REV signal is required. The INS terminal is used for jogging. When jogging, the INS signal is first activated, followed by the FWD/REV signal to control left or right movement. 3. Application in Glass Screen Transfer Machine The glass transfer machine structure is shown in Figure 3. The motor is a 2.2kW unit with a rated voltage of 380V, operating frequency of 50Hz, current of 5.0A, and speed of 1420r/m. The gear ratio is 1:17, and two proximity switches are installed. The distance between the 1# and 2# switches is about 1400~1800mm, and the load is around 150~170kg. The transfer machine must move and position between the two limit switches, with a positioning accuracy error within 3mm. Each single stroke takes approximately 2-3 seconds, involving acceleration from the 1# limit switch to constant speed, then deceleration to stop at the 2# limit. According to Figure 2(a), set F4.00 = 2. First, use the INS and REV terminals to open the car to one side, then close FWD and SL to complete the self-learning. To improve efficiency, set S-curve parameters to maximum, zero out brake delay times F7.00 and F7.01, and set start frequency and wait time F3.00, F3.01 to zero. S-curve parameters F3.02, F3.11, F3.12, F3.14, F3.15 are all set to 2.400m/s², while F3.10, F3.13, F3.21 are set to 2.00m/s². F3.02 is set to 0.3m/s². This results in smooth operation that meets process accuracy requirements and achieves servo-like positioning. IV. Multi-Point Positioning Using TD3100 For applications requiring multi-position control, such as three-dimensional warehouses and garages, the TD3100 simplifies circuit design, reduces costs, and improves reliability. With up to 128 floors, controlling by destination floor is straightforward. The system using TD3100 in a stereoscopic warehouse is shown in Figure 4. UPL and DWL signals can use leveling switches or connect directly to COM. FLE is the target floor enable terminal, and INI is the current floor initialization terminal. From the comparison in the figure, it is evident that communication control simplifies the circuit, saves resources, and reduces costs. Note that this function requires customization. Before application, floor height self-learning is necessary, following the same method as before, adjusting F7.00 according to actual conditions. (a) Binary given floor control (b) Communication control Figure 4 Stereoscopic Warehouse System with TD3100 Converter V. Two-Point Distance Control Using TD3100 When implementing two-point distance control with the TD3100, the method is similar to the two-point fixed positioning approach. The key difference is that the floor height value F4.09 must be manually or automatically changed in parking mode before running. Due to the difficulty of manual adjustment, it is usually controlled by the upper computer. Additionally, due to the nature of distance-based control, two limit switches are required for positional discrimination to prevent mechanical shocks. This function is commonly used in multi-motor, multi-axis high-precision systems, such as smart digital stage control. The modern stage drive system using PROFIBUS-DP fieldbus control is shown in Figure 5. The system is controlled by a PC and uses a Siemens plug-in PROFIBUS master control board, such as CP5611 or CP5412, for manual and automatic control. The adapter uses the PROFIBUS-DP EMERSON TDS-PA01 and connects directly to the TD3100. Adopting PROFIBUS control allows for higher real-time accuracy and faster response, meeting the demands of fast and precise control. Figure 5 Modern Stage Drive System with PROFIBUS-DP Fieldbus Control VI. Conclusion Beyond elevator applications, the TD3100 can be applied in various systems requiring positioning and distance control. It effectively reduces hardware and software design costs, enhances system reliability, and provides a versatile solution for modern automation needs. References: 1. TD3100 Frequency Converter Product Specification 2. 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