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Single Chip Connected Multi-Axis Servo Drive for Industrial Systems

Servo motor drives are systems involved in precision motion and position control used in multiple applications in industrial automation, e.g. robotic arm, conveyer belts etc. A typical servo motor drive receives position reference over industrial Ethernet from a motion controller and uses that reference to close the position/speed/torque loops to actuate the drive. The position reference is received over industrial Ethernet at a cyclic rate of 32 Khz i.e. every 31.25usecs and the position/speed/torque loops are closed at a cyclic rate of 100Khz, i.e. every 10usecs. In order to precisely control the servo motor drive, the SW blocks used to close the loops need to be synchronized precisely and with hard real-time limits set by cyclic rate of Ethernet communication and position/speed/torque loops. Additionally, modern servo drive systems need to control multiple servo drives, typically 3-axis servo drive to control a robotic arm in factory automation systems. This paper proposes a single chip solution to handle the industrial Ethernet protocols and multi-axis servo motor drive control software. The proposed solution uses multiple novelties namely, multi-core ARM R5F micro controllers to run the Ethernet and motor control loops, hard real-time offload to dedicated Programmable Real-time Units (PRUs), high precision time-sync to synchronize the SW blocks. The proposed implementation is done on TI AM243x SOC and is able to achieve 3-axis servo motor drive control, using < 10% R5F utilization, < 2MB of internal RAM and time-sync precision of < 20ns. This ensures the servo motor drive operates at the precise position/sneed/torque that is desired.