Note: Descriptions are shown in the official language in which they were submitted.
~IIC:ROPROCE:SSOR CON~OLLE:D D . C . ~qOTOR
P~)R CONl'ROLLING PRIl~TING PIEANS
BACKGROUND OF THE INVENTION
The present invention is generally concerned with
apparatus including sheet feeding and printing means, for
example, a postage meter including a rotary sheet feeding and
printing drum, and improvements therein.
In ~.S. Patent No. 2,934,009 issued April 26, 1960 to
Bach, et al. and assigned to the assignee of the present
invention there is described a postage meter which includes a
drive mechanism connected by means of a drive train to a
postage meter drum. The drive mechanism includes a single
revolution clutch for rotating the drum from a home position
and into engagement with a letter ~ed to the drum. The drum
prints a postage value on the letter while feeding the same
downstream beneath the drum as the drum returns to the home
position. Each revolution of the single revolution clutch
and thus the drum, is initiated by the letter engaging a trip
lever to release the helical spring of the single revolution
clutch. The velosity versus time profile of the peripherary
of a drum driven by the clutch approximates a trapezoidal
configuration, having acceleration, constant velocity and
deceleration portions, fixed by the particular clutch and
drive train used in the application. This being the case,
the throughput rate of any mailing machine associated with
the meter is dictated by the cycling speed of the postage
meter rather than by the sp~ed with which the individual
mailpieces are fed to the postage meter. Further, although
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the single revolution clutch structure has served as the
workhorse of the industry for many years it has long
been recognized that it is a complex mechanism which is
relatively expensive to construct and maintain ? does not
precisely follow the ideal trapezoidal velocity vs. time
motion profile which is preferred for drum motion, tends
to be unreliable in high volume applications, and is
noisy and thus irritating to customers.
Accordingly, an object of an aspect of the
invention is to replace the postage meter drum drive
mechanism of the prior art with the combination of a
D.C. motor and a computer, and program the computer for
causing the D.C. motor to drive the drum in accordance
with an ideal trapezoidal-shaped velocity versus time
profile which is a function of the input velocity of a
mailpiece; and
An object of an aspect of the invention is to
replace the trip lever as the drive initiating device
and utilize in its place a pair of spaced apart sensing
devices in the path of travel of a mailpiece fed to the
postage meter, and program the computer to calculate the
input velocity of a mailpiece, based upon the time taken
for the mailpiece to traverse the distance between the
sensing devices, and adjust the time delay and
acceleration of the drum before arrival of the mailpiece
at a position at which drum rotation is commenced to
cause the drum to timely engage the leading edge of the
mailpiece.
SUMMARY OF THE INVENTION
Various aspects of the invention are as follows:
In a system for controlling rotary means having a
periphery, wherein the periphery includes indicia
printing means, and wherein the periphery is adapted for
feeding a sheet having a leading edge in a path of
travel, an improvement in the system comprising:
a) first means for sensing a time interval duriny
which the leading edge of the sheet is linearly
displaced a prede-termined distance in the path of
travel;
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b) a d.c. motor coupled to -the rotary means for
rotation thereof;
c) second means for sensing angular displacement
of the rotary means and,
d) computer means coupled to the first and second
sensing means and to the d.c. motor, the computer means
comprlsing:
i) means for providinq successive sampling
time periods;
ii) means responsive to the first sensing
means for providing respective counts representative of
desired angular displacements of the rotary means during
successive sampling time periods,
iii) means responsive to the second sensing
means for providing respective counts representative of
actual angular displacements of the rotary means during
successive sampling time periods, and
iv) means for compensating for the difference
between desired and actual counts and generating a d.c.
motor control signal for controlling rotation of the
motor to cause the indicia printing means to initially
engage the sheet in the path of travel a predetermined
marginal distance from the leading edge of the sheet.
In a system for controlling rotary means, wherein
the rotary means includes a periphery having indicia
printing means and is constructed and arranged for
feeding a sheet having a leading edge in a path of
travel, a process for controlling rotation of the rotary
means, the process comprising:
a~ providing means for providing successive
sampling time periods;
b) sensing a time interval during which the
leading edge of the sheet is linearly displaced a
predetermined distance in the path of travel and
providing counts representative of respective desired
angular displacements of the rotary means during
successive sampling time periods;
c) providing a d.c. motor for rotating the rotary
means;
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d) sensing angular displacement of the rotary
means and providing counts representative of respective
actual angular displacements of the rotary means during
successive sampling time periods; and
e) digitally compensating for the difference
~etween desired and actual counts and generating a motor
control signal for controlling rotation of the rotary
means to cause the indicia printing means to initially
engage the sheet in the path of travel a predetermined
distance from the leading edge of the sheet.
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B~IEF_ DESCRIPTION OF THE DR~WINGS_
As shown in the drawings wherein like reference
numerals designate like or corresponding parts throughout the
several views:
Figure 1 is a schematic view of a postage meter
mounted on mailing machine in accordance with the invention;
Figure 2 is a schematic view of the mailing machine of
Figure 1, showing the location of the mailpiece sensors
relative to the postage meter drum;
Figure 3 shows the relationship between ~he position
of a sheet and the postage meter drum as a function of time,
and an ideal velocity versus time profile of the periphery of
the drum;
Figure 4 is a perspective view of the quadrature
encoder mounted on a D.C. motor drive shaft;
Figure 5 shows the output signals from the quadrature
encoder of Fig. 4 for clockwise and counter-clockwise
rotation of the D.C. motor drive shaft;
Figure 6 is a schematic diagram of a preferred
counting circuit for providing an eight bit wide digital
signal for the computer which numerically represents the
direction of rotation, and angular displacement, of the motor
drive shaft, and thus the drum, from its home position;
Figure 7 shows a power amplifier circuit for coupling
the computer to the D.C. motor.
~z~
Figure 8 is a truth table showing the status of the
transistors in the power amplifying circuit fox clockwise and
counte~-clockwise rotation of the D.C. motor;
Figure 9 shows the relationship between the encoder
output signals for various D.C. motor duty cycles;
Figure 10 shows a closed-loop servo system including
the D.C. motor and computer;
Figure 11 is a block diagram portraying the laplace
transform equations of the closed-loop servo system shown in
Fig. 10;
Figure 12 shows the equations for calculating the
overall gain of the closed loop servo system of Fig. 10
before (Fig. 2a) and after (Fig. 2b) including a gain factor
corresponding to the system friction at motor start up;
Figure 13 is a bode diagram including plots for the
closed loop servo system before and after compensation to
provide for system stability and maximization of the system's
bandwidth;
Figure 14 shows the equation for calculating, in the
frequency domain, the value of the system compensator;
Figure 15 shows the equation for calculating the
damping factor, overshoot and settling time of the servo
controlled system;
Figure 16 shows the equation for the laplace operator
expressed in terms of the Z-transform operator;
Figure 17 shows the equation for calculating the value
of the system compensator in the position domain;
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Figure 18 shows the equations for converting the
system compensator of Fig. 17 to the position domain;
Figure 19 shows the equation of the output of the
system compensator in the time domain;
Figure 20 is a block diagram of a preferred
microprocessor for use in controlling the D.C. Motor;
Figure 21 (including Figs. 21a, 21b and 21c) shows the
time intervals during which the motor control signal and its
separable components are calculated to permit early
application of the signal to the motor;
Figure 22 (including Figs. 22a and 22b) is a block
diagram of the computer according to the inventionj and
Figure 23 (including Figs. 23a-1, 23a-2, 23b and 23c)
shows the flow charts portraying the processing steps of the
computer.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in Fig. 1, the apparatus in which the
invention may be incorporated generally includes an
electronic postage meter 10 which is suitably removably
mounted on a conventional mailing machine 12, so as to form
therewith a slot 14 (Fig. 2) through which sheets, including
mailpieces 16, ~uch as envelopes, cards or other sheet-like
materials, may be fed in a downstream path of travel 18.
The postage meter 10 ~Fig. 1) insludes a keyboard 30
and display 32. The keyboard 30 includes a plurality of
numeric keys, labeled 0-9 inclusive, a clear key, labeled "c"
and a decimal point key, labeled n . n ~ for selecting postage
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values to be entered; a set postage key, labeled '511, for
entering selected postage values; and an arithmetic function
key, labeled "-", for adding subsequently selected charges
tsuch as special delivery costs) to a previously selected
postage value before entry of the total value. In addition,
there is provided a plurality of display keys, designated 34,
each of which are provided with labels well known in the art
for identifying information stored in the meter 10, and shown
on the display 32 in response to depression of the particular
key 34, such as the "postage used", "postage unused",
"control sum", "piece count", "batch value" and "batch count"
values. A more detailed description of the keys of the
keyboard 30 and the display 32, and their respective
functions may be found in U.S. Patent NG. 4,283,721 issued
~ugust 11, 1981 to Eckert, et alO and assigned to the
assignee of the present inventionO
In addition, the meter 10 (Fig. 1) includes a casing
36l on which the keyboard 30 and display 32 are
conventionally mounted, and which is adapted by well kno~n
means for carrying a cyclically operable, rotary, postage
printing drum 38. The drum 38 (Fig. 2) is conventionally
constructed and arranged for feeding the respective
mailpieces 16 in the path of travel 18, which extends beneath
the drum 38, and for printing entered postage on the upwardly
disposed surface of each mailpiece 16. For postage value
selecting purposes, the meter 10 (Fig. 1) also includes a
conventional postage value selection mechanism 40, for
example, of the type shown in U.S. Patent No. 4,2B7,825
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issued September 8, 1981 to Eckert, et al. and assigned to
the assignee of the present invention. The mechanism 40
which is operably electrically coupled via the postage
meter's computer 41 to the keyboard 30 and display 32,
includes a first stepper motor 42 for selecting any one of a
plurality of racks 43, associated on a one for one basis with
each of the print wheels 44, and a second stepper motor 45
for actuating each selected rack 43 for positioning the
appropriate printing element of the associated print wheel
44. The rack selection stepper motor 42, which is referred
to by skilled artisans as a bank selector motor, is
appropriately energized via power lines 46 from the computer
41 for selecting the appropriate rack; and the rack actuating
stepper motor 45, which is referred to by skilled artisans as
a digit selector motor, is appropriately energized via power
lines 47 from the computer 41 to move the selected rack for
~electing the appropriate digit element of the associated
print wheel 44. ~ more detailed description of the value
selection mechanism 40 may be found in the aforesaid U.S.
