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S-Curve Motion Profiles -Vital for Optimizing Machine Performance

Preprint · June 2022

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 S-Curve Motion Profiles - Vital for
Optimizing Machine Performance
Many companies Provide S curve Motion Solution using PLC block or through importing Library

You can use it and run machine without jerk free

But if you have not such library or function block .. here is solution for your machine

Motion control engineers spend hours optimizing tuning parameters for their servo-based motion
controllers. But what if they are using step motors? And what if, no matter how much time they
spend on tuning, they can’t get the performance they want? The answer, for many systems, is to
focus on the motion profile instead. In the past ten years advanced profiling features such as
asymmetric acceleration/deceleration, 7-segment S-curve profiling, change-on-the-fly, and electronic
camming have become widely available, providing engineers with new tools to make machines work
faster and better. This article will take you through the mathematics of motion profiles, discuss which
profiles work best for which applications, and provide insights into how to “tune” your profile for
maximum performance.
In the context of a point-to-point move, a full S-curve consists of 7 distinct phases of motion. Phase 1
starts moving the load from rest at a linearly increasing acceleration until it reaches the maximum
acceleration. In phase II. the profile accelerates at this max. acceleration rate until it must start
decreasing as it approaches the max. velocity. This occurs in phase III when the acceleration linearly
decreases until it reaches zero. In phase IV the velocity is constant until deceleration begins, at which
point the profiles decelerates in a manner symmetric to phases I, II and III.

A trapezoidal profile, on the other hand, has 3 phases. It is a subset of an S-curve profile, having only
the phases corresponding to #2 of the S-curve profile (constant acceleration), #4 (constant velocity),
and #6 (constant deceleration). This reduced number of phases underscores the difference between
these two profiles: The S-curve profile has extra motion phases which transition between periods of
acceleration,

1. PLC Program
Frist calculate Velocity, Acceleration, deceleration Using Below Formula

Or used below Function

//Calculate Velocity

//Total Time

//Acc Time

//Dec Time

//Distance

//Jerk Percent % 0--100

Velocity:=Distance/((Tacc/2)+(Tdec/2)+(Ttotal -(Tacc+Tdec)));

Velocity_GVL:=Velocity;

IF Tacc<> 0 THEN

Acceleration:=(Velocity/Tacc)/(1-Jerk_Percent/200);

Acceleration_GVL:=Acceleration;

ELSE

Acceleration:=0;

END_IF;

IF Tdec<>0 THEN

Deceleration:=(Velocity/Tdec)/(1-Jerk_Percent/200);

ELSE

Deceleration:=0;

END_IF;

IF Acceleration<>0 THEN

Acceleration_Dst:=(EXPT(Velocity,2))/(2*Acceleration*(1-Jerk_Percent/200));

ELSE

Acceleration_Dst:=0;

END_IF;

IF Deceleration<>0 THEN
 Deceleration_Dst:=(EXPT(Velocity,2))/(2*Deceleration*(1-Jerk_Percent/200));

ELSE

Deceleration_Dst:=0;

END_IF;

Constant_Dst:=(Distance-(Acceleration_Dst+Deceleration_Dst));

IF Tacc<>0 AND Jerk_Percent >0 THEN

Jerk:=(EXPT(Acceleration,2)/Velocity)*((200/Jerk_Percent)-1);

Jerk_GVL:=Jerk;

Jerk_Time:=(Acceleration-0)/Jerk;

Jerk_Time_GVL:=Jerk_Time;

ELSIF Tdec<>0 AND Jerk_Percent>0 THEN

Jerk:=(EXPT(Deceleration,2)/Velocity)*((200/Jerk_Percent)-1);

Jerk_Time:=(Deceleration-0)/Jerk;

ELSE

Jerk:=0;

Jerk_Time:=0;

END_IF;

Movement_Time:=Ttotal;

//NJ system only one jerk

JRound:=LREAL_TO_REAL(Jerk_Time);

IF (Tacc>Tdec) THEN

IF JRound>=Tdec THEN

Movement_Time_NJ:=Movement_Time+JRound;

ELSE

Movement_Time_NJ:=Movement_Time+(JRound/2);

END_IF;

ELSE

Movement_Time_NJ:=Movement_Time;

END_IF;

