Production equipment for performing control parameter setting and quality determination

Abstract

The production equipment according to an embodiment of the present invention includes: a frequency response analysis unit configured to send a sine wave of variable frequency to a controller connected to a load, receive a sensed current for sensing a current output from the load from the controller, and analyze the received sensed current to which the sine wave has been applied to the load; and a processing unit configured to receive, from the frequency response analysis unit, a result of analyzing the sensed current, thereby performing quality determination of the controller or calculating control parameters of the controller to send the result to the controller.

Description

Technical Field

[0001] The present invention relates to production equipment, and more specifically, to sending a sine wave of variable frequency, setting control parameters of a controller using a signal received from the controller, and performing quality determination on the controller or a motor, as well as a production method, a control device for setting control parameters using a sine wave of variable frequency and performing quality determination, and a control parameter setting method. Background Art

[0002] In the production process of a control board for a production control motor, quality determination is performed on the control board or the motor, and thus the control board and the motor determined to be good products leave the factory. At this time, in order to determine the quality of the control board and the motor, quality determination is performed on each of the control board and the motor, and the control board and the motor leave the factory according to the result of each quality determination. At this time, since quality determination is performed separately, when performing quality determination on the control board, the motor control parameters are fixed to one control parameter, and when performing quality determination on the motor, the control parameters of the control board are fixed to one control parameter. However, since the control parameters of each motor or control board are different, there is a problem that even if the actual product is a good product, the actual product is determined to be defective, or even if the product is a non-good product, the actual product is determined to be good.

[0003] In addition, the motor has unique characteristics such as resistance, inductance, and frictional force, and the measured values or design values of these characteristics are used to design position / speed / current control logic. However, there is a deviation between the design value and the manufactured product, and there may also be measurement errors in the measured values.

[0004] The characteristic values of the above-mentioned motor vary depending on the sample, and may also vary depending on temperature or aging. In order to reflect these characteristics in control, currently, since the characteristic values of the motor are measured with multiple samples under various conditions during the development stage to design the controller values, there are errors between the actual samples, and thus the optimal control performance cannot be achieved.

[0005] Due to these problems, there is a problem that the control performance becomes lower than the design value due to variations between samples, temperature changes, and aging. Summary of the Invention

[0006]

Technical Subject

[0007] The technical problem to be solved by the present invention is to send a sine wave of variable frequency, set the control parameters of the controller using a signal received from the controller, and provide a production equipment and a production method for performing quality determination on the controller or the motor.

[0008] Another technical problem to be solved by the present invention is to provide a control device and a control parameter setting method for setting control parameters and performing quality determination using a sine wave with a variable frequency.

[0009] The subject matter of the present invention is not limited to the above subject matter, and those skilled in the art will clearly understand other unmentioned subject matters from the following description.

[0010]

Technical Solution

[0011] To solve the above technical problems, a production device according to an embodiment of the first embodiment of the present invention includes: a frequency response analysis unit that sends a sine wave with a variable frequency to a controller connected to a load, receives a sensed current that senses the current output from the load, and analyzes the received sensed current, wherein the sine wave is applied from the controller to the load; and a processing unit that receives the result of analyzing the sensed current from the frequency response analysis unit to perform quality determination on the controller or calculate control parameters of the controller and send the control parameters to the controller.

[0012] In addition, the frequency response analysis unit can analyze the received sensed current by performing a fast Fourier transform.

[0013] In addition, the frequency response analysis unit can perform a fast Fourier transform using the received sensed current and the sine wave sent to the controller.

[0014] In addition, the sine wave is a sine wave with a variable frequency, and a signal having one of the variable frequencies can be output for one or more cycles, or a signal having a continuously changing frequency can be output for one or more cycles.

[0015] In addition, the controller can receive the sine wave from the frequency response analysis unit, convert the sine wave into a voltage signal, and apply the voltage signal to the load.

[0016] In addition, the processing unit can perform quality determination on the controller or the load using the result of analyzing the sensed current.

[0017] In addition, the processing unit can use the result of analyzing the sensed current to determine the cause of a fault in the load.

[0018] In addition, the processing unit can use the result of analyzing the sensed current to calculate PI control parameters, PID control parameters, or a filtering coefficient of the controller.

[0019] In addition, the processing unit can control the frequency response analysis unit by sending a mode entry signal to the frequency response analysis unit.

[0020] In addition, the frequency response analysis unit can send the sine wave to the controller using communication or a digital-to-analog converter (DAC).

[0021] In addition, the load may be an actuator.

[0022] To solve the above technical problems, a production method according to another embodiment of the first embodiment of the present invention includes the following steps: sending a mode entry signal to a frequency response analysis unit; generating a sine wave with a variable frequency by the frequency response analysis unit and sending the sine wave to a controller connected to a load; receiving a sensed current for sensing the current output from the load from the controller, wherein the sine wave is applied to the load; analyzing the received sensed current by the frequency response analysis unit; receiving the result of analyzing the sensed current from the frequency response analysis unit; using the result of analyzing the sensed current to perform quality determination on the controller or the controller and the load or calculating control parameters of the controller; and sending the calculated control parameters to the controller.

[0023] In addition, the step of analyzing the received sensed current may be performed by performing a fast Fourier transform using the received sensed current and the sine wave sent to the controller.

[0024] In addition, the sine wave is a sine wave with a variable frequency, and a signal having one of the variable frequencies may be output for one or more cycles, or a signal having a continuously changing frequency may be output for one or more cycles.

[0025] In addition, the step of calculating the control parameters of the controller may include calculating the PI control parameters, PID control parameters or filtering coefficients of the controller using the result of analyzing the sensed current.

[0026] In addition, the step of performing quality determination on the controller or the load may use the result of analyzing the sensed current to determine the cause of the failure of the load.

[0027] To solve other technical problems, a control device according to an embodiment of the second embodiment of the present invention includes: a controller for sending a control signal for controlling a load to the load; a sine wave generation unit for generating a sine wave with a variable frequency and sending the sine wave to the load; an analysis unit for analyzing a sensed current that senses the current output from the load; and a processing unit for setting the control parameters of the controller using the result of analyzing the sensed current.

[0028] In addition, it further includes: a voltage output unit for converting the control signal and the sine wave of the controller into a voltage signal and sending the voltage signal to the load; and a current measurement unit for sensing the current output from the load.

[0029] In addition, the analysis unit may include: a storage unit for storing the sine wave or the sensed current; and an FFT transformation unit for performing a fast Fourier transform using the sine wave and the sensed current.

[0030] In addition, the processing unit may perform quality determination on the load or the control device using the result of analyzing the sensed current.

[0031] In addition, the sine wave generation unit may generate a sine wave by receiving a mode operation signal from a controller, a production device, or a higher-level controller.

[0032] In addition, the sine wave generation unit may generate a sine wave periodically.

[0033] In addition, the sine wave is a sine wave with a variable frequency, and a signal having one of the variable frequencies may be output for one or more cycles, or a signal having a continuously changing frequency may be output for one or more cycles.

[0034] In addition, the frequency of the sine wave may be different from the control signal of the controller.

[0035] In addition, the processing unit may calculate the PI parameters, PID parameters, or filtering coefficients of the controller by using the result of analyzing the sensed current.

[0036] In addition, the processing unit may set the control parameters of the controller by using the inductance and impedance of the load derived from the result of analyzing the sensed current.

[0037] In addition, the processing unit may use the result of analyzing the sensed current to determine the cause of the failure of the load.

[0038] In addition, the processing unit may determine whether the load is disconnected, short-circuited, has a large contact resistance, is demagnetized, or has reduced coil insulation.

[0039] In addition, the processing unit may estimate the temperatures of the stator and rotor included in the load by determining whether the magnetic flux intensity, resistance, or inductance of the load changes.

[0040] In addition, the load may be an actuator.

[0041] In addition, the controller may be a microcontroller unit (MCU), and the sine wave generation unit, the analyzer, and the processing unit may be implemented as processors in the MCU.

[0042] To solve other technical problems, a method for setting control parameters according to another embodiment of the second embodiment of the present invention includes the following steps: generating a sine wave with a variable frequency by a sine wave generation unit; sending the sine wave together with a control signal generated by a controller to a load; sensing the current output from the load; analyzing the sensed current; and setting the control parameters of the controller using the result of analyzing the sensed current.

[0043] In addition, the step of analyzing the sensed current may include performing a Fast Fourier Transform using a sine wave and the sensed current.

[0044] In addition, it may include the step of performing quality determination on the load or the controller using the result of analyzing the sensed current.

[0045] In addition, the step of generating a sine wave may generate a sine wave or periodically generate a sine wave by receiving a mode operation signal from a controller, a production device, or a high-level controller.

[0046] In addition, the frequency of the sine wave may be different from the control signal of the controller.

[0047] In addition, the step of setting the parameters of the controller may set the control parameters of the controller by using the inductance and impedance of the load derived from the result of analyzing the sensed current.

[0048] In addition, the step of analyzing the sensed current may determine whether the load is disconnected, short-circuited, has a large contact resistance, is demagnetized, or has reduced coil insulation.

[0049] In addition, the step of analyzing the sensed current may estimate the temperature of the stator and rotor included in the load by determining whether the magnetic flux intensity, resistance, or inductance of the load changes by using the result of analyzing the sensed current.

[0050] In addition, the control parameter setting method may be executed in the processor of the MCU.

[0051]

Beneficial Effects

[0052] According to the embodiment of the first embodiment of the present invention, it is possible to perform quality determination on the motor and the controller in a state where the controller and the motor are connected. In addition, the stability of the controller can be measured in the frequency domain. In addition, control parameters can be designed for each sample, and the deviation between products can be reduced.

[0053] In addition, it is possible to perform quality determination on the motor and the controller in a state where the controller and the motor are connected. In addition, faults such as demagnetization of the magnet of the motor, reduction of winding insulation, winding disconnection, and winding short circuit can be diagnosed. In addition, the stability (phase margin, gain margin) of the controller can be measured in the frequency domain. In addition, the optimal controller values (P, I, D, gain, and filter) can be designed by analyzing the characteristics of the required frequency of the sine wave generation unit inside the controller. In addition, even if the characteristics of the motor change with the operating environment (temperature, aging, etc.) of the motor, the control performance (steady-state ripple, transient responsiveness, etc.) can always be kept optimal by finding the optimal control value through online measurement of the motor characteristics. In addition, since the mutual interference components to be compensated can be measured based on an equation, the mutual interference components can be accurately compensated.

[0054] The effects according to the present invention are not limited by the above - exemplified content, and thus more various effects are included in this specification. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] Figure 1 Shows the production process of a control parameter measuring device according to a comparative example of the first embodiment of the present invention.

[0056] Figure 2 Is a block diagram of a production device according to an embodiment of the first embodiment of the present invention.

[0057] Figure 3 Shows a sine wave used in the production device according to an embodiment of the first embodiment of the present invention.

[0058] Figure 4 and Figure 5 Is a diagram for explaining the operation of the production device according to the first embodiment of the present invention.

[0059] Figure 6 Is a flowchart of a production method according to an embodiment of the first embodiment of the present invention.

[0060] Figure 7 Is a flowchart of a production method according to another embodiment of the first embodiment of the present invention.

[0061] Figure 8 Shows the operation of a controller according to a comparative example of the second embodiment of the present invention.

[0062] Figure 9 Is a block diagram of a control device according to an embodiment of the second embodiment of the present invention.

[0063] Figure 10 Is a block diagram of a control device according to another embodiment of the second embodiment of the present invention.

[0064] Figures 11 to 15 Is a diagram for explaining the operation of the control device according to the second embodiment of the present invention.

[0065] Figure 16 Is a flowchart of a control parameter setting method according to an embodiment of the second embodiment of the present invention.

[0066] Figures 17 to 19 Is a flowchart of a control parameter setting method according to another embodiment of the second embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0067] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[0068] However, the technical concept of the present invention is not limited to the several embodiments to be described, but can be implemented in various forms, and within the scope of the technical concept of the present invention, one or more of the constituent elements can be selectively combined or replaced between the embodiments.

[0069] In addition, unless clearly defined and described, the terms (including technical terms and scientific terms) used in the embodiments of the present invention can be interpreted according to the meanings commonly understood by those skilled in the art, and the commonly used terms (such as the terms defined in a dictionary) can be interpreted considering their meanings in the relevant technical background.

[0070] In addition, the terms used in this specification are for describing the embodiments and are not intended to limit the present invention.

[0071] In this specification, unless specifically stated in a phrase, the singular form can include the plural form, and when described as "at least one (or more than one) of A, B, and C", this can include one or more of all combinations that can be formed by combining A, B, and C.

[0072] In addition, terms such as first, second, A, B, (a), and (b) can be used to describe the components of the embodiments of the present invention. These terms are only intended to distinguish the components from other components, and the nature, order, or sequence of these components are not limited by these terms.

[0073] And when a component is described as "connected", "coupled", or "interconnected" to another component, the component is not only directly connected, coupled, or interconnected to the other component, but can also include the case where it is "connected", "coupled", or "interconnected" to the other component based on other components in between.

[0074] In addition, when described as being formed or arranged "above (on top of)" or "below (beneath)" each component, "above (on top of)" or "below (beneath)" means not only including the case where the two components are in direct contact, but also including the case where one or more other components are formed or arranged between the two components. In addition, when expressed as "above (on top of)" or "below (beneath)", it can include not only the meaning in the upward direction based on one component, but also the meaning in the downward direction based on one component.

[0075] Figure 1 The production process of the control parameter measurement device of the comparative example according to the first embodiment of the present invention is shown.

[0076] For the control board that forms the controller and the motor that is the load controlled by the control board, quality determination of whether the control board and the motor meet the design specifications is performed before leaving the factory. To determine whether the control board 21 or the motor 22 is a good product, a control parameter measurement device 10 is used to measure the control parameters of the control board 21 and the motor 22, and quality determination is performed on the control board 21 and the motor 22 using the measured control parameters. For the motor, as shown in (A) of Figure 1 , control parameters such as resistance and inductance in the single-unit state of the motor 22 are measured, it is determined whether the measured control parameters meet the good-product standards, and the good products are shipped out. After calibration and quality determination for each sample in the single-product state, the control board 21 is shipped out. When setting the control parameters of the control board 21 before leaving the factory, it is assumed that the control parameters of the motor are the same as those of the development sample, and the controller values (P, I, D, gain, and filter) are applied as the same value before leaving the factory.

[0077] After performing quality determination on the motor 22 and the control board 21, as shown in (B) of Figure 1 , when the connection state between the control board 21 and the motor 22 is poor, it can be determined as defective. In the case of good products that have passed the response test, due to applying all the same controller values as described above, there may be performance differences between the products that have been determined as good products.

[0078] In this way, when performing quality determination by separately measuring the control parameters of each of the control board 21 and the motor 22, when the actual control board 21 is applied to the motor 22, it may not be suitable for the operation of the motor 220 to which the control parameters of the control board 21 are connected. To perform more accurate quality determination and control parameter setting during the production process, the production equipment according to the embodiment of the first embodiment of the present invention uses frequency response analysis. Hereinafter, the production equipment according to the embodiment of the first embodiment of the present invention will be described in detail.

[0079] Figure 2 is a block diagram of the production equipment according to the embodiment of the first embodiment of the present invention.

[0080] The production equipment 100 according to the embodiment of the first embodiment of the present invention includes a frequency response analysis unit 110 and a processing unit 120. It may include a communication unit for sending and receiving signals or a memory for storing control parameters.

[0081] The frequency response analysis unit 110 sends a sine wave of variable frequency to the controller 210 connected to the load 220, receives the sensed current that senses the current output from the load 220, the sine wave is applied from the controller 210 to the load, and analyzes the applied sine wave and the received sensed current.

[0082] More specifically, to measure the control parameters of the controller 210 and the load 220, the frequency response analysis unit 110 sends a sine wave of variable frequency to the controller 210 connected to the load 220. That is, the controller 210 and the load 220 are connected, and while the controller 210 and the load 220 are connected, a sine wave of variable frequency is sent to the controller 210.

[0083] Here, a sine wave refers to a signal (also called a sine wave) whose waveform is a sine curve. The frequency response analysis unit 110 sends a sine wave with a variable frequency, but can output one frequency in one or more cycles. As Figure 3 shown, a sine wave with a variable frequency can be sent. At this time, as Figure 3 (A) of shows. A sine wave can be output such that the frequency gradually increases or the frequency gradually decreases. Or, the frequency can gradually increase and decrease, or decrease and increase, or can vary randomly. The changing frequency can vary linearly or exponentially. In addition, the frequency can vary in various ways. At this time, a signal with one of the variable frequencies can be output for more than one cycle. Since the response in one cycle is used to measure the control parameter, the frequency response analysis unit 110 can output a waveform formed by one frequency in one or more cycles.

[0084] Or, as Figure 3 (B) of shows, a signal whose frequency changes continuously can be output in one or more cycles. As Figure 3 (B) of shows, the frequency can change such that the frequency increases gradually from the start time f S(Start) to the end time f E(End) over time. For example, the frequency can be in the form of a chirp signal. The frequency can gradually increase or gradually decrease, and can vary linearly or exponentially, as Figure 3 (B) of shows. Or, it can increase and then decrease, or can vary randomly. In addition, the frequency can vary in various ways.

[0085] The frequency response analysis unit 110 can send the sine wave to the controller 210 using communication or a digital-to-analog converter (DAC). The frequency response analysis unit 110 can use communication or a digital-to-analog converter (DAC) when sending a sine wave of variable frequency to the controller 210. The frequency response analysis unit 110 can convert the sine wave signal into a communication signal according to the communication to which the sine wave will be sent and send the communication signal to the controller 210. At this time, the frequency response analysis unit 110 uses various wired and wireless communications to send a communication signal corresponding to the sine wave of variable frequency, and the controller 210 can receive the communication signal, convert the communication signal back into a sine wave, or convert the communication signal into another form and apply it to the load 220.

[0086] Alternatively, the frequency response analysis unit 110 may send a sine wave through the DAC. The DAC is a device that converts a digital signal into an analog signal. The frequency response analysis unit 110 may apply a sine wave with a variable frequency through the DAC and send the sine wave to the controller 210 through the conversion in the DAC. The controller 210 senses the current output from the load 220 according to the sine wave with a variable frequency sent from the frequency response analysis unit 110 to the controller 210, and the frequency response analysis unit 110 receives the sensed current from the controller 210. The controller 210 may receive the sine wave from the frequency response analysis unit 110, convert the sine wave into a voltage signal, and apply the voltage signal to the load 220. The load 220 connected to the controller 210 may be an actuator. Here, the actuator is a driving device that operates a device using power, and refers to a motor that forms a predetermined controller, or a piston or cylinder mechanism that operates through hydraulic or pneumatic pressure. That is, the load 220 may be a motor, and the controller 210 may be a motor drive controller that drives the motor.

[0087] The controller 210 converts the sine wave with a variable frequency into a voltage signal and applies the voltage signal to the load 220, and the load 220 operates according to the applied voltage signal and outputs a current. The controller 210 measures the current output from the load 220, and the controller 210 sends the measured current to the frequency response analysis unit 110. The controller 210 may measure the current output from the load 220 using a current measuring device such as a shunt resistor. Alternatively, various devices such as a current mirror circuit and a voltage measuring device may be used to measure the current output from the load 220.

[0088] The frequency response analysis unit 110 analyzes the sensed current. In order to derive the control parameters of the controller 210 and the load 220 from the sensed current, the frequency response analysis unit 110 analyzes the sensed current sensed by the controller 210 and received by the frequency response analysis unit 110 from the controller 210.

[0089] When analyzing the sensed current, the frequency response analysis unit 110 may analyze the received sensed current by performing a fast Fourier transform. The fast Fourier transform (FFT) is a method for high-speed processing of the Fourier transform of discrete data and is used to analyze signals. When using the fast Fourier transform, by decomposing the discrete Fourier transform of a long signal sequence into the discrete Fourier transforms of short signal sequences in order and using the symmetry and periodicity of the rotation factor to change the order of the data to reduce the number of multiplications that take time, fast processing can be performed.

[0090] The frequency response analysis unit 110 may perform a fast Fourier transform using the received sensed current and the sine wave sent to the controller 210. The sine wave sent from the frequency response analysis unit 110 to the controller 210 is stored in the memory, and when the sensed current corresponding to the stored sine wave is received, the received sensed current and the stored sine wave may be used to perform a fast Fourier transform. The frequency response analysis unit 110 may know the frequency response characteristics of the controller 210 to which the load 220 is connected through the fast Fourier transform. Frequency response refers to measuring what kind of response is output when input signals of various frequencies are applied to a certain system, and is used to analyze the corresponding system. The amplitude of the signal may be constant or may vary. The frequency response may represent the amplitude and phase of the signal output from the system as a curve with respect to frequency.

[0091] The frequency response analysis unit 110 may be implemented as a frequency response analyzer. A frequency response analyzer (FRA) is a high-precision measuring device for analyzing components, circuits, or systems in the frequency domain, generating a sine wave signal, and applying the sine wave signal to a test object. One of the input channels of the frequency response analyzer is used to measure the sine wave signal at the injection point, the injected signal passes through the object under test, and the output signal is measured in another channel to analyze the frequency response. At this time, the frequency response analyzer may perform a fast Fourier transform. The frequency response of the test object may be analyzed using the sine wave.

[0092] The processing unit 120 receives the result of analyzing the sensed current from the frequency response analysis unit 110, performs quality determination on the controller 210, or calculates the control parameter of the controller 210 and sends the control parameter to the controller 210.

[0093] More specifically, the processing unit 120 receives the result of analyzing the sensed current from the frequency response analysis unit 110. As described above, the frequency response analysis unit 110 analyzes the sensed current by fast Fourier transform and sends the analysis result to the processing unit 120. The processing unit 120 can perform quality determination on the controller 210 using the result received from the frequency response analysis unit 110. By performing quality determination on the controller 210 in a state where the load 220 is connected, accurate quality determination can be performed on the controller 210 and the load 220 that are actually connected together and installed and driven in the system. In the case of performing quality determination without connecting the controller 210 and the load 220, problems that may occur in practical applications where quality determination is performed by assuming control parameters of another component do not occur in the production equipment according to the embodiment of the first embodiment of the present invention, in which the load 220 is connected to the controller 210 and the control parameters of the controller 210 to which the load 220 is connected are measured. The processing unit 120 can perform quality determination on the load 220 as well as the controller 210. Since the load 220 is connected to the controller 210, the processing unit 120 can perform quality determination on the load 220 as well as the controller 210. That is, the processing unit 120 can perform quality determination on each of the controller 210 and the load 220, or perform quality determination on the controller 210 and the load 220 as a group.

[0094] The processing unit 120 can perform quality determination on the controller 210 or the load 220 using the result of analyzing the sensed current. Quality determination on the controller 210 or the load 220 can be performed based on whether the control parameters according to the result of analyzing the sensed current satisfy the quality determination criteria. The quality determination criteria can have a lower limit and an upper limit, or can be set within a predetermined range having a lower limit or an upper limit. The quality determination criteria are set according to the design specifications of the controller 210 and the load 220, or can be set according to safety or safety levels, or can be set by the user. The quality determination criteria can be stored in a memory. The quality determination criteria can be stored as a look-up table (LUT).

[0095] The processing unit 120 can derive the inductance value L, the resistance value R, or the impedance value Z from the result of analyzing the sensed current. The derived inductance value, resistance value, or impedance value can be used to perform quality determination on the controller 210 or the load 220. That is, quality determination on the controller 210 and the load 220 can be performed by determining whether it is within the reference range of the inductance value and the resistance value or whether the impedance value is within the inductance reference range.

[0096] The processing unit 120 can use the result of analyzing the sensed current to determine the cause of the failure of the load 220. The processing unit 120 not only uses the result of analyzing the sensed current to perform quality determination on the load 220, but also can determine the cause of the failure of the load 220 when it is determined that the load 220 is defective. By determining which failure causes the load 220 to be defective and storing and accumulating the failure cause information, it is possible to know the defect causes that often occur during the production process of the load 220 currently, and it is possible to know which defects occur at which rate in which production line. That is, the defect cause information can be used to perform the management of the production line or the production system.

[0097] The processing unit 120 can derive the inductance value and the impedance value by analyzing the sensed current, and can use the inductance value and the impedance value to determine the cause of the failure. At this time, the criteria for determining the cause of the failure and classification can vary according to the type of the load 220. For example, when the load 220 is a three-phase motor and the controller 210 drives the motor using a three-phase power supply, the processing unit 120 can determine disconnection, short circuit, increased contact resistance, magnet demagnetization, reduced coil insulation, etc. as the causes of the defects.

[0098] If the impedance of the phase where disconnection occurs suddenly drops to zero, it can be determined that a winding disconnection has occurred. On the contrary, if the impedance of the phase where a short circuit occurs suddenly increases compared with the existing value, it can be determined that a winding short circuit has occurred. In addition, if the resistance of a specific phase in the measured impedance increases, it can be determined that the contact resistance has increased due to the increase in the contact resistance of this phase.

[0099] When the amplitude of the current measured at the frequency of the applied voltage (predetermined frequency) (for example, in the region less than 100 Hz) at the same temperature and rotational speed becomes larger than before, it can be determined that the magnet has been demagnetized. In addition, when the current is large and at the same time the winding temperature increases, if the inductance measured in the region where the frequency of the applied voltage is 100 Hz or higher becomes smaller than the existing value, it can be determined that the magnet has been demagnetized. When the resistance and inductance of the coil whose insulation has decreased develop in the direction where the insulation slightly decreases, it can be determined that the insulation of the coil has decreased. In addition, various causes of failure can be determined.

[0100] In addition, the processing unit 120 can estimate the temperatures of the stator and the rotor included in the load by using the result of analyzing the sensed current to determine whether the magnetic flux intensity, resistance, or inductance of the load has changed. For example, the load of a motor can include a stator and a rotor, and the load including the stator and the rotor is greatly affected by temperature. Therefore, when measuring the temperatures of the stator and the rotor, the result of analyzing the sensed current can be used. The temperatures of the stator and the rotor can be estimated by using the result of analyzing the sensed current to determine at least one of the change in the magnetic flux intensity, the change in the resistance, or the change in the inductance of the load. In this way, it is possible to determine whether a failure has occurred or the probability of a failure occurring based on the estimated temperature.

[0101] The processing unit 120 can not only perform quality determination on the controller 210 or the load 220, but also use the result of analyzing the sensed current to calculate the control parameters of the controller 210. The calculated control parameters can be sent to the controller 210 to change or set the control parameters of the controller 210. The controller 210 sets the control parameters to control the load 220. The control parameters of the controller 210 set according to the type and characteristics of the controller 210 can vary.

[0102] The processing unit 120 can use the result of analyzing the sensed current to calculate the PI control parameters, the PID control parameters, or the filtering coefficient of the controller 210.

[0103] The processing unit 120 calculates the PI control parameters when the controller 210 is a PI controller, calculates the PID control parameters when the controller 210 is a PID controller, and can calculate the filtering coefficient when a filter is included. The controller 210 can be an automatic controller and can be controlled using a combination of P, I, and D.

[0104] Here, P represents proportional, I represents integral, and D represents derivative. Proportional (P) control is a control that makes the control amount proportional to the difference between the target value and the current position, and as it approaches the target value, the difference in the control value decreases, enabling fine control. When performing proportional control, when the control amount approaches the target value, the control amount becomes too small to perform fine control, resulting in a residual deviation that remains uncontrollable. PI control is a control that uses proportional and integral, and the residual deviation can be removed by using PI control. The small residual deviation accumulates over time, and the control amount is increased according to the accumulated residual deviation to eliminate the deviation. Since PI control is a control that adds an integral operation to the proportional operation, it is called PI control. In the case of PI control, it is possible to control close to the actual target value, but as it approaches the target value, the control amount decreases, requiring continuous operation for a certain period or longer. At this time, if the integer is large, the response performance may deteriorate when there is an external disturbance. That is, it may be difficult to quickly respond to the external disturbance and it may be difficult to return to the target value. To solve this, a derivative operation can be performed. By observing the deviation of a sudden disturbance, and if the difference from the previous deviation is large, the manipulated value is increased to respond. Observing the difference in deviation from the previous time corresponds to the derivative, and PID control is performed by applying the derivative to the proportional and integral. Even if the control amount deviates from the target value, it can be determined as the deviation from the previous time, and the target value can be quickly reached by applying the control amount.

[0105] PID control can be expressed as a PID control equation, and the PID control parameters can be expressed as Kp, Ki, and Kd. The PID parameters can be calculated through optimization using the step response method or the limit reduction method. PI control can correspond to this, and calculate the PI control parameters Kp and Ki.

[0106] The processing unit 120 can send the calculated control parameters to the controller 210, so that the controller 210 sets or changes the control parameters using the calculated control parameters. Since the control parameters calculated by the processing unit 120 are the control parameters calculated in the state where the load 220 is connected, these control parameters are adaptively calculated control parameters in the state where the load 220 and the controller 210 are connected, and correspond to the optimal control parameters of the controller 210.

[0107] The processing unit 120 can calculate the control parameters of the controller 210 simultaneously with or after the quality determination. When the controller 210 and the load 220 are good products, the control parameters can be calculated to set the optimal parameters for the controller 210 in the state where the load 220 is connected. When the controller 210 or the load 220 is defective, the calculation of the control parameters may not be performed. Or, according to the result of the control parameters set in the current controller 210 being poor, but when it can be determined to be within a good range when the control parameters are changed and is determined to be poor, the quality determination result of the controller 210 or the load 220 can be changed by changing the control parameters of the controller 210 or the load 220. Or, the quality determination can be performed again after changing the control parameters. Thus, it is possible to prevent a situation where it may be determined to be defective even when it can be determined to be good when the control parameters are changed. When performing a separate quality determination on the load 220 using fixed control parameters, there may be a situation where a defective determination is made on the load 220 even when the load 220 can be used as a good product when the control parameters are changed. However, in the production equipment according to the first embodiment of the present invention, not only is the quality determination performed on the controller 210 to which the load 220 is connected, but also the possibility and accuracy of the quality determination of the load 220 are improved by changing the result of the load 220 using the change of the control parameters.

[0108] The processing unit 120 can control the frequency response analysis unit 110 by sending a mode entry signal to the frequency response analysis unit 110. The processing unit 120 sends the mode entry signal to the frequency response analysis unit 110 to perform quality determination or control parameter calculation for the controller 210 to which the load 220 is connected, so that the frequency response analysis unit 110 can send a sine wave with a variable frequency to the controller 210. That is, the processing unit 120 can send the mode entry signal to the frequency response analysis unit 110 to start a series of processes of quality determination or control parameter calculation. The frequency response analysis unit 110 can receive the mode entry signal from the processing unit 120 and send a sine wave with a variable frequency to the controller 210. Alternatively, when the controller 210 is located at a predetermined position, the frequency response analysis unit 110 can send a sine wave with a variable frequency to the controller 210 without receiving the mode entry signal. Alternatively, a sine wave with a variable frequency can be sent to the controller 210 periodically.

[0109] Figure 4 and Figure 5 FIG. is a diagram for explaining the operation of the production equipment according to the first embodiment of the present invention. The frequency response analysis unit can be implemented using a frequency response analyzer (FRA) 110, and the processing unit can be the production equipment 120. The load connected to the controller 210 can be a motor 220. In the process of setting control parameters by analyzing the frequency response of the controller 210 to which the motor 220 is connected, as Figure 4As shown, first, the production device 120 sends a mode entry signal to the FRA device 110 using communication or the like. When entering the mode, a sine wave with a variable frequency is generated in the FRA device 110, and this signal is sent to the controller via communication or a DAC. Here, the variable-frequency signal must output one or more cycles. For example, if a 1 Hz signal and a 10 Hz signal are being output, after the 1 Hz signal is output for one or more cycles, the 10 Hz signal should be output for one or more cycles. The controller 210 can receive the sine wave with a variable frequency via communication or an ADC. The sine wave with a variable frequency received from the controller 210 is converted into a voltage signal to be applied to the motor 220, thereby applying a voltage to the motor 220. At this time, the variable frequency can change, but the frequency does not change. Current flows according to the input voltage, and the current value is measured by the controller 210. The controller 210 sends the measured current signal to the FRA device via communication or a DAC. The FRA device 110 can receive the measured current signal via communication or an ADC. The FRA device 110 performs a fast Fourier transform (FFT) using the sine wave signal with a variable frequency output by the controller 210 and the current signal received from the controller, and transmits the result to the production device 120. The production device 120 that receives the FFT signal can design an optimal control value (P, I, D, gain, or filter coefficient) and send this optimal control value to the controller 210 to set the control parameters of the controller 210. Thus, control parameters can be set for each sample, and the deviation between products can be reduced by compensating for the deviation between products using P, I, D, gain, or a filter.

[0110] In addition, the production device 120 can perform quality determination based on the FFT signal, as Figure 5 shown. Thus, quality determination of the motor 220 and the controller 210 can be performed while the controller 210 and the motor 220 are connected. In addition, the controller stability (phase margin and gain margin) can be measured in the frequency domain according to the step response in the time domain without repeating the test.

[0111] Figure 6 is a flowchart of a production method according to an embodiment of the first embodiment of the present invention; and Figure 7 is a flowchart of a production method according to another embodiment of the first embodiment of the present invention. Figure 6 and Figure 7 The detailed description of each step of Figures 1 to 5 corresponds to the detailed description of the production device of Figure 6 and Figure 7 and thus repeated descriptions will be omitted.

[0112] In step S11, a mode entry signal is sent to the frequency response analysis unit. In step S12, the frequency response analysis unit generates a sine wave with a variable frequency and sends the sine wave to a controller connected to a load. The sine wave is a sine wave with a variable frequency, and a signal with one of the variable frequencies can be output in one or more cycles, or a signal with a continuously changing frequency can be output in one or more cycles. After that, in step S13, a sensed current that senses the current output from the load is received from the controller, and the sine wave is applied to the load. In step S14, the frequency response analysis unit analyzes the received sensed current. When analyzing the received sensed current, a fast Fourier transform can be performed using the received sensed current and the sine wave sent to the controller for analysis.

[0113] After that, in step S15, the result of analyzing the sensed current is received from the frequency response analysis unit. In step S16, the control parameters of the controller are calculated using the result of analyzing the sensed current. When calculating the control parameters of the controller, the result of analyzing the sensed current can be used to calculate the PI control parameters, PID control parameters, or filter coefficients of the controller. When the control parameters are calculated, in step S17, the calculated control parameters are sent to the controller.

[0114] In addition, after step S15, quality determination can be performed on the controller or the load in step S21. When performing quality determination on the controller or the load, the result of analyzing the sensed current can be used to determine the cause of the failure of the load.

[0115] As described above, the production equipment and production method according to the first embodiment of the present invention have been described with reference to Figures 1 to 7 Next, a control device and a control parameter setting method according to a second embodiment of the present invention will be described with reference to Figures 8 to 19 The detailed descriptions of the control device and the control parameter setting method according to the second embodiment of the present invention, as well as the production equipment and production method according to the first embodiment of the present invention, in terms of names, terms, or functions, are based on the detailed descriptions of each embodiment and may be the same as or different from each other.

[0116] Next, the configuration of the control device and the control parameter setting method according to the second embodiment of the present invention will be described with reference to the accompanying drawings.

[0117] Figure 8Shows the operation of a controller of a comparative example according to a second embodiment of the present invention. In a controller for driving a load such as a motor, the controller 2010 applies a voltage for driving the motor to the motor 2021 through a voltage output 2015 in a position / speed / current control logic 2011, senses the current flowing through according to the applied voltage in a current measurement 2015, and uses the sensed current to drive the motor 2021 in the position / speed / current control logic 2011. In the position / speed / current control logic 2011, control parameters for driving the motor 2021 are set, and the control parameters are set using characteristic values or design values of the motor.

[0118] At this time, when using design values, since there may be a deviation between the design values and the manufactured product, and the characteristic values of the motor may change with temperature change or aging, it may be difficult to achieve optimal control performance using the previously set control parameters of the position / speed / current control logic 2011.

[0119] In order to achieve optimal control performance even when there is an error or change in the load characteristics according to the characteristics of the load, the control device according to an embodiment of the second embodiment of the present invention can use frequency response analysis to set or change control parameters. Hereinafter, the production equipment according to an embodiment of the second embodiment of the present invention will be described in detail.

[0120] Figure 9 Is a block diagram of a control device according to an embodiment of the second embodiment of the present invention.

[0121] The control device 1100 according to an embodiment of the second embodiment of the present invention includes: a controller 1110, a sine wave generation unit 1120, an analysis unit 1130, and a processing unit 1140, and may include a voltage output unit 1150, a current measurement unit 1160, a storage unit 1131, and an FFT conversion unit 1132.

[0122] The controller 1110 sends a control signal for controlling the load 1210 to the load 1210.

[0123] More specifically, the controller 1110 controls the load 1210 according to the set control parameters and transmits a control signal to the load 1210 to control the load 1210. The load 1210 connected to the control device 1100 may be an actuator. Here, the actuator is a driving device that uses power to operate the device, refers to a motor operated by a predetermined controller, or a piston or cylinder mechanism operated by hydraulic or pneumatic pressure. The load 1210 may be a motor, and the control device 1100 may be a motor driving device for driving the motor.

[0124] The sine wave generation unit 1120 generates a sine wave with a variable frequency and sends the sine wave to the load 1210.

[0125] More specifically, the sine wave generation unit 1120 generates a sine wave with a variable frequency and sends the sine wave to the load 1210 to determine the characteristics of the load 1210.

[0126] Here, a sine wave refers to a signal (also known as a sine wave) whose waveform is a sine curve. The sine wave generation unit 1120 sends a sine wave with a variable frequency, but can output one frequency in one or more cycles. As Figure 3 shown, the sine wave generation unit 1120 can send a sine wave with a variable frequency, which is formed by a sine curve. At this time, as Figure 3 (A) of FIG. shows, a sine wave can be output such that the frequency gradually increases or the frequency gradually decreases. Alternatively, the frequency can gradually increase and then decrease, or decrease and increase, or can vary randomly. The changing frequency can vary linearly or exponentially. In addition, the frequency can vary in various ways. At this time, a signal with one of the variable frequencies can be output for one or more cycles. Since the response in one cycle is used to measure the control parameter, the sine wave generation unit 1120 can output a waveform formed by one frequency within one or more cycles.

[0127] Alternatively, as Figure 3 (B) of FIG. shows, a signal whose frequency continuously changes can be output in one or more cycles. As Figure 3 (B) of FIG. shows, the frequency can change such that the frequency gradually increases from the start time f S(Start) to the end time f E(End) over time. For example, the frequency can be in the form of a chirp signal. The frequency can gradually increase or gradually decrease, and can vary linearly or exponentially, as Figure 3 (B) of FIG. shows. Alternatively, it can increase and then decrease, or can vary randomly. In addition, the frequency can vary in various ways.

[0128] The sine wave generation unit 1120 can receive a mode operation signal from the controller 1110 to generate a sine wave with a variable frequency. When it is necessary to reset or change the control parameter, the controller 1110 can control the sine wave generation unit 1120 to generate a sine wave with a variable frequency. Alternatively, the advanced controller 1220 can cause the sine wave generation unit 1120 to generate a sine wave with a variable frequency through the mode operation signal. When setting the control parameter during the production process, the production device 1220 can control the sine wave generation unit 1120 to generate a sine wave with a variable frequency. Upon receiving the mode operation signal, the sine wave generation unit 1120 generates a sine wave with a variable frequency and sends the sine wave to the load 1210.

[0129] Alternatively, the sine wave generation unit 1120 may periodically generate a sine wave. Even if no mode operation signal is received from the controller 1110, the advanced controller 1220, or the production equipment 1220, a sine wave with a variable frequency may be periodically generated for periodic control parameter updates. The period for generating the sine wave with a variable frequency may be set to update the control parameters in units of months or years, and may be set to perform a fault determination of the load 1210 in units of seconds, minutes, hours, and days. In addition, of course, various periods may be set. The variable frequency sine wave generation period may vary according to the characteristics of the load 1210 connected to the control device 1100 or the characteristics of the control device 1100, and may be set by the user. Alternatively, the sine wave generation unit 1120 may continuously change the frequency to generate a sine wave.

[0130] The load 1210 receives a control signal from the controller 1110 and a sine wave with a variable frequency from the sine wave generation unit 1120. The load 1210 may receive the control signal and the sine wave with a variable frequency together. At this time, the frequency of the sine wave may be different from the frequency of the control signal of the controller. Since the frequency of the control signal for driving the load 1210 and the frequency of the sine wave for setting the control parameters should be distinguished, the sine wave generation unit 1120 may generate a sine wave having a frequency different from the frequency of the control signal. The sine wave generation unit 1120 may generate a sine wave by changing the frequency to include at least one frequency different from the frequency of the control signal. When generating a variable frequency, the sine wave generation unit 1120 may change the frequency other than the sine wave having the same frequency as the control signal. A response to the corresponding frequency may be received from the control signal and analyzed. Alternatively, the frequency may be changed by including the same frequency as the frequency of the control signal. Alternatively, the load 1210 may independently receive the control signal and the sine wave with a variable frequency through separate input lines, or different input periods may be applied.

[0131] The control signal of the controller and the sine wave with a variable frequency may be sent to the load 1210 through the voltage output unit 1150. The voltage output unit 1150 may convert the control signal of the controller 1110 and the sine wave of the sine wave generation unit 1120 into voltage signals and send the voltage signals to the load 1210. The load 1210 may be a device that receives voltage and operates, such as a motor, and the voltage output unit 1150 receives the control signal and the sine wave to apply voltage to the load 1210, and the voltage output unit 1150 may send a voltage corresponding to the frequency to the load 1210 according to the frequency of the control signal and the sine wave. The voltage output unit 1150 may be a bridge circuit formed by a plurality of switches. The upper switch and the lower switch forming the bridge conduct complementary to each other, and three-phase voltages with a phase difference may be sent to the load 1210 in each bridge circuit.

[0132] The analysis unit 1130 analyzes the sensed current sensed from the current output from the load 1210.

[0133] More specifically, to set the control parameter, the sine wave generation unit 1120 generates a sine wave and applies the sine wave to the load 1210, and the analysis unit 1130 analyzes the sensed current sensing the current output from the load 1210 according to the applied sine wave.

[0134] The current measurement unit 1160 senses the current output from the load. The current measurement unit 1160 is connected to the output line of the load 1210 to sense the current. The current can be formed by a current measurement element such as a shunt resistor. Alternatively, various devices such as a current mirror circuit and a voltage measurement device can be used to sense the current output from the load 1210.

[0135] The sensed current sensed by the current measurement unit 1160 can be used by the controller 1110 to generate a control signal, and the analysis unit 1130 can be used to analyze the frequency response of the control parameter.

[0136] When analyzing the sensed current, the analysis unit 1130 can analyze the received sensed current by performing a fast Fourier transform. The fast Fourier transform (FFT) is a method of the Fourier transform for processing discrete data at high speed and is used to analyze signals. When using the fast Fourier transform, fast processing can be performed by decomposing the discrete Fourier transform of a long signal sequence into the discrete Fourier transforms of short signal sequences in order and using the symmetry and periodicity of the rotation factors to change the order of the data to reduce the number of multiplications that take time.

[0137] The analysis unit 1130 can perform a fast Fourier transform using the received sensed current and the sine wave sent from the sine wave generation unit 1120 to the load 1210. When performing the fast Fourier transform, the analysis unit 1130 can include a storage unit 1131 for storing the sine wave or the sensed current, and an FFT transform unit 1132 for performing a fast Fourier transform using the sine wave and the sensed current.

[0138] The sine wave generated by the sine wave generation unit 1120 and sent to the load 1210 is branched and stored in the storage unit 1131, and when the sensed current corresponding to the stored sine wave is received, the FFT transformation unit 1132 can perform a fast Fourier transform using the received sensed current and the stored sine wave. The FFT transformation unit 1132 can know the frequency response characteristics of the load 1210 through the fast Fourier transform. The frequency response refers to measuring what kind of response is output when input signals of various frequencies are applied to a certain system, and is used to analyze the corresponding system. The amplitude of the signal can be constant or variable. The frequency response can represent the amplitude and phase of the signal output from the system as a curve with respect to frequency.

[0139] The processing unit 1140 uses the result of analyzing the sensed current to set the control parameters of the controller 1110.

[0140] More specifically, the processing unit 1140 receives the result of analyzing the sensed current from the frequency response analysis unit 1130. As described above, the analysis unit 1130 analyzes the sensed current through the fast Fourier transform and sends the analysis result to the processing unit 1140. The processing unit 1140 can use the result of analyzing the sensed current to calculate the control parameters of the controller 1110. The calculated control parameters can be sent to the controller 1110 to change or set the control parameters of the controller 1110. The controller 1110 sets the control parameters to control the load 1210. The control parameters of the controller 1110 can be different parameters set according to the characteristics of the type of the controller 1110.

[0141] The processing unit 1140 can use the result of analyzing the sensed current to calculate the PI control parameters, PID control parameters or filter coefficients of the controller 1110.

[0142] The processing unit 1140 calculates the PI control parameters when the controller 1110 is a PI controller, calculates the PID control parameters when the controller 1110 is a PID controller, and can calculate the filter coefficients when a filter is included. The controller 1110 can be an automatic controller and can be controlled using a combination of P, I, and D.

[0143] Here, P represents proportional, I represents integral, and D represents derivative. Proportional (P) control is a control that makes the control quantity proportional to the difference between the target value and the current position, and as it approaches the target value, the difference in the control value decreases, enabling fine control. When performing proportional control, when the control quantity approaches the target value, the control quantity becomes too small to perform fine control on it, resulting in a residual deviation that remains uncontrollable. PI control is a control that uses proportional and integral, and the residual deviation can be removed by using PI control. The minute residual deviation accumulates over time, and the control quantity is increased according to the accumulated residual deviation to eliminate the deviation. Since PI control is a control that adds integral operation to the proportional operation, it is called PI control. In the case of PI control, it is possible to control close to the actual target value, but as it approaches the target value, the control quantity decreases, requiring continuous operation for a certain period or longer. At this time, if the integer is large, the response performance may deteriorate in the presence of external disturbances. That is, it may be difficult to quickly respond to external disturbances and it may be difficult to return to the target value. To solve this, derivative operation can be performed. By observing the deviation of a sudden disturbance, and if the difference from the previous deviation is large, the manipulated value is increased for response. Observing the difference from the previous deviation corresponds to derivative, and PID control is performed by applying derivative to proportional and integral. Even if the control quantity deviates from the target value, it can be determined as the deviation from the previous time, and the target value can be quickly reached by applying the control quantity.

[0144] PID control can be expressed as a PID control equation, and the PID control parameters can be expressed as Kp, Ki, and Kd. The PID parameters can be calculated by optimization using the step response method or the limit reduction method. PI control can correspond to this, and calculate the PI control parameters Kp and Ki.

[0145] The processing unit 1140 can send the calculated control parameters to the controller 1110, so that the controller 1110 uses the calculated control parameters to set or change the control parameters of the controller 1110. The control parameters calculated by the processing unit 1140 are the control parameters calculated while connecting the load 1210. That is, by reflecting the characteristic values according to the temperature or aging of the load 1210, the control parameters are adaptively calculated, and the control parameters correspond to the optimal control parameters of the controller 1110.

[0146] The processing unit 1140 may perform quality determination on the controller 1210 and the control device 1100 or the load 1210 using the results received from the analysis unit 1130. When performing quality determination during the production process, accurate quality determination can be performed by performing quality determination on the controller 1110 with the load 1210 connected. In the case of performing quality determination without connecting the controller 1110 and the load 1210, problems that may occur in practical applications where quality determination is performed by assuming the control parameters of another component do not occur in the production equipment according to the second embodiment of the present invention, in which the load 1210 is connected to the controller 1110 and the control parameters of the controller 1110 to which the load 1210 is connected are measured. The processing unit 1140 may perform quality determination on the load 1210 as well as the controller 1110. Since the load 1210 is connected to the controller 1110, the processing unit 1140 may perform quality determination on the load 1210 as well as the controller 1110. That is, the processing unit 1140 may perform quality determination on each of the controller 1110 and the load 1210, or perform quality determination on the controller 1110 and the load 1210 as a group.

[0147] The processing unit 1140 may perform quality determination on the controller 1110 or the load 1210 using the results of analyzing the sensed current. Quality determination on the controller 1110 or the load 1210 may be performed based on whether the control parameters according to the results of analyzing the sensed current satisfy the quality determination criteria. The quality determination criteria may have a lower limit and an upper limit, or may be set within a predetermined range having a lower limit or an upper limit. The quality determination criteria are set according to the design specifications of the controller 1110 and the load 1210, or may be set according to safety or security levels, or may be set by the user. The quality determination criteria may be stored in a memory. The quality determination criteria may be stored as a look-up table (LUT).

[0148] The processing unit 1140 may derive the inductance value L and the resistance value R or the impedance value Z from the results of analyzing the sensed current. The derived inductance value, resistance value, or impedance value may be used to perform quality determination on the controller 1110 or the load 1210. That is, quality determination on the controller 1110 and the load 1210 may be performed by determining whether it is within the reference range of the inductance value and the resistance value or whether the impedance value is within the inductance reference range.

[0149] The processing unit 1140 can not only perform quality determination on the load 1210 by using the result of analyzing the sensed current, but also determine the cause of the load 1210 failure when it is determined that the load 1210 is defective. By determining which failure causes the load 220 to be defective and storing and accumulating the failure cause information, it is possible to know the defect causes that often occur during the current production process of the load 1210, and it is possible to know which defects occur at which rate in which production line. That is, the defect cause information can be used to perform the management of the production line or production system.

[0150] The processing unit 1140 can derive the inductance value and impedance value through the analysis of the sensed current, and can use the inductance value and impedance value to determine the cause of the failure. At this time, the criteria for determining the cause of the failure and classification can vary according to the type of the load 1210. For example, when the load 1210 is a three-phase motor and the controller 1110 drives the motor using a three-phase power supply, the processing unit 1140 can determine disconnection, short circuit, increased contact resistance, magnet demagnetization, reduced coil insulation, etc. as the causes of the defects.

[0151] The processing unit 1140 can calculate the control parameters of the controller 1110 simultaneously with or after the quality determination. When the controller 1110 and the load 1210 are good products, the control parameters can be calculated to set the optimal parameters for the controller 1110 in the state where the load 1210 is connected. When the controller 1110 or the load 1210 is defective, the calculation of the control parameters may not be performed. Or, according to the result of the control parameters set in the current controller 1110 is poor, but when it can be determined to be good within the range when the control parameters are changed, the quality determination result of the controller 1110 or the load 1210 can be changed by changing the control parameters of the controller 1110 or the load 1210. Or, the quality determination can be performed again after changing the control parameters. Thus, it is possible to prevent the situation where it may be determined to be defective even when it can be determined to be good when the control parameters are changed. When performing a separate quality determination on the load 1210 using fixed control parameters, there may be a situation where a defective determination is made on the load 1210 even when the load 1210 can be used as a good product when the control parameters are changed. However, in the production equipment according to the embodiment of the first embodiment of the present invention, not only the quality determination is performed on the controller 1110 to which the load 1210 is connected, but also the possibility and accuracy of the quality determination of the load 1210 are improved by using the change of the control parameters to change the result of the load 1210.

[0152] The processing unit 1140 can use the result of analyzing the sensed current to determine whether a fault has occurred in the load 1210. The process of determining whether a fault exists can correspond to the process of performing quality determination. Quality determination is performed during the production process, and fault determination can be performed during the process of controlling the load by installing the load in a device or system. The processing unit 1140 can determine whether a fault exists according to the fault determination criteria. The fault determination criteria can be different from the quality determination criteria. Quality determination is for the determination of sales, while fault determination is for the determination of whether to stop operating due to a fault during the current operation period. Therefore, the fault determination criteria may be weaker than the quality determination criteria. If it is not a critical fault, even within the range determined to be defective during quality determination, it may not be determined as a fault when determining whether a fault exists. That is, the range of criteria determined to be normal rather than defective can be wider than the criteria used to determine good products. Or, of course, the fault determination criteria can be the same as the quality determination criteria. The fault determination criteria can be set according to the design specifications of the controller 1110 and the load 1210, or can be set according to safety or safety levels, or can be set by the user. The fault determination criteria can be stored in the storage unit 1131. The fault determination criteria can be stored as a look-up table (LUT).

[0153] In addition, the processing unit 1140 can not only determine whether a fault exists, but also determine the cause of the fault. The load 1210 can determine what the cause of the fault is and provide the cause of the fault to the system or the high-level controller 1220 through an alarm, so that the cause of the fault can be used to quickly handle the fault.

[0154] The processing unit 1140 can derive the inductance value and the impedance value through the analysis of the sensed current, and can use the inductance value and the impedance value to determine the cause of the fault. At this time, the fault cause determination criteria and classification can vary according to the type of the load 1210. For example, when the load 1210 is a three-phase motor and the controller 1110 drives the motor using a three-phase power supply, the processing unit 1140 can determine an open circuit, a short circuit, and an increase in contact resistance as the cause of the fault in the load 1210, as Figure 11 shown, and can determine magnetic demagnetization, a decrease in coil insulation, etc., as Figure 12 shown. The process of determining the cause of the fault can correspond to the process of determining the cause of the fault in quality determination.

[0155] If the impedance of the disconnected phase suddenly drops to zero, it can be determined that a winding break has occurred. On the contrary, if the impedance of the short-circuited phase suddenly increases compared with the existing value, it can be determined that a winding short circuit has occurred. In addition, if the resistance of a specific phase in the measured impedance increases, it can be determined that the contact resistance has increased due to the increase in the contact resistance of this phase.

[0156] When the amplitude of the current measured at the frequency of the applied voltage (predetermined frequency) (e.g., in a region less than 100 Hz) at the same temperature and rotational speed becomes larger than before, it can be determined that the magnet has demagnetized. Additionally, when the current is large and the winding temperature increases simultaneously, if the inductance measured in a region where the frequency of the applied voltage is 100 Hz or greater becomes smaller than the existing value, it can be determined that the magnet has demagnetized. When the resistance and inductance of the coil with reduced insulation develop in the direction of slightly reduced insulation, it can be determined that the insulation of the coil has decreased. In addition, various failure causes can be determined.

[0157] Furthermore, the processing unit 1140 can estimate the temperatures of the stator and rotor included in the load by determining whether the magnetic flux intensity, resistance, or inductance of the load has changed by using the result of analyzing the sensed current. Since the load of a motor can include a stator and a rotor, and the load including the stator and rotor is greatly affected by temperature. Therefore, when measuring the temperatures of the stator and rotor, the result of analyzing the sensed current can be used. The temperatures of the stator and rotor can be estimated by determining at least one of the change in the magnetic flux intensity, the change in the resistance, or the change in the inductance of the load by using the result of analyzing the sensed current. In this way, it can be determined whether a failure has occurred or the probability of a failure based on the estimated temperature.

[0158] The controller is a microcontroller unit (MCU), and the sine wave generation unit, the analysis unit, and the processing unit can be implemented as processors in the MCU. That is, the sine wave generation unit, the analysis unit, and the processing unit can be implemented as software on the processor included in the MCU embedded in a vehicle or the like, or can be implemented in the form of a hardware companion chip. When implemented in the form of hardware, it can be formed as one hardware or separate hardware.

[0159] Figure 13 and Figure 14 is a diagram for explaining the operation of the production equipment according to the second embodiment of the present invention. As Figure 13 shown, the controller 1100 can be a control device including an FRA online calibration function, drive the motor 1210 used as a load, and perform a frequency response using a variable frequency sine wave. The controller 1100 receives a calibration operation signal from the production device or the advanced controller 1220 and applies a voltage including a sine wave with a variable frequency to operate the motor 1210. The controller 1100 is connected to the motor 1210, and when the motor is a three-phase motor, the three phases are connected, while in the case of a DC motor, + and - can be connected. When an output current according to the voltage applied to the motor 1210 is generated, quality determination can be performed by performing frequency response analysis using the sensed current sensed by the current, and the control parameters of the controller in the controller 1100 can be set. The quality determination information can be sent to the production device or the advanced controller 1220.

[0160] Figure 14 It is a block diagram of each specific function of the controller 1100, which may include: position / speed / current control logic as a controller for driving the motor 1210 serving as a load; a voltage output unit 1150; a current measurement unit 1160. In addition, it further includes a sine wave generation unit for detecting the characteristics of the motor 1210 using a sine wave of variable frequency, a memory 1131 for storing voltage and current signals, an FFT conversion unit 1132 for performing FFT on the stored signals, and an FRA online calibration including a processing unit 1140 for designing and analyzing control parameters.

[0161] When the production device or the advanced controller 1220 sends a calibration operation signal to the sine wave generation unit, the sine wave generation unit generates a sine wave signal of variable frequency, and the voltage output unit 1150 converts the sine wave signal of variable frequency together with the control signal output from the position / speed / current control logic into a voltage to apply the voltage to the motor 1210. Here, the variable frequency signal should output one or more cycles. For example, if a 1 Hz signal and a 10 Hz signal are output, after the 1 Hz signal is output for one or more cycles, the 10 Hz signal should be output for one or more cycles. In addition, this variable frequency refers to a frequency different from the rotation frequency of the motor. For example, when the motor rotates at 600 rpm and the number of pole pairs is 4, a voltage is applied at 40 Hz. However, in the FRA online calibration function, a variable signal including 40 Hz is added and applied. When the current corresponding to the applied voltage is output from the motor 1210, the current measurement unit 1160 senses the current and performs a fast Fourier transform (FFT) using the pre-stored voltage and the current signal of the sine wave according to the variable frequency. The stored data is data corresponding to the same frequency, and the number of voltage and current data is the same. The gain and phase value are calculated through FFT, and the gain and phase value according to the frequency are sent to the processing unit 1140. The processing unit 1140 designs and analyzes the control parameters accordingly to calculate the quality determination or control parameters. The quality determination information is sent to the production device or the advanced controller 1220, and the control value of the position / speed / current control logic is changed using the calculated control parameters. Thus, quality determination can be performed in the state where the motor, the controller, and the controller are connected to the motor. In addition, the controller stability (phase margin, gain margin) can be measured in the frequency domain. In addition, the characteristics of the required frequency can be analyzed through the sine wave generation unit inside the control device, and the optimal controller values (P, I, D, gain, and filter) can be designed. In addition, even if the motor characteristics change with the change of the motor usage environment (temperature, aging, etc.), the motor characteristics can be measured online to obtain the optimal control value, and the control performance (steady-state ripple, transient responsiveness, etc.) can always be kept optimal.

[0162] In addition,Figure 15 The mutual interference component of the dual motors 1700 can be measured by using a sine wave generation unit. Sine waves with different frequencies are respectively applied to different motors 1710 and 720, and the mutual interference components of the two motors 1710 and 720 can be respectively calculated through frequency response analysis of the output current. Thus, the mutual interference component can be accurately compensated by calculating the accurate mutual interference component.

[0163] Figure 16 is a flowchart of a control parameter setting method according to an embodiment of the second embodiment of the present invention; and Figures 17 to 19 is a flowchart of a control parameter setting method according to another embodiment of the second embodiment of the present invention. Figures 16 to 19 The detailed description of each step of Figures 8 to 15 corresponds to the detailed description of the method for setting the control parameters in the control device of

[0164] In step S11, the sine wave generation unit generates a sine wave with a variable frequency. In step S12, the sine wave is sent to the load together with the control signal generated by the controller. Thereafter, in step S13, the current output from the load is sensed, and in step S14, the sensed current is analyzed. When analyzing the sensed current, the fast Fourier transform can be performed using the sine wave and the sensed current.

[0165] Then, in step S15, the control parameters of the controller are set using the result of analyzing the sensed current in step S14.

[0166] When setting the parameters of the controller, the inductance and impedance of the load derived from the analysis result of the sensed current can be used to set the control parameters of the controller.

[0167] In addition, in step S21, the result of analyzing the sensed current in step S14 can be used to perform a quality determination on the load or the controller.

[0168] When generating the sine wave, the sine wave can be generated by receiving a mode operation signal from the controller, the production device, or the high-level controller, or the sine wave can be generated periodically, and the frequency of the sine wave can be different from the control signal and frequency of the controller.

[0169] In addition, when analyzing the sensed current, in step S31, the result of analyzing the sensed current in step S14 can be used to determine whether the load is disconnected, short-circuited, has an increased contact resistance, magnetic demagnetization, or reduced coil insulation.

[0170] In addition, when analyzing the sensed sensing current, in step S41, the temperature of the stator and rotor included in the load can be estimated by determining whether the magnetic flux intensity, resistance, or inductance of the load has changed by using the result of analyzing the sensing current in step S14.

[0171] The control parameter setting method according to the second embodiment of the present invention can be executed in a processor of an embedded controller (MCU) formed in a vehicle or the like. That is, by using frequency response analysis (FRA), the optimal control parameters (PID / PI / filter coefficient) can be found. By using frequency response analysis, the optimal control parameters (PID / PI / filter coefficient) can be found online (or at runtime) in real time or periodically during vehicle operation.

[0172] A modified embodiment according to the present embodiment may include some configurations of the first embodiment and some configurations of the second embodiment together. In other words, the modified embodiment may include the first embodiment, but some configurations of the first embodiment may be omitted, and some configurations of the corresponding second embodiment may be included. Alternatively, the modified embodiment may include the second embodiment, but some configurations of the second embodiment may be omitted, and some configurations of the corresponding first embodiment may be included.

[0173] The features, structures, effects, etc. described in the above embodiments are included in at least one embodiment and are not necessarily limited to only one embodiment. In addition, the features, structures, effects, etc. shown in each embodiment can be combined or modified by those of ordinary skill in the art to which the embodiments belong for other embodiments. Therefore, the content related to such combinations and modifications should be construed as being included within the scope of the embodiments.

[0174] Meanwhile, the embodiments of the present invention can be implemented as computer-readable code on a computer-readable recording medium. The computer-readable recording medium includes all types of recording devices that store data that can be read by a computer system.

[0175] Examples of the computer-readable recording medium are ROM, RAM, CD-ROM, magnetic tape, floppy disk, and optical data storage device. In addition, they are distributed in a distributed manner in a networked computer system, in which computer-readable code can be stored and executed. And, the functional programs, codes, and code segments for implementing the present invention can be easily deduced by programmers in the technical field to which the present invention belongs.

[0176] As described above, in the present invention, specific matters such as specific components and limited embodiments and drawings have been described, but these are provided only to help a more general understanding of the present invention, and the present invention is not limited to the above embodiments, and those of ordinary skill in the art to which the present invention belongs can make various modifications and variations based on these descriptions.

[0177] Therefore, the spirit of the present invention should not be limited to the described embodiments, and not only the claims to be described later, but also all those equivalent to the claims or equivalent modifications to the claims will be regarded as falling within the scope of the spirit of the present invention.

Claims

1. A production device for performing quality determination, comprising: A frequency response analysis unit that sends a sine wave of variable frequency to a controller connected to a load, receives a sensed current that senses the current output from the load, and analyzes the received sensed current, wherein the