Patent No. 4,287,825.
The computer 41 for the postage meter 10 generally
comprises a conventional, microcomputer system having a
plurality of microcomputer modules including a control or
keyboard and display module, 41a, an accounting module 41b
and a printing module 41c. The control module 41a i5 both
operably electrically connected to the accounting module 41b
and adapted to be operably electrically connected to an
external device via respective two-way serial communications
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channels, and the accounting module 41b is operably
electrically connected to the printing module 41c via a
corresponding tw~-way serial communication channel. In
general~ each of the modules 41a, 41b and 41c includes a
dedicated microprocessor 41d, 41e or 41f, respectively,
having a separately controlled clock and programs. And two-
way communications are conducted via the respective serial
communication channels utilizing the echoplex communication
discipline, wherein communications are in the form of
serially transmitted single byte header-only messa~es,
consisting of ten bits including a start bit followed by an B
bit byte which is in turn followed by a stop bit, or in the
form of a multi-byte message consisting of a header and one
or more additional bytes of information. Further, all
transmitted messages are followed by a no error pulse if the
message was received error free. In operation, each of the
modules 41a, 41b and 41c is capable of processing data
independently and asynchronously of the other. In addition,
to allow for compatibility between the postage meter 10 and
any external apparatus, all operational data transmitted to,
from and between each of the three modules 41a, 41b and 41c,
and all stored operator information, is accessible to the
external device via the two~way communication channel, as a
result of which the external apparatus ~if any) may be
adapted to have complete control of the postage meter 10 as
wPll as access to all current operational information in the
postage meter 10. In additionl the flow of messages to, from
and between the three internal modules 41a, 41b and 41c is in
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a predetermined, hierarchical direction. For example, any
command message from the control module 41a is communicated
to the acc~unting module 41b, where it is processed either
for local action in the accounting module 41b and/or as a
command message for the printing module 41c. On the other
hand, any message fr~m the printing module 41c is
communicated to the accounting module 41b where it is either
used as internal information or merged with additional data
and communicated to the control module 41c. ~nd, any message
from the accounting module 41b is initially directed to the
printing module 41c or to the control module 41a. A more
detailed description of the various prior art modules 41a,
41b and 41c, and various modifications thereof, may be found
in U.S. Patent Nos. 4,280,180; 4,280,179; 4 r 283,721 and
4,301,507; each of which patents is assigned to the assignee
of the present invention.
The mailing machine 12 (Fig. 2), which has a casing
19, ineludes a A.C. power supply 20 which is adapted by means
of a power line 22 to be connected to a local source of
supply of A.C. power via a normally open main power switch ?4
which may be closed by the operator. Upon such closure, the
mailing machine's D.C. power supply 26 is energized via the
power line 28. In addition, the mailing machine 12 includes
a conventional belt-type conveyor 49, driven by an A.C. motor
50, which is connected for energization from the A.C. power
supply 20 via a conventional, normally open solid state, A.C.
motor, relay 52, which is timely energized by a computer 500
for closing the relay 52. Upon such closure the A.C.
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motor 50 drives the conveyc~r 49 for feeding mailpieces 16 to
the drum 38. To facilitate operatox control of the switch
24, the ~nailing rnachine preferably includes a keyboard ~3
having a "start`' key 53a and a "stop" key 53b, which are
conventionally coupled to the main power switch 24 to permit
the operator to selectively close and open the switch 24.
Assuming the computer 500 has tirnely energized the relay 52,
the A.C. motor 50 is energized from the ~.C. power supply 20.
Whereupon the conveyor 49 transports the individual
mailpieces 16, at a velocity corresponding to the angular
velocity of the motor 50, in the path of travel 18 to the
postage pr i nt i ng pl aten 5 ~ .
According to the invention, the machine 12 includes
f irst and second sensing devices respectively designated 56
and 58, which are spaced apart from each other a
predetermined distance dl, i.e., the distance between points
and B in the path of travel lB. Pre~erably, each of khe
sensing devices 56 and 58, is an electr~optical device which
is suitably electrically coupled to the computer 500; sensing
device 56 being connected via corr~nunication line 60 and
sensing device 58 being connected via cornmunication line 62.
The sensing devices 56, 58 respectively respond to the
arrival of a mailpiece 16 at points A and B by providing a
signal to the computer 500 on cornrnunication line 60 from
sens.ing device 56 and on cornmunication line 62 rom sensing
device 58. Thus, the rate of movement or velocity Vl of any
mailpiecè 16 may be calculated by counting the elapsed time
tv (Fig. 3 ) between arrivals of the mailpiece 16 at points A
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and B, and dividing the distance ~1~ by the elapsed time tv.
To that end, the computer 500 is programmed for continuously
polling the communications lines 60 and 62 each time instant
Tn at the end of a predetermined sampling time period, T,
preferably T=l millisecond, and to commence counting the
number of time instants Tn when the leading edge of ~ given
mailpiece 16 is detected at point A, as evidenced by a
transition signal on communication line 60, and to end
counting the time instants Tn when the given mailpiece 16 is
detected at point B, as evidenced by a transition signal on
communication line 62. Since the distance dl, is a
mechanical constant of the mailing machine 12, the velocity
of the mailpiece may be expressed in terms of the total
number Nt Of time instants Tn which elapse as the given
mailpiece traverses the distance dl. For example, assuming a
maximum velocity of 61 inches per second, dl=2.75 inches and
T=l millisecond; the total number Nt of elapsed time instants
Tn may be found by dividing dl=2.75 inches by Vl-61 inches
per second to obtain Nt=45, i.e., the total number of time
instants Tn which elapse between arrivals of the mailpiece at
points A and B. Thus, the number Nt=45 corresponds to and is
representative of a mailpiece velocity of Vl=61 inches per
second.
Assuming normal operation of the transport system and
calculation of the value of Vl having been made, the time
delay td (Fig. 3) before arrival of the mailpiece 16 at point
C may be calculated by dividing the distance d2 between
points ~ and C by the mailpiece's velocity Vl, provided the
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33
~`
distance d2 is known. Since the integral of the initial,triangularly-shaped, portion of the velocity versus time
profile is equal to one-half of the value of the pr~duct of
Ta and Vl, and is equal to the arc d3 described ~y point E on
the drum 38, as the drum 38 is rotated counter-clockwise to
point D, the distance between points C and D is equal to
twice the arcuate distance d3. Accordingly, d2 may be
conventionally calculated, as may be the time delay ~d for
the maximum throughput velocity. Assuming rotation of the
drum 38 is commenced at the end of the time delay td and the
drum 38 is linearly accelerated to the velocity Vl to match
that of the mailpiece 16 in the time interval Ta during which
point E on the drum 38 arcuately traverses the distance d3 to
point D, Ta may be conventionally calculated. In addition,
assuming commencement of rotation at the end of the time
delay td and that the drum 38 ls linearly accelerated to the
velocity Vl during the time interval Ta, the mailpiece 16
will arrive at point D coincident with the rotation of point
E of the outer periphery 73 the drum 38 to point D, with the
result that the leading edge 73a vf the drum's outer
periphery 73, which edge 73a extends transverse to the path
of travel 18 of the mailpiece 16, will engage substantially
the leading edge of the mailpiece 16 for feeding purposes and
the indicia printing portion 73b of the periphery 73 will be
marginally spaced from the leading edge of the mailpiece 16
by a distance d4 which is equal to the circumferential
distance between points E and F on the drum 38. Since the
ciroumferential distance d5 on the drum 38 between points E
and G is fixed, the time interval Tc during which the drum 38
is rotated at the constant velocity Vl may also be
calculated. When point G ~n the drum 38 is rotated out of
engagement with the mailpiece 16, the drum 38 commences
deceleration and continues to decelerate to rest
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during the time interval Td. The distance d6 which istraversed by point G, as the d~um 38 is r~tated to return
point E to its original position of being spaced a distance
d3 from point D, is fixed, and, Td may be chosen to provide a
suitable deceleration rate for the drum, preferably less than
Ta. In addition, a reasonable settling time interval Ts is
preferably added to obtain the overall cycling time Tct of
the drum 38 to allow for damping any overshoot of the drum 38
before commencing the next drum cycle. For a typical maximum
drum cycle time period Tct of 234 milliseconds and a maximum
mailpiece transport rate of 61 inches per second, typical
values for the acceleration, constant velocity, deceleration
and settling time intervals are Ta=37 milliseconds, TC=124
milliseconds, Td=24 milliseconds and Ts=234-185=49
milliseconds. Utili~ing these values, the required
acceleration and deceleration values for the drum 38 during
the time intervals Ta and Td may be conventionally
calculated. In addition, since the integral of the velocity
versus time profile i5 equal to the distance traversed by the
circumference of the drum 38 during a single revolution of
the drum 38, the desired position of the drum 38 at the end
of any sampling time period of T=l millisecond may be
calculated. For target ~elocities Vl which are less than the
maximuJn throughput velocity, it is preferably assumed that
integral of, and thus the area under, the velocity versus
time profile remains constant, and equal to the area thereoE
at the maximum throughput velocity, to facilitate
conventional calculation of the values of the time delay td,
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, ............................... .
~ ~ .
,~
the time intervals Ta, Tc and Td, and the acceleration anddeceleration values for each of such lesser velocities Vl.
For computer implementation purposes, the computer 500
is progra~med as hereinbefore discussed to continously poll
the communication lines 60 and 62, from the sensing devices
56 and 58, respectively, each time interval Tn~ and count the
time intervals Tn between arrivals of the mailpiece 16 at
points A and B as evidenced by a transition signals on lines
60 or 62. Further, the computer 500 is programmed to
calculate the current velocity of the mailpiece 16 in terms
of the total number Nt of the counted time intervals Tn~
store the current velocity and, preferably, take an average
of that velocity and at least the next previously calculated
velocity (if any) to establish the target velocity Vl. In
addition, it i5 preferable that precalculated values for the
time delay td, acceleration and deceleration corresponding
to each of a plurality of target velocities be stored in the
memory of the computer 500 for fetching as needed after
calculation of the particular target velocity. For
marginally spacing the indicia a different predetermined
distance from the leading edge of the sheet then would be
provided due to the drum's periphery initially engaging the
leading edge of the sheet, the value of td may be altered at
the time of programming the computer to cause the indicia to
initially engage the sheet a different predetermined marginal
distance from the leading edge of the sheet. The velocity at
any time "t" of the drum 38 may be expressed by adding to the
original velocity VO each successive increment of the product
of the acceleration and time during each time period of T=l mi
llisecond, each successive increment of constant velocity and
each successive increment of the product of the deceleration
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and ti~e during each time period T. Preferably, theacceleration and deceleration values are each stored in the
form of an amount corresponding to a predetermined number of
counts per millisecond square which are a function of the
actual acceleration or deceleration value, as the case may
be, and of the scale factor hereinafter discussed in
connection with measuring the actual angular displacement of
the motor drive shaft 122; whereby the computer 500 may
timely calculate the desired angular displacement of the
motor drive shaft 122 during any sampling time interval T.