2. CALL initial and Final Value of Velocity, Acceleration, Deceleration, Jerk in

to Function Block
IF NOT xExecute THEN mStage:=0;END_IF

rStep:=0.01; //Put here your scanTime, if you wont you can put as input param

CASE mStage OF
0: //Initial Case
OutBusy:=FALSE;
OutDone:=FALSE;
IF xExecute THEN
CalcVelocity(Ttotal:= TTotal,Tacc:=TAcc , Tdec:=TDec , Distance:=
RelativeDist, Jerk_Percent:=JerkPercent ,
Velocity=> mVelOut,
Acceleration=> mAccOut,
Deceleration=> mDecOut,
Jerk=> mOutJerk,
Jerk_Time=> mOutJerkTime ,
Acceleration_Dst=> ,
Deceleration_Dst=> ,
Constant_Dst=> ,
Movement_Time=> );

mJerkAcc := mOutJerk;//The same Jerk For Acc and Dec

mJerkDec := mOutJerk;

mJerkTimeAcc := mOutJerkTime; //The same Jerk For Acc and Dec

mJerkTimeDec := mOutJerkTime;
rTime:=0;
rTend:= TTotal;
rTimeVelCnts:=rTend - (TAcc+ TDec);
rTimeDec:=0;
rTimeConst:=0;
rTimeAccConst:=0;
ProfileStage:=0;
accStage:=0;
decStage:=0;
 OutPos:=0;
OutVel:=0;
//OutAcc:=0;

xkey:=TRUE;
mStage:=1;

END_IF
3. PLC CYCLE TIME Adaption

m_Time_In:=Rounded;
m_nScans:=m_Time_In/ScansSg;
m_IntScans:=LREAL_TO_DINT(m_nScans);
Rounded:=m_IntScans*ScansSg;
4. PART 1 OR PHASE 1 Calculation

1:
OutBusy:=TRUE;
IF xkey THEN
rTime:=rStep;
xkey:=FALSE;
END_IF
 CASE (ProfileStage) OF
0: //Acc
IF (rTime < TAcc) THEN //AccStage
OutVel := OutVel + (OutAcc*rStep);
CASE (accStage) OF
0: //Phase 1
IF (rTime < mJerkTimeAcc)THEN
OutAcc := mJerkAcc * rTime;
ELSE
OutAcc := mAccOut;
IF(mJerkTimeAcc * 2.0 = TAcc) THEN
accStage :=2;
rTimeAccConst :=mJerkTimeAcc;
ELSE
accStage:=1;
END_IF;
END_IF;
5. PART 2 OR PHASE 2 Calculation

1: //Phase 2

rTimeAccConst:=TAcc - mJerkTimeAcc;

ScanAdapt(ScansSg:=rTimeAccConst , Rounded:=
rTimeAccConst);
 IF (rTime>=rTimeAccConst) THEN

accStage:=2;

END_IF

6. PART 3 OR PHASE 3 Calculation

2: //Phase 3

OutAcc:=mAccOut -mJerkAcc*(rTime -
rTimeAccConst);

END_CASE

ELSE

OutAcc:=0;

IF (rTimeVelCnts <>0.0) THEN

//Cnst

ProfileStage := 1;

ELSE

//Dec

ProfileStage := 2;

END_IF

END_IF

7. PART 4 OR PHASE 4 Calculation

 1://Cnst //Phase 4
IF (rTime >=(TAcc +rTimeVelCnts)-rStep) THEN
//Dec
ProfileStage := 2;
END_IF
8. PART 5 OR PHASE 5 Calculation

2: //Dec
rTimeDec:=rTimeDec + rStep;
ScanAdapt(ScansSg:=rTimeDec , Rounded:= rTimeDec);
OutVel:=OutVel + (OutAcc * rStep);
CASE (decStage) OF
0://Phase 5
IF(rTimeDec <mJerkTimeDec) THEN
OutAcc:= - mJerkDec * rTimeDec;
ELSE
 OutAcc:=-mDecOut;
IF(mJerkTimeDec*2.0 = TDec) THEN
decStage:=2;
rTimeAccConst:=mJerkTimeDec;
ELSE
decStage:=1;
END_IF
END_IF
9. PART 6 OR PHASE 6 Calculation

1://Phase 6
rTimeAccConst: =TDec - mJerkTimeDec;
ScanAdapt(ScansSg:=rTimeAccConst , Rounded:=
rTimeAccConst);
OutAcc:=-mDecOut;
IF(rTimeDec>=rTimeAccConst) THEN
decStage:=2;
END_IF
10. PART 7 OR PHASE 7 Calculation
 2://Phase 7
OutAcc:=-(mDecOut -mJerkDec *(rTimeDec
-rTimeAccConst));
END_CASE
END_CASE
OutPos:= OutPos +(OutVel*rStep);
11. END OF Calculation
IF rTime> rTend THEN

OutPos:=RelativeDist;

OutVel:=0;

OutAcc:=0;

OutBusy:=FALSE;

OutDone:=TRUE;

mstage:=2;

END_IF;

ScanAdapt(ScansSg:=rTime + rStep , Rounded:= rTime);

2:

OutDone:=TRUE;

END_CASE

12. CALL FAUNCTION BLOCK IN MAIN PROGRAM

13. ONLINE PROGRAM AND SEE DIFFERENT RESULT
RESULT1
RESULT2

RESULT3
14. APPLY THIS SOLUTION TO PLC BLOCK
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