In this connection it is noted that the summation of all such
counts is representative of the de~ired linear displacement
of the circumference of the drum 38, and thus of the desired
velocity versus time profile of drum rotation for timely
accelerating the drum 38 to the target velocity Vl,
maintaining the drum velocity at Vl for feeding the
partlcular mailpiece 16 and timely decelerating the drum 38
to rest.
The postage meter 10 (Fig. 1) additionally includes a
conventional, rotatably mounted, shaft 74 on which the drum
38 is fixedly mounted, and a conventional drive gear 76,
which is fixedly attached to the shaft for rotation of the
shaft 74.
According to the invention, the mailing machine 12
(FigO 1) includes an idler shaft 80 which is conventionally
journaled to the casing 19 for rotation, and, operably
coupled to the shaft 80, a conventional home position encoder
82. The encoder 82 includes a conventional circularly-shaped
disc 84, which is fixedly attached to the shaft B0 for
rotation therewith, and an optical ~ensing device 86, which
is operably coupled to the disc 84 for detecting an opening
f
,
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88 formed therein and, upon such detection, signalling the
computer 500. The machine 12, also includes an idler gear 90
which is fixedly attached to the shaft 80 for rotation
therewith. Further, the machine 12 includes a D.C. motor
120, which is suitably attached to the casing 19 and has a
drive shaft 122. The machine 12 also includes a pinion gear
124, which i5 fixedly attached to the drive shaft 122 for
rotation by the shaft 122. The gear 124 is disposed in
driving engagement with the idler gear 90. Accordi~gly,
rotation of the motor drive shaft 122 in a given direction,
results in the same direction of rotation of the drum drive
shaft 76 and thus the drum 38. Preferably, the pinion gear
124 has one-fifth the nurnber of teeth as the drum drive gear
76, whereas the idler gear 90 and drum drive gear 76 each
have the same number of teeth. With this arrangement, five
complete revolutions of the motor drive shaft 122 effectuate
one complete revolution of the drum 38, whereas each
revolution of the gear 90 results in one revolution of the
gear 76. Since there is a one-to-one relationship between
revolutions; and thus incremental angular displacements, of
the drum shaft 74 and idler shaft 90, the encoder disc 84 may
be mounted on the idler shaft 90 such that the disc's opening
88 is aligned with the sensing device 86 when the drum 38 is
disposed in its home position to provide for detection of the
home position o the drum shaft 74~ and thus a position of
the drum shaEt 74 from which incremental angular
displacements may be counted.
For sensing actual incremental angular displace~ents
of the mo~or drive shaft 122 (Fig. 1) from a home position,
and thus incremental angular displacements of the drum 38
from its rest or home position as shown in Fig. 2, there is
provided a quadrature encoder 126 (Fig. 1). The encoder 126
is preferably coupled to the motor drive shaft 122, rather
than to the drum shaft 74, for providing higher mechanical
stiffness between the armature of the d.c. motor 120 and th~
encoder 126 to avoid torsional resonance effects in the
system. The encoder 126 includes a circularly-shaped disc
128, which is fixedly attached to the motor drive shaft 122
for operably connecting the encoder 126 to the motor 120.
The disc 128 (Fig. 4) which is otnerwise transparent to
light, has a plurality of opayue lines 130 which are formed
on the disc 1~8 at predetermined, equidistantly angularly-
spaced, intervals along at least one of the dics's opposed
major surfaces. Preferably the disc 128 includes one hundred
and ninety-two lines 130 separated by a like number of
transparent spaces 132. In addition, the encoder 126
includes an optical sensing device 134, which is
conventionally attached to the casing 19 and disposed in
operating relationship with respect to the disc 128, for
serially detecting the presence of the respective opaque
lines 130 as they successively pass two reference positions,
for example, positions 136ra and 136rb, and for responding to
such detection by providing two output signals, one on each
of communications lines 136a and 136b, such as signal A tFig~
5) on line 136a and signal B on line 136b. Since the d.isc
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128 (Fig. 4) includes 192 lines 130 and the gear ratio of thedrum drive gear 76 (Fig. 1) to the motor pinion gear 124 is
five-to-one, nine hundr2d and sixty signals A and B (Fig. 5)
are provided on each of the communications lines 136a and
136b during five revolutions of ~he motor drive shaft 122,
and thus, during each cycle of rotation of the drum 38.
Since the angular distance bet~een successive lines 130 (Fig.
4) is a constant, the time interval between successive
leading edges (Fig. 5) of each signal A and B is inversely
proportional to the actual velocity of rotation of the motor
drive shaft (Fig. 1) and thus of the drum 38. The encoder 126
is conventionally constructed and arranged such that the
respective reEerence positions 136a and 136b ~Fig. 4) are
located with respect to the spacing between line 130 to
provide signals ~ and B ~Fig. 5) which are 90 electrical
degrees out of phase. Accordingly, if signal A lags signal B
by 90 (Fig. 5) the D.C. motor shaft 122 ~Fig. 1~, and thus
the drum 38, is rotating clockwise, whereas if signal A leads
signal B by 90 tFig. 5) the shaft 122 and drum 38 are both
rotating counter-clockwise. Accordingly, the angular
displacement in either direction of rotation of the drum 38
(Fig. 1) from its home position may be incrementally counted
by counting the number of pulses A or B, (Fig. S) as the case
may be, and accounting for the lagging or leading
relationship o pulse A (Fig. 5) with re~pect to pulse B.
The quadrature encoder communication lines, 136a and
136b (Fig. 1), may be connected either directly to the
computer 500 for pulse counting thereby or to the computer
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500 via a conventional counting circuit 270 (Fig. 6),
depending on whether or not the internal counting circuitry
of the compute~ 500 is or is not available for such counting
purposes in consideration of other design demands of the
system in which the computer 500 is being used. Assuming
connection to the computer 500 via a counting circuit 270,
the aforesaid communications lines, 136a and 136b are
preferably connected via terminals A and B, to the counting
circuit 270.
In general, the counting circuit 270 (Fig. 6) utilizes
the pulses A (Fig. 5) to generate a clock signal and apply
the same to a conventional binary counter 274 (Fig. 6), and
to generate an up or down count depending on the lagging or
~eading relationship of pulse ~ (Fig. 5) relative to pulse B
and apply the up or down count to the binary counter 274
(Fig. 6) for counting ~he~eby. More particularly, the pulses
A and B (Fig. 5) which are applied to the counting circuit
terminals A and B (Fig . 6) are respectively fed to Schmidt
trigger inverters 276A and 276B. The output from the
inverter 276A is fed directly to one input of an XOR gate 278
and additionally via an R-C delay circuit 280 and an inverter
282 to the other input of the XOR gate 278. The output
pulses from the XOR gate 278, which acts as a pulse frequency
doubler, is fed to a conventional one-shot multivibrator 284
which detects the trailing edge of each pulse from the XOR
gate 278 and outputs a clock pulse to the clock input CK of
the binary counter 274 for each detected trailing edge. The
output from the Schmidt trigger inverters 276A and 276B are
- 20 -
~;~3~
respecti~ly fed to a second XOR gate 286 which outputs a lowlogic level signal t~ero), or up-count, to the up-down pins
U/D o~ the binary counter 274 or each output pulse A (Fig.
5) which lags an output pulses B by 90 electrical degrees.
On the other hand the XOR gate 286 (Fig. 6) outputs a high
logic level (one) or down-count, to the up-down input pins of
the binary counter 274 for each encoder output pulse A (Fig.
5) which leads an output pulse B by 90 electrical degrees.
Accordingly, the XOR gate 286 (Fig. 6) provides an output
signal for each increment of angular displacement of the
encoded shaft 122 (Fig. 1) and identifies the direction,
i.e., clockwise or counter-clockwise, of rotation of the
encoded shaft 122. The binary counter 274 (Fig. 6) counts
the up and down count signals from the XOR gate 286 whenever
any clock signal is received from the multivibrator 284, and
updates the binary uutput signal 272 to reflect the count.
Accordingly, the counting circuit 270 converts the
digital signals A and ~, which are representative of
incremental angular displacements of the drive shaft 122 in
either direction of rotation thereof, to an eight bit wide
digital logic output signal 272 which corresponds to a
summation count at any given time, of such displacements,
multiplied by a factor of two, for use by the computer 500.
Since the angular displacement of the shaft 122 from its home
position is proportional to the angular displacement of the
drum 38 from its home position, the output signal 272 is a
count which is proportional to the actual linear displacement
of the outermost periphery of the drum 38 at the end of a
given time period of rotation of the drum 38 from its home
p~sition. For a typical postage meter drum 38, having a
circumference, i.e., the arc described by the outermost
periphery of the drum 38 in the course of revolution thereof,
of 9.42 inches, which is connected to the motox drive shaft
122 via a mechanical transmission system having a 5:1 gear
ratio between the motor 120 and drum 38, wherein the encoder
disc 128 has 192 lines; the counting circuit 270 ~ill provide
an output of 2 x 192 = 384 counts per revolution of the shaft
122, and 5 x 384 = 1920 counts per revolution of the drum 3S
which corresponds to 203.82 counts per inch of linear
displacement of the periphery of the drum. Accordingly, the
maximum mailpiece transport velocity of Vl = 61(10-3) inches
per millisecond may be multiplied by a scale factor of 203.82
counts per inch to express the maximum transport velocity in
terms of counts per millisecond, or, counts per sampling time
period T where T=l millisecond; i.e., 61(10-3) inches per
millisecond times 203.~2 counts per inch = 12.43 counts per
sampling ~ime period T. Similarly, any other target velocity
Vl, or any acceleration or decceleration value, may ~e
e~pressed in terms of counts per sampling time interval T, or
counts per square millisecond, as the case may be, by
utilization of the aforesaid scale factor.
For energizing the D~C. motor 120 (Fig. 1) there i5
provided a power amplifying circuit 300. The power
amplifying circuit 300 (Fig. 7) is conventionally operably
connected to the motor terminals 302 and 304 via power lines
306 and 308 respectively. The power amplifying circuit 300
- 22 -
~z~
preferably comprises a conventional, H-type, push-pull,
control signal amplifier 301 having input leads ~, s, C and
D, a plurality of optical-electrical isolator circuits 303
which are connecte~ on a one-for-one basis between the leads
A-D and four output terminals of the computer 500 for
coupling the control signals from the computer 500 to the
input leads A, B, C, and D of the ~mplifier 301, and a
plurality of conventional pull-up resistors 305 for coupling
the respective leads A-D to the 5 volt source The amplifier
301 includes four conventional darlington~type, pre-amplifier
drive circuits including NPN transistors Tl, T2, T3 and T4,
and four, conventional, darlington-type power amplifier
circuits including PNP transistors Ql, Q2, Q3 and ~4 which
are respectively coupled on a one-for-one basis to the
collectors of transistors Tl, T2; T3 and T4 for driving
thereby. The optical-electrical isolator circuits 303 each
include a light emitting diode Dl and a photo-responsive
transistor T5. The cathodes of Dl are each connected to the
5 volt source, the emitters of T5 are each connected to
ground and the collectors of T5 are each coupled, on a one-
for-one basis, to the b~se of one of the transistors Tl, T2,
T3 and T4. With respect to each of the opto-isolator
circuits 303, when a low logic level signal is applied to the
anode of D1, Dl conducts and illuminates the base of T5
thereby driving T5 into its conductive state; whereas when a
high logic level signal is applied to the anode of Dl, Dl is
non-conductive, as a result of which T5 is in its non-
~onductive state. With respect to each of the combined
- 23 -
3~3
~mplifier circuits, Tl and ?1, T2 and Q2, T3 and ~3, and T4and Q4, when the lead A, B, C or D, as the case may be, is
not connected to ground via the collector-emitter circuit of
the assoclated opto-isolator circuit's transistor T5, the
base of Tl, T2, T3 or T4, as the case may be, draws current
from the 5 volt source via the associated pull-up resistor
305 to drive the transistor Tl, T2, T3 or T4, as the case may
be, into its conductive state. As a result, the base of
transistor Ql, Q2, Q3 or Q4, as the case may be, is clamped
to ground via the emitter-collector circuit of its associated
driver transistor Tl, T2, T3 or T4, thereby driving the
transistor ~1, Q2, Q3 or Q4, as the case may be, into its
conductive state. Contrariwise, th~ transistor pai~s Tl and
Ql, T2 and Q2, T3 and Q3, and T4 and Q4 are respectively
biased to cut-off when lead A, B, C or D, as the case may be,
is connected to ground via the collector-emitter circuit of
the associated opto-isolator circuit's transistor T5. As
shown in the truth table ~Fig. 8) for clockwise motor
rotation, Ql and 74 are turned on and ~2 and ~3 are turned
off; whereas for counter-clockwise motor rotation, Q2 and Q3
are turned on and Ql and ~4 are turned off. Accordingly, or
clockwise motor rotation: terminal 302 ~Fig. 7) of the motor
120 is connected to the 30 volt source via the emitter-
collector circuit of Ql, which occurs when Q2 is turned off
and the base of Q1 is grounded through the emitter-collector
circuit of Tl due to the base of Tl drawing current from the
5 volt source in the presence of a high logic level control
signal at input terminal A; and terminal 304 o the motor 120
- 24 -
"
is connected tc ground via the emitter-collector circuit of
Q4, which occurs when Q3 is turned off and the base of Q4 is
grounded through the emitter-collector circuit of T4 due to
the base of T4 drawing current from the 5 volt source in the
presence of a high logic level signal at the input terminal
D. On the other hand, for counter clockwise rotation of the
motor 120: terminal 302 of the motor 120 is connected to
ground via the emitter collector circuit of Q2, which occurs
when Ql is turned off and the base of Q2 is grounded through
the emitter-collector circuit of T2 due to the base of T2
drawing current from the 5 volt source in the presence of a
high logic level control signal at the input terminal B; and
terminal 304 of the motor 120 is connected to the 30 volt
source via the emitter-collector circuit of Q3, which occurs
when Q4 is turned off and the base of Q3 is grounded through
the emitter-collector of T3 due to the base of T3 drawing
current from the 5 volt source in the presence of a high
logic level control signal at the input terminal C. For
turning off the respective powers transistors Ql-Q4, on a two
at a time basis, low level control signals are applied on a
selective basis to the two terminals B and C, or A and D, as
the case may be, to which high logic control level signals
are not being applied; which occurs when the opto-isolator
circuit's transistors T5 associated with the respective leads
B and C or A and D are driven to their conductive states.
When this occurs the bases of the transistor~ T2 and T3, or
Tl and T4 ~ as the case may be, are biased to open the emitter-
collectors circuits of the transistors T2 and T3, or Tl and
- ~5 -
~2~ 3
T4, as the case may be, as a res~lt of which the bases of thetransistors Q2 and ~3, or Ql and Q4, as the case may be, are
biased to open the emitter-collector circuits of ~ransistors
Q2 and ~3, or Ql and Q4, as the case may be.
The velocity of the motor 120 tFig. 7) is con~rolled
by modulating the pulse width and thus the duty cycle of the
high logic level, constant frequency, control signals, i.e.,
pulse width modulated (PWM) signals, which are timely applied
on a selective basis to two of the leads A-D, while applying
the low level logic signals to those of leads A-D which are
not selected. For example, assuming PWM signals (Fig. 9)
having a 50~ duty cycle are applied to leads A and D (Fig.
7), and low level logic signals are applied to leads R and C,
for clockwise rotation of the motor 120, the velocity of the
motor 120 will be greater than it would be if high logic
level PWM signals (Fig. 9) having a 25% duty cycle were
similarly applied and will he less than it would be if high
logic level PWM signals having a 75% duty cycle were
similarly appliecl. Accordinyly, assuming rotation of the
motor 120 (Fig. 7) is commenced by utilizing high logic level
PWM signals having a given duty cycle percentage, the
velocity of the motor 120 may be decreased or increased, as
the case may be, by respectively decreasing or increasing the
duty cycle percentage of the appliec1 high loc;ic level PWM
signals. Further, assuming the motor 120 is rotating
clockwise due to PWM signals having a selected positive
average value being applied to leads ~ and D, in combination
with low level logic signals being applied to leads B and C,
- 26 -
the motor 120 may be dynamically braked by temporarilyap~lying high level PwM signals having a selected duty cycle
corresponding to a given positive average value to leads s
and C, in combination with low logic signals being applied to
leads A and D. To avoid damage to the power transistors ~1,
Q2, Q3 and ~4 which might otherwise result, for example, due
to current spikes accompanying back emf surges which occur in
the course of switching the circuit 301 from one mode of
operation to the other, the ernitter-collector circuits of the
power transistors Ql, Q2, Q3 and 24 are respectively shunted
to the 30 volt source by appropriately poled diodes, Dl, D2,
D3 and D4 connected across the emitter-collector circuits of
Ql, Q2, Q3 and ~4.
To control the motion of the drum 38 (Fig. 1) during
each cycle of dr~ rotation, the D.C. motor 120 and its shaft
encoder 126 are respectively connected to the computer 500
via the power amplifier circuit 300 and the counting circuit
270. ~nd the computer 500 is programmed to calculate the
duration of and timely apply PWM control signals to the power
amplifier circuit 300 after each sampling time instant Tn,
utilizing an algorithm based upon a digital compensator D(s)
derived from analysis of the motor 120, motor load 38, 74,
76, 90 and 124 amplifying circuit 300, encoder 126, counting
circuit 270, and the digital compensator D(s) in the closed-
loop, sampled-data, servo~control system shown in Fig. 10.
With reference to Fig. 10, in general, at the end of
each predete~rmined sampling time period of T=l millisecond,
the eight bit wide count representing the angular
- 27 -
displacement of the motor drive shaft 1221 and thus the drum38, from its home position is sampled by the computer 500 at
the time ins~ant Tn. Under the control of the program of the
computer 500 (Fig. 10), a summation is taken of the aforesaid
actual count and the previously calculated count repr2senting
the desired position of the motor drive shaft 122, and thus
the drum 38, at the end of the time period T, and, under
control of the computer program implementation of the
algorithm, a PWM control signal which .is a function of the
summation of the respective counts, or error, is applied to
the power amplifier circuit 301 for rotating the motor drive
shaft 122 such that the error tends to become zero at the end
of the next sampling time period T.
To derive the algorithm, the servo-controlled system
of Fig. 10 is preferably analy~ed in consideration of its
equivalen~ Laplace transformation equations shown in Fig. 11,
which are expressed in terms of the following Table of
Parameters and Table of Assumptions.
Table I - Parameters
,_ .
Parameter Symbol Value and/or
Dimenslon
Zero-Order-Hold ZOH None
Laplace Operator S jw
Sampling Interval T Milliseconds
P~ D.C. Gain Kv Volts
PWM Pulse Amplitude Vp 5 Volts
- 28 -
PW~ Pulse Width tl 10-6 Micro-
seconds
P~wer Switching Circuit Gain Xa None
Motor back e.m.f. Constant Ke 0.63 Vol~s/
radian/second
Motor Armature Resistance ~a 1.65 Ohms
Motor Armature Moment of Ja 2.12 (10-5)
Inertia kilograms (~eters2)
Motor Torque Constant Kt 0.063 Newton-
Meter s/am2
Drum Moment of Inertia Jl 70.63 (10-5)
kilograms (meters2)
Gear Ratio, Motor to Load G 5:1, None
Motor Armature Inductance La 2.76 Millihenrys
Motor Shaft Encoder Gain Rp Counts/radian
Motor Shaft Encoder Constant Kb 192 Lines/
revolution
Counting Circuit ~ultiplier Xx 2, None
Motor Gain Rm 16, None
Poles in frequency domain fl;f2 48;733 Radians/
second
Starting Torque Gain Kc None
System Overall Gain Ko None
Table II - ~ssumptions
ZGH: Since the output and input are held constant during
each sampling period a zero-order-hold is assumed to
approximate the analog time function being sampled.
Veq.: Since the integral of the voltage in time is assumed
equal to the area under the PWM pulse, the output
from ~he PWM is linear.
~ 29 -
:~3~
With reference to Fig. 10, D(S) is the unknown
transfer function of an open loop compensator in the
frequency domain. Due to a key factor for providing
acceptably fast motor response being the systemls resonance
between the motor and load, the derivation of the transfer
function D(S) for stabilization of the system i5 preferably
considered with a view to maxi~izing the range of frequencies
within which the system will be responsive, i.e., maximizing
the system's bandwidth, Bw. For calculation purposes a
sampling period of T=l millisecond was chosen, due to having
chosen a Model 8051 microprocessorr available from Intel
Corporation, Palo Alto California, for control purposes, and
inasmuch as the Model 8051 microprocessor equipped with a 12
MHz crystal for providing a clock rate of 12 MHz, is able to
conveniently implement a 1 KHz sampling rate and also
implement application software routines, after control
algorithm 1terations7 during the sampliny period of T=l
millisecond. ~lowever, other sampling periods and other
conventional microprocessors may be utilized without
departing from the spirit and scope of the invention.
The open loop system gain Hl(S) without compensation,
of the servo-loop system of Fig. 10 is shown in Fig. 12(a).
To tolerate inaccuracies in the transmission system between
the motor and drum load, such as backlash, it was considered
acceptable to maintain a steady-state count accuracy of plus
or minus one count. To reflect this standard, the gain
equation oE Fig. 12ta) was adjusted to provide a corrective
torque Ct with a motor shaft movement, in radians per count,
- 30
~ j
equivalent to the inverse expressed in radians per count, of
the gain Kp of the encoder counting circui~ transfor~. Since
the corrective torque Ct is primarily the friction of the
transmission system which has to be overcome by the motor at
start-up, the value of Ct msy be assumed to be substantially
equal to a maximum estimated numerical value based on actual
measurements of the starting friction of the system, i.e., 35
ounce-inches, as a result of which a numerical value of the
starting voltage VS may be calculated from the expression VS
= (Ct)Ra/Kt, i.e., Vs = 6.5 volts, which, in turn, permits
calculation of a numerical value for the minimum overall
system gain Ko~ at start-up, from the equation Ko = Ys/Kp,
i.e., Ko = 397 volts per radian, or for simplication
purposes, 400 volts/radian. ~ccordingly, the open~loop
uncompensated gain Hl(S) may be rewritten as H2(S) as shown
in Fig. 12(b), in which a gain factor of Rc has been
included, to account for the torque Ct and the value of Ko
is substituted for the overall D.C. gain, i.e.,
~KV)(Km)(Kp)(Xa)(Kc) = Ko~ Although the numerical value of
~c may also be calculated, it is premature to do so, since it
has not as yet been established that Ko~ which has been
adjusted by the value of Rc to provide a minimum value of K
is acceptable for system stability and perormance purposes.
Otherwise stated, Ko may not be the overall system gain which
is needed for system compensation for maximizing the system
bandwidth BW, as a result of which it is premature to
conclude that Xc will be equivalent to the D.C. gain of the
system compensator ~S).
- 31 -
At this j~lncture, the B~de diagram shown in Fig. 13,
ma~ be c~nstructed due to having calculated a minimum value
f~r ~O. ~s sh~wn in Fig. 13, the abs~lute value of H2(S), in
decibels, has been plotted against the frequency W in radians
per second, based on the calculated minimum value of Ko~ the
selected value of T and calculated values of the poles fl and
f2. From the Bode diagram, a numerical value of the cross-
over frequency Wcl of the Bode plot of H2(S) may be
determined, i.e., Wcl was found to be substantially 135
radians per second. And, since the value of Wcl is
substantially equal to the bandwidth BWU of the uncompensated
open-loop system H2(S), a calculation may be made of the
phase margin em of the uncompensated system from the
expression 0m = 180~ - e [H(S)] at Wcl, or, otherwise stated:
a 1 f Wcl ) -tan~l(Wcl/fl)-tan~l(W l/f2) tan~l
(WClT/2). From this calculation, there was obtained a phase
margin value which was much, much, less (i.e., 5) than 45,
which, for the purposes of the calculations was taken to be a
minimum desirable value for the phase margin 0m in a position-
type servo system. Accordingly, it was found that the
uncompensated system H2(S) was unstable if not compensated.
Since an increase in phase lead results in an increase in
bandwidth BW, and the design criteria calls for maximizing
the bandwidth BW and increasing the phase margin to At least
95~; phase lead compensation was utili~ed.
By definition, a phase lead compensator D(S) has the
Laplace transform shown in Fig. 14, wherein ~c is the phase
lead D.C. gain, and fz and fp are respectively a zero
- 32 -
~2~ 3
frequency and a pole frequency. ~dding the transferfunction of the phase lead compensator D(S) to the Bode
plot of the uncompensated system's transfer function
H~(S), results in the Bode plot of the compensa-ted
system -transfer function H3 (S), if the zero frequency fz
of -the phase lead compensator D (S) is chosen to be
equivalent to fl in order to cancel the lag due to the
mechanical time constant of the uncompensated transfer
function H2S. As shown in Fig. 13, the cross-over
frequency Wc2 for the compensa-ted system H3(S) may be
read from the Bode diagram, i.e., Wc2 was found to be
substantially equal to 400 radians per second. Andl
since by definition the cross-over frequency Wc2 lies at
the yeometric means of fp and fz, the value of the fp
may be established by doubling, from fz, the linear
distance between Wc2 and f~, as measured along the
logarithmic frequency axis, W, and reading the ~alue of
fp from the Bode diagram, i.e., fp was found to be
substantially equal to 3,400 radians per second. Since
numerical values may thus be assigned to both Wc2 and fp
from the Bode diagram, the compensated phase margin mc'
i.e., the phase margin for the phase lead compensated
system H3lS3 in which fz has been equated to fl, may be
found from the expression Omc=180-90-tan l(WC2/f2)
tan (WC2T/2). Upon calcula-ting the compensated phase
margin mc it was found to be 50 and, therefore,
greater than the minimum phase margin criteria of 45.
In addition, the value of Wc2 for the compensated system
H3(S) was found to be substantially three times that of
the uncompensated system H2(S), as a result of
-33-
,; .;
~ 23~
~L ~
w~ich the bandwidth BW of the system H(S) w~s increased by a
factor of substantially three to BWC.
At this juncture, the compensated system H3(S) is
preferably anal.yzed with reference to the system's overshoot
s and settling time tS based on a calculation of the system
damping factor df and the assumption that the system will
settle in five times constants, i.e., tS=5tX. The relevant
values may be calculated or estimated, as the case may be,
from the expressions, for df, o5, tx and tS shown in Fig. 15.
In connection with this analysis~ reference is also made to
the typical mailing machines hereinbefore described, wherein
a maximum drum cycle time period TCt (Fig. 3) of 234
milliseconds and a maximum mailpiece transport speed (Fig. 2)
of 61 inches per second are typical values. Assuming the
velocity profile of Fig. 3, and, as previously discussed an
acceleration time period of Ta=37 milliseconds, a constant
velocity time period of TC=124 milliseconds and deceleration
time period of Td=24 milliseconds, the longest permissible
settling time for the system was calculated, i.e., TCt
(Ta+TC+Td) = 234-185 = 49 millis~conds. For analysis
purposes a series of calculations of the aforesaid system
characteristics and phase margin were performed, assuming
incremental increases in the overall system gain Kol while
hol.ding fz=fl. The results of such calculations are shown in
the following Table III.
- 3~ -
~23~
Table III - H~(S) with f~--f~
KO=sys~em ~c=sw ~m=Phase 05=overshoot tS=settling
gain (rad.~sec.~ ~argin (deg.) (percent) time (~S.)
400 400 50 28 28.67
~47 45~ 46 31 27.78
501 500 42 34 27.50
56~ 550 38 38 27.41
As shown in Table III, the system bandwidth ~-~ may be
maximized at 450 radians per second while maintaining a phase
margin 0m of at least 45 the two design criteria discussed
above. Although this results in an increase in system
overshoot s accompanied by a negligible decrease in the
settling ti~e tS~ the settling time tS is well within the
maximum allowable settling time, Ts=49 milliseconds. On the
other hand, if a bandwidth of 400 radians per second is
acceptable, it is desirable to reduce the percentage of
overshoot Os~ and increase the phase margin to emc~50 to
provide for greater system stability than would be available
with a phase maryin value (i.e., 46) which i5 subgtantially
equal to the design criteria minimum of 45; in which
instance it is preferable to choose the bandwidth of BW=400
radians per second, overshoot of Os=28% and compensated phase
margin of emc=50- For the example given, a compensated
Bandwidth of ~Wc=400 radians per second is acceptable
inasmuch as ~orst case load conditions were assumed. In
this connection it is noted that the foregoing analysis is
based on controlling a postage meter drum, which has a high
~oment of inertia, contributes high system friction, and
- 35 -
~,
calls for a cyclical start-stop rnode of operation during
which the load follows a predetermined displacement versus
time trajectory to accommodate the maximum mailpiece
transport speed in a typical mailing machine. Accordingly,
the compensated system bandwidth BWC=400 radians per second
may be chosen, as a result of which the overall system gain
Ko may be fixed at Ko=400~ and the value oE Kc may be
calculated from the expression KC=Ko/(Kv)(Ka)(Kp). Since
fz=fl, and fl and fp are also known, the Bode plot of the
compensator D(S), Fig. 14, may be added to the Bode diagram
(Fig. 13) wherein the system compensator D(S) is shown as a
dashe~ line.
Since the analog compensator D(S) was derived in the
frequency domain, D(S) ~as converted to its Z-transform
equivalent D(Z) in the sampled data domain for realization in
the form of a numerical algorithm for implementation by a
computer. Of the numerous well-known techniques or
transforming a function in the frequency domain to a function
in the sampled-data domain, the bi~linear transformation may
be chosen. For bi-linear transformation purposes the Laplace
operator S is defined by the expression shown in Fig. 16.
Using the values K~=13.64, fz=fl=48, and fp=3,400 in the
expression for D(S) shown in Fig. 14, and substituting the bi-
linear transfor~ation expression for S shown in Fig. 16 and
the sampling interval T=l millisecond, in the expression
shown in Fig. 14 results in the expression for D(Z) shown in
Fig, 17~ As shown in Fig. 11, D(T)=output/input=g(T)/e(T),
which, in the sampled data domain is expressed by the
- 36 -
~2~ 3
equation D(Z)-G(Z)/E(Z). Accordingly, the expression for
D(Z) shown in Fig. 17 may be rewritten as shown in Fig. 18a.
Cross-multiplying the equivalency of Fig. 18a results in the
expression shown in Fig. 18b, which defines the output G(Z)
in the sampled data domain of the system compens~tor D(S).
Taking the inverse Z transform of the expression shown in
Fig. 18b, results in the expression shown in Fig. 19 which
defines the output G(Tn) in the time domain of the system
compensator D(S), and is a numerical expression of the
algorithm to be implemented by the computPr for system
compensation purposes. As shown by the expression in FigO 19
and in the following Table IV the output of the digital
compensator for any current sampling instant Tn is a function
of the position error at the then current sampling time
instant Tn~ is a function cf the position error at the end of
the next previous sampling time instant ~n-l and is a
function of the algorithm output at the end of the next
previous sampling time instant Tn_l.
TABLE IV
~ . ~
Function Definition
G(Tn) Algorithm output for current sampling time
instant Tn
E(Tnl Position error for current sampling time
instant ~n
G(Tn 1) Algorithm output for next previous sampling
time instant Tn-l
E(Tn-t) Position error for next previous sampling
time instant Tn_
- 37 -
~2i~ 3
K1r K2 & K3 Constants of the compensated sy~m which
aIe a function of the parameters of the
motor load and system friction for a
sampling time period of T~l millisecond.
Accordingly, the algorithm which is to be implemented
by the computer 500 for system compensation purposes is a
function of a plurality of historical increments of sampled
data for computing an input value for controlling a load to
follow a predetermined position trajectory in a closed loop
sampled-data servo-control system.
As shown in Fig. 20 the computer 500 preferably
includes a conventional, inexpensively commercially
available, high speed microprocess~r 502, such as the Model
8051 single chip microprocessor commercially available from
Intel Corporation, 3065 Bowers ~venue, Santa Clara,
California 95051. The microprocessor 502~ generally
comprises a plurality of discrete circuits, including those
of a control processor unit or CPU 504, an oscillator and
clock 506, a program memory 508, a data memory 510, timer and
event counters $12, programmable serial ports 514,
programmable I/O ports 516 and control circuits 518, which
are respectively constructed and arranged by well known means
for executing instructions from the program memory 508 that
pertain to internal data, data from the clock 506, data
memory 510, timer and event counter 512, serial ports 514,
I/O ports 514 interrupts 520 and/or bus 522 and providing
appropriate outputs from the clock 506, serial ports 514, I/O
ports 516 and timer 512. A more detailed discussion of the
internal structural and functional characteristics and
- 3~ -
features of the Model 8051 microprocessor, including optionalmethods of pr~gramming p~rt 3 f~r use as a conventional bi-
directional port, may be found in the Intel Corporation
publicati~n entitled MCS-51 Family ~f Single Chip
Microcomputers ~sers Manual, dated January 1981.
For implementing the sampling time period of T=l
millisecond, one of the microprocessor~s timer and event
counters 512 (Fig. 20) is conventionally programmed as a
sampling time period clock source. To that end, a timer 512
is programmed for providing an interrupt signal each 250
microseconds, and each successive fourth interrupt signal is
utilized as a clock signal for timing the commencement of
successive sampling time periods of T=l millisecond.
In general, as shown in Fig. 21, at the commencement
of each sampling time period of T=l millisecond, during the
sampling instant Tnr a sample is taken of the count
representative of the actual angular displacement of the
motor drive shaft and, substantially immediately thereafter,
the actual count is summed with the count representative of
the desired angular displacement of the motor drive shaft
which was calculated during the next preceeding time period T
in order to obtain the then current error value E(Tn) for
calculating the then current compensation algorithm output
value G(Tn). Due to the recursive mathematical expression
for G(Tn) [Fig. 19] being a function of the then current
error value E(Tn), the next previous error value E(Tn_l) and
the next previous compensation algorithm output value
G(Tn_l), the expression for G(Tn) is preferably separated
39 -
~ 6~ ~ ~
into tw~ comp~nents for calculation purposes, i.e., G(~rl~ =
gl + 92i wherein gl = Kl ~ ~(Tn)~ and wherein g2 = -[K2 x
E(Tn-l) + K3 x G(Tn-l)]l to permit calculation of the value
of g2 in advance of the time period T when it is to be added
to the value of gl for calculating the value of G(Tn),
thereby reducing to a negligible value (in view of the time
period T) the time delay Tdy before completion of sampling
the actual displacement of the motor drive shaft at the
instant Tn and applying the PWM motor control signal to the
output ports of the microprocessor. For example, when
calculating the value of G(Tn) based upon the first error
value resulting from the summation of the counts representing
the desired and actual angular displacements of the motor
drive shaft, the value of g2 is by definition equal to zero
since the error signal E(Tn_l) is equal to zero, due to the
desired and actual angular displacement values during the
next previous sampling time period T having been equal to
each other. Accordingly, upon obtaining the value of ~he
first error signal El(Tn), the value of Gl(Tn) may be
calculated as being equivalent to gl, i.e., Gl(Tn) = gl = K
x El(Tn). And, upon calculating Gl(Tn) the value of g2 for
use in calculating the next successive compensation algorithm
output value G(Tn+l) may be calculated for subsequent use,
since g2(Tn+l) = -lK2 x El(Tn~ ~ K3 x Gl~Tn)], and K~, K3,
El(Tn) and Gl(Tn) are all known values. In addition, during
any given time period T, a calculation may be made of the
desired angular displacement of the motor drive shaft or the
next subsequent time period T. Preferablyr the
- 40 -
~L23~
microprocessor is programmed for implementation of theaforesaid calculation process to facili~ate early utilization
of the compensation algorithm output value G(Tn) for driving
the D.C. motor. Accordingly, the microprocessor is
preferably programmed for: during the first sampling time
period Tl, sampling the count representative of the actual
angular displacement of the motor drive shaft at the time
instant Tn, then taking the summation of that count and the
previously calculated value of the desired angular
displacement of the motor drive shaft to obtain the first
error value El(Tn), then calculating the first compensation
algorithm output value Gl(Tn) = Kl x El(Tn) ~92~ wherein
92=~ and generating a PWM motor control signal
representative of Sl(Tn), then calculating the value of g2
for the next sampling time period, i.e., g2 = -~R2 ~ El(Tn) ~
K3 x Gl(Tn)3, and then calculating the count representing the
desired anqular displacement of the motor drive shaft for use
during the next sampling time period T2; during the second
sampling time period T2, sampling the count representative of
the actual angular displacement of the motor drive shaft and
taking the summation of that count and the previously
calculated desired count to obtain the error value E2(Tn+l),
calculating the compensation algorithm output value G2(Tn+l)
= Kl x E2(Tn+l) ~ ~2 = Kl x ~2(Tn+l) - K2 x El(Tn) - R3 x
Gl(Tn), and generating a PWM motor control signal
representative thereof, then calculating the value of g2 for
the next sampling time period T3, i-e-, g2 -[K2 x E2(Tn+l) +
R3 x G2(Tn+l)], and then calculating the c~unt representative
- 41 -
~23~
of the desired angular displacement of the motor drive shaftfor use during the time period T3; and so on, during each
successive sampling time period.
Accordingly, as shown in Fig. 21, the microprocessor
is programmed for i~nediately after calculating the ~hen
current com?ensation algorithm output value G(Tn), and thus
while the calculation of the value of g2 for the next
sampling time period is in progress, generating a motor
control signal for energizing the power amplifier. For this
purpose, the relative voltage levels oE motor contr~1 signal
are determined by the sign, i.e., plus or minus, oE the
compensation algorithm output value GtTn), and the duty cycle
of the control signal is determined by the absolute value of
the compensation algorithm output value G(Tn). Preferably,
for timing the duration of the motor control signal, the
other timer and event counter 512, i.e., the timer 512 which
was not used as a sampling time period clock source, is
utilized for timing the duration of the duty cycle of the
motor control signal. For examplel by loading the absolute
value of the G(Tn) into the other timer 512, commenciny the
count, and tirnely invoking an interrupt for terminating the
duty cycle of the control signal. As shown in Fig. 21tc),
the time delay T~y from co~nencement of the time period T to
updating the PWM motor control signal at the output ports of
the microprocessor is substantially 55 microseconds, and the
time interval allocated for calculating the value of g2 and
he count representative of the desired angular displacement
of the motor drive shaft for use during the next time period
~:3~3
is substantially 352 microseconds. As a result,
substantially 593 microseconds of microprocessor calculation
time is available during any given sampling time period T=l
millisecond for implementing non-motor control applica~ions.
As shown in Fig. 22 the computer 500 is preferably
modularly constructed for segregating the components of the
logic circuit 501a and analog circuit 501b of the computer
500 from each other. To that end, the respective circuits
501a and 501b may be mounted on separate printPd circuit
boards which are electrically isolated from each other and
adapted to be interconnected by means of connectors located
along the respective dot-dash lines 516, 527 and 528. In any
event, the components of the logic circuit 521a and analog
circuit 521b are preferably electrically isolated from each
other. To that end, the logic circuit 501a preferably
includes 5V and ground leads from the mailing machine's power
supply for providing the logic circuit 501a with a local 5
volt source 530 having 5V and GND leads shunted by filter
capacitors Cl and C2. And the analog circuit 501b includes
30 volt and ground return leads rom the mailing machine's
power supply for providing the analog circuit 501h with a
local 30 volt source 536 including 30V and GND leads shunted
by filter capacitors C3 and C4. In addition, the analog
circuit 501b includes a conventional 30 volt detection
circuit 542 having its input conventionally connected to the
analog circuit's 30 volt source 536, and its output coupled
to a power up/down lead from the analog circuit via a
conventional optical-electrical isolator circuit 544.
- ~3 -
~L~3~
Further, to provide the anal~g circuit 501b with a local 5volt source 546, the analog circuit 501b is equipt with a
conventional regulated power supply h~ving its input
appropriately connected to the analog circuit's 30 volt
source 536 via a series connected resistor Rl and a 5 volt,
voltage regulator 548. A zener diode ~1, having its cathode
shunted to ground and having its anode connected to the input
of the 5V regulator 548 and also connected via the resistor
Rl to the 30 volt terminal line, is provided for maintaining
the input to the 5V regulator 548 at substantially a 5 volt
level. In addition, a pair of capacitors C5 and C6 are
provided across the output of the regulator 548 for
fiitration purposesO
To accommodate interfacing the postage meter's
computer 41 (Fig. 1) with the computer S00, any two available
ports of the computer 41 may be programmed or two-way serial
communications purposes and coupled to the computer 500. For
example, the postage meter's printing module 41c may be
conventionally modified to include an additional two-way
serial communications channel for communication with the
computer 500.
Assuming the latter arrangement, serial input
communications to the computer S00 ~Fig. 22) are received
from the postage meter computer's printing module 41c via the
serial input lead to the logic circuit 501a (Fig. 22), which
is operably coupled to port P30 of the microprocessor 502 by
means of a conventional inverting buffer circuit 550.
Accordingly, port P30 i5 preferably programmed for serial
- 44 ~
input comm~nications, and the input to the buffer circuit 550
is resistively coupled to the logic circuit's 5 volt source
530 via a conventional pull-up resistor R2. Serial output
communications from the microprocessor 502 are transmitted
from port P31. Accordingly, port P31 is preferably
programmed for serial output com~unications, and is operably
coupled to the input of a conventional inverting buffer 552,
the output of which is resistively coupled to the logic
circuit's 5V source 530 via a suit~ble pull-up resistor R2
and is additionally electrically connected to the serial
output lead from the logic circuit 501a.
Since it is preferable that the microprocessor 502 be
reset in response to energization of the lo~ic circuit 501a,
the logic circuit's 5V source 530 is connected in series with
an R-C delay circuit and a conventional inverting buffer
circuit 554 to the reset pin, RST, of the microprocessor 502.
The R-C circuit includes a suitable resistor R3 which is
connected in series with the logic circuit's local 5V source
530 and a suitable capacitor C7 which has one end connected
between the resistor R3 and the input to the buffer circuit
554, and the other end connected to the logic circuit's
~round return.
In addition to the VCC and GND (i.e., VSS) ter~inals o~ ~e
microprocessor 502 being respectively conventionally
connec~ed to the logic circuit's 5 volt source and ground,
since the microprocessor 502 does not utilize an external
program memory, the F,A terminal is connected to the logic
circuit's 5V source. And, since no other external m4mory is
used, the pr~gram storage enable and address latch enable
terminals, PSE~ and ALE are not used. In addition to the
EA terminal being available for future expansion, ports Pls-
P17, ports P20-P27, the read and write terminals, RD and WR,
and one of the interupt terminals INTO/P32 are also available
for future expansi~n.
In general, the microprocessor 502 is programmed for
receiving input data from the postage meter drum's home
position encoder 82 each of the envelope sensors 56, 58 and
the D.C. motor shaft encoder 126, and, in response to a
conventional communication from the postage meter's printing
module 41c, timely energizing the D.C. motor under the
control of the CP~ of the microprocessor 502. Port P0 is
programmed for receiving a transition signal representative
of the disposition of the postage meter's drum 38 at its home
position; transition signals from the envelope sensors 56 and
58 which represent detection of the leading edge of a
mailpiece or other sheet 16 being fed to the drum 38 to
permit calculation by the computer 500 of the velocity of the
mailpiece and thus the desired angular displacement of the
D.C. motor shaft 122 and thus the drum 38; and a count
representative of the actual angular displaçement of the D.C.
motor shaft 122. Preferably, port P0 is multiplexed to
alternately receive inputs from groups of the various
sensors, under the control of an output signal from Port P34
of the microprocessor 502. The shaft encoder 82 which is
utilized for sensing the home position of the postage meter
drum 38 is coupled to the computer 500 via the drum home
- 46 -
position lead of the logic circuit, which, in turn, isconnected to one input of a differential amplifier 562, the
output of which is connected to the other input of the
differential amplifier 562 via a feedback resistor R4. The
aforesaid other input to the amplifier 562 is also
resistively coupled, by means of a resistor R5, to the mid-
point of a voltage divider circuit including resistors R6 and
R7. Resistors R6 and R7 are connected in series with each
other and across the logic circuit's 5V source and ground
return leads. The LED sensors 56 and 58, which are utilized
for successively sensing the leading edges of each envelope
being fed by the letter transport, are separately coupled to
the computer S00 via the en~elope sensor-l and envelope
sensor~2 input leads of the logic circuit 501a. In the logic
circuit 501a, the envelope sensor-1 and sensor-2 leads are
connected on a one-for-one basis to one of the inputs of a
pair of conventional amplifiers 564, the other inputs of
which are connected together and to the mid-point of a
Yoltage divider including resistors R8 and R9. Resistors R8
and R9 are connected in series with each other and 2cross the
logic circuit's 5V source and ground return leads. Further,
the three output signals fxom the differential amplifier 562
and the two amplifiers 564 are connected on a one-for-one
basis to the three input ports POo-2 of the microprocessor
502, each via a conventional tri-state buffer circuit 566,
one of which is shown. The input signals A and B from the
D.C. motor ~haft encoder 126 are coupled to the logic circui~
501a
- ~7 -
~3~ 3
by means of leads A and B, which are conventially
electrically connected to the counting circuit 270 to provide
the micropr~cessor 502 the the count representative of the
actual angular displacement of the mot~r shaft 122 from its
home position. The counting circuit's leads Q0-Q7 are
electrically con~ected on a one-f~r-one basis to Ports POo-
PO7 of the microcomputer 502 via one of eight conventional
tri-state buEfer circuits 568, one of which is shown, having
their respective control input leads connected to each other
and to the output of a conventional inverting buffer circuit
570, which has its input conventionally connected port P34 of
the microprocessor 502. Thus, either the three input
signals, i.e., from the drum home position and the two
envelope position sensors are operably electrically coupled
to Ports POo-P02 of the microprocessor 502, or the eight
input signals Q0-Q7 from the counter circuit 270 are operably
electrically coupled to ports POo-PO7 of the microprocessor
502, for scanning purposes, in response to an appropriate
control signal being applied to the respective buffer
circuits 566 and 568 from port P3~ of the microprocessor 502.
In operation, assuming a low logic level signal is re~uired
for activating either of the sets of buffers 566 or 568; when
the microprocessor 502 applies such a signal to port P34, the
buffer circuits 566 operate, whereas since the buffer circuit
570 inverts this signal to a high logic level signal before
applying the same to the buffer circuit 568, the latter is
inoperative. Conversely, a high logic level siqnal from port
P34 will operate buffer circuits 568 and not operate the
- 48 -
buffer circuits 566. Accoraingly, d~pendins upon the level,high or low, of the signal from port P34 of the
microprocessor 502, the eight bit input to one or the other
buffer circuits 566 or 568 will be made available to port Po
for scanning purposes. Aside from the foregoing, to permit
the microprocessor 502 to clear the counter 2~0 for any
reason in the course of execution of the program, port P35 is
connected to the clear pin CLR of the counter 270 via a
conventional inverting buffer 572, and the microprocessor 502
is programmed for timely applying the appropriate signal to
port P35 which, when inverted, causes the counting circuit
270 to be cleared~
In general, ports Plo-P13 are utilized by the
microprocessor 502 for providing pulse width modulated (PWM)
motor control signals for controlling energization of the
D.C. motor 120 and port P14 is utilized by the microprocessor
502 for controlling energization of the solid state, A.C~
motor, relay 52 and thus operation of the mailpiece conveyor
49. To that end, ports Plo-P14 of the microprocessor 502 are
each conventionally electrically connected on a one-for-one
basis to the inp~t of a conventional inverting buffer circuit
580, one of which is shown. The outputs of each of the
buffer circuits 580 are sonnected on a one-for-one basis, via
a conventional resistor R10, to output leads from the logic
circuit 501b, one of which is designated solid state, A.C.
motor, relay, and four of which are respectively designated
~1, T3, T2 and T4, since, as shown in Fig. 7, the four
preamplifier stages of the power amplifier utilized for
-- 0,9 --
~:3~
driving the D.C. motor 120 include the t~ansist~rs Tl-T4.
Thus, the upper nibble of the signal from port Pl is utilized
for controlling energization of the D.C. motor and one bit of
the lower nibble is utilized for controlling energization of
the solid state, h.C. motor, relay 52 and thus the A.C. motor
50. In the analo~ circuit 501b, each of the leads Tl, T2,
T3, T4 and solid state relay, from the logic circuit 501a, is
electrically connected on a one-for-one basis to the anode of
the light emitting diode Dl of five, conventional, photo-
transistor type, optical-electrical isolator circuits 303.
Since the cathodes of the light emitting diodes Dl of the
opto-isolator circuits 303 are connected to each other and to
the 5 volt lead from the analog circuit 501b which extends to
the 5 volt source of the logic circuit 501a, the motor
control signals are isolated from the power system of the
analog circuit 501b to avoid having spurious noise signals in
the analog circuit 501b and its components interfere with the
control signals generated by the microprocessor 502. The
analog circuit 501b also includes a lead, designated power
up/down, which extends from the analog circuit 501b to the
logic circuit 501a and is connected to the microprocessorls
interrupt INTI, port P33, to provide the microprocessor 502
with an appropriate input signal when the power i5 turned on,
off or fails. In the analog circuit 501b, the power up/down
lead from the logic circuit 501a is coupled to the thirty
volt detect circuit 542 by means of a conventional opto-
isolator 544, the power up/down lead being electrically
connected to ground through collector-emitter circuit of the
-- ~0 --
opto-isolator's photo-transistor when the light emitting
diode Dl is lit in response to the D.C. supply voltage lev~l
matching the internal reference voltage level~ e.g~, 30
volts, of the 30 volt detection circuit.
In the analog circuit 501b each of the output~ from
the photo-transistors of each of the opto-isolators 303 are
resistively coupled to the analog circuits 5V source by means
of a conventional pull-up resistor 305, and the emitters of
the photo-transistors T5 are connected to the analog
circuit's ground system. In addition, the collectors of the
photodiodes of the opto-isolators 303, which are utilized for
transmitting the motor control signals from ports Plo-P13 of
the microprocessor S02 are connected on a one-for-one basis
to the appropriate input leads A, B, C and D of the power
amplifiers shown in Fig. 7, the outputs of which are
connected to the D.C. motor 120. Further, the collector of
the photodiode of the opto-isolator 303 which is utilized for
transmitting the A.C. relay control signals from port P14 of
the microprocessor 502 is connected to the input lead of a
conventional darlington-type power ampliEier 550, the output
of which is conventionally connected to the mailing machine's
30 volt D.C. source via a solid state, A.C. motor, relay 52,
which is turn conventionally connected for energizing the
A.C. motor 50 from the local A.C. sollrce.
In general, the computer 500 includes three software
programs, including a main line program Fig. 23, a transmit
and receive program and a command execution program,
respectively identified by the 600, 700 and B00 series of
- 51 -
~Z3~39~3
numbers. When the mailing machine l0 is energized byactuation of the main power switch 24, the resulting low
level logic signal from D.C. supply is applied to the reset
terminal RST of the computer's microprocessor 502, thereby
enabling the microprocessor 502. Whereupon, as shown in Fig.
23, the microprocessor 502 commences execution of the main
line program 600.
The main line program 600 ~Fig. 23) commences with
the step of conventionally initializing the microprocessor
602, which generally includes establishing the initial
voltage levels at the microprocessor's ports, and interrupts~,
and setting the timers and counters. Thereafter, the D.C.
motor drive unit is initialized 604. Step 604 entails
scanning the motor home position sensor input port PO0, to
determine whether or not the D.C. motor 120 is located in Its
home position and, if it is not, driving the motor 120 to its
home position. ~ssuming the D.C. motor 120 is in its home
pos1tion, either before or after the initiali~ation step 604,
the program then enters an idle loop routine 606.
In the idle loo~ routine 606, a determination lS
initially made as to whether or not the sampling time period
of T=l millisecond has elapsed, step 60B, it;being noted~that
each successive sample is taken at the time instant Tn;
immediately after and in response to the fourth 250
millisecond interrupt generated by the timer uti~lized~for
implementing the~sampling;t1me per1od~T. Assuming the time
period T has not elapsed, the program loops to idle 606. On
the other hand, ass~uming the time~period~T has elapsed, the
52 ~
~: :
~3~
microprocessor 502 updates the servo-control system, step
610. F~r the purpose of explaining step 61Q it will be
assumed until otherwise stated that the desired location of
the postage meter dr~n 38, and thus the motor drive shaft
122, is the home p~sition. Step 610 includes the successive
steps 610a and 610b, respectively, of sampling the count of
the actual position Pa of the motor drive shaft 122 at the
sampling time instant Tn~ and fetching the previously
computed count representing the desired position Pd of the
shaft 122 at the same sampling time instant Tn. If for any
reason the motor drive shaft 122 is not located in its home
position when the value of the desired position count Pd(Tn)
is representative of the home position location, then the
values of Pa~Tn~ and Pd(Tn) will be different. On the other
hand, if the motor drive shaft 1~2 is located in its home
position when the desired position count Pd(Tn1 is
representative of the home position location, then the values
of Pa(Tn) and Pd(Tn) will be the same. Accordingly,
computation of the error count, 610c, may or may not result
in an error count value E(Tn) of zero. Further,
independently oE the computed value of E(Tn), the computed
value G(Tn) of the motor control signal~ step 601d, may or
may not result in a value of G(Tn) of zero; it being noted
that although step 610c results in a computed value of
E(Tn)=O, the value of g2 may not be e~ual to zero due to the
computed value of the error for the next previous sampling
time instant E(Tn_l~ having resulted in a non-zero value,
~tep 610g. ~ssuming steps 610c and 610d both result in zero
~ ~3 -
13
value computations, then, upon updating and generating thePWM motor control signal, step 610e, no motor control signal
will be generated. Under any other circumstances, step 610e
will result in generating a P~M motor control signal for
driving the D.C. motor 120, and thus the drum 38, to its hom~
position. Thereafter, as shown in step 610f, the computed
values of E(Tn) and G(Tn) are utilized as the values of
E(Tn_l) and G(Tn_l) respectively for pre-calculating the
value of g2 for the next subsequent time instant Tn~
Accordingly, the computation made in the next step,
610g, to obtain the value of g2 for the next sampling time
instant Tn is made by utilizing the replacement values
E(Tn-l) and G(Tn-l). Thereafter, as shown in step 610h, the
desired position count Pd for the next sampling time instant
Tn is made, which, as previously stated has been assumed to
be representative of location of the motor drive shaft 122 in
its home position. At this juncture it should be noted that
the next step 612 in the program is to determine whether or
not the enable flag is set, and, as hereinafter further
discussed, this inquiry will be ans~ered in the negative,
causing the program to return to idle 606, unless a command
has been received from the postage meter's computer 41 which
results in feeding a mailpiece 16 to the postage meter drum
38. Accordingly, until a mailpiece 16 is fed to the postage
rneter drum 38, the main line program will continuously loop
through steps 60B, 610 and 612. As a result the motor drive
shaft 122, and thus the drum 38, will be driven to the home
position, against any force tending to move the drum 38 or
~ ~4 -
shaft 122 out of the home position, u~til a mailpiece 16 isfed to the drum 38.
At this juncture it will be assumed that the enable
flag is set, as a result of which the inquiry of s~ep 612 is
answered affirmatively, or, as above stated, a mailpiece 16
is being fed to the drum 38. Accordingly, the microprocessor
502 commences polling the ports connected to the envelope
sensors 56 and 58, step 61Ç. Since polling occurs at one
millisecond time intervals, the polling sequence is
continuous. ~s shown by the follo~ing step 616, between
successive time instants Tn~ the program continuously loops
to idle 606 and through steps 608-616 inclusive until the
envelope sensing sequence for a given envelope is complete.
Whereupon the microprocessor comr~nces executing step 618,
which includes the steps of calculating the envelope's
velocity, 618a; then fetching from memory the corresponding
acceleration, deceleration and constant velocity constants
618b, for computation of the desired position counts Pd at
each successive time instant Tn in advance of sampling the
actual position counts Pa as hereinbefore discussed in
connection with step 610; then fetching and implementing the
time delay td for timely commencing acceleration of the drum
38 to the target veloclty V1; and then commencing drum
rotation by generating the desired position Pd for the
initial one millisecond sampling time instant of acceleration
of the motor drive shaft 122 and storing the value for
subsequent use in step 601b. Accordingly, the value of Pd
- 5~ -
~L23~
will no longer be assumed to be the value representative ofthe home position.
Thereafter, the inquiry is made as to whether or not
the drum cycle is complete, step 620. ~ssuming as stated
above that only the initial desired value of Pd has been
computed and stored, the inquiry of step 620 will be answered
in the negative. Whereupon the microprocessor 502 transmits
a status message, step 622, to the postage meter's computer
41 and the program loops to idle 606. Thereafter the
microprocessor 502 continuously executes steps 60B-620 until
the entire Pd count sequence 618d for the trapazoidal-shaped
velocity versus time profile for the target velocity Vl has
been exhausted. In this connection it is noted that the drum
cycle TCt is not complete until the settling time interval Ts
which is allowed for damping any overshoot of the motor drive
shaEt 122 is complete. During the settling time interval Ts
the value of Pd is a constant and representative of the home
position of the shaft 122 and thus the drum 38. Assuming
that the drum cycle is complete, the inquiry of step 620 will
be answered affirmatively~ Whereupon the microprocessor 502
transmits a status message, step 624, to the postage meter's
computer 41 and the program loops to idle 606. Thereafter,
the foregoing steps 606-622 of the main line, servo-control,
idle loop are continuously executed by the microprocessor 502
in accordance wlth the above discussion until the main power
switch 24 is opened by the operator.
The serial communications program 700 includes the
transmit status routine 704. The latter routine 704 includes
- 56 -
the steps of receiving and decoding any message, step 706,and invoking the execute command routine, step 708, both of
which steps are self explanatory.
Assuming the execute command routine 800 has been
invoked, step 708, the microprocessor 502 executes the
routine 80~ commencing with the step B02 of inquiring whether
or not the decoded message is an enable command. ~ssuming
the answer is yes, an enable status flag is set, step 804, to
indicate that an envelope is to be fed to the drum 38.
Whereupon the A.C. motor relay 52 is energized, step 806, for
feeding the envelope to the drum 38, and the transmit status
routine is invoked, step 808. On the other hand, assuming
the decoded message is not an enable command, step 802, a
ena~le status flag is cleared, step ~10. Whereupon the A.C.
relay is deenergized, step 812, and the status transmit
routine is invoked 808.
Assuming the status kransmit routine 702 has been
invoked, step B06, the microprocessor 502 executes the
routine 702 commencing with the step 71D of inquiring whether
or not the drum cycle is complete. Assuming completion of
the drum cycle, a drum cycle complete message is transmitted
to the postage meter's computer 41, step 712. On the other
hand, assuming the drum cycle is not complete, an inquixy is
made as to whether or not the A.C. relay is energized, step
716, and, if it is, an A.C. relay energized message is
transmitted to the postage meter's computer 41, step 718. If
however the drum cycle is not complete, step 710, and the
A.C. relay is n~t energized, step 716, then, an A.C xelay
- 57 -
~23~
deenergized message is transmitted to the postage meter'sco~ ter 41, step 720. ~pon transmitting any of the
messages, drum cycle ccm?lete, step 71~, A.C. relay
energized, step 716, or A.C. relay deenergized, step 720, the
microprocessor 502 returns to the idle 606 of the main line
program 600.
The term postage meter as used herein includes any
device for affixing a value or other in~icia on a shee~ or
sheet like material for governmental or private carrier
parcel, envelope or package delivery, or other purposes. For
exam~le, private parcel or freight services purchase and
em?loy postage meters for providing unit value pricing on
tape for application on individual parcels.
A more detailed description of the prosrams herein-
before discussed is disclosed in the appended program listing
which describes in greater detail the various ro~tines
incorporated in, and used in the operation of, the postage
meter.
Although ~he invention disclosed herein has been
described with reference to a simple embodiment thereof,
variations and modifications may be made therein by persons
skilled in the art without departing from the spirit and
scope of the invention. Accordingly, it is intended that the
following claims c~ver the disclosed invention and such
variations and modifications thereof as fall within the true
spirit and scope of the invention.
- 58 -
B - 9 8 2
" APPENDEX " ~3~8~
For patent application entitled MICROPROCESSOR CONTROLLED
D.C. MOTOR FOR CONTROLLING PRINTING MEANS
Inventors: Edilberto I. Salazar and Wallace Kirschner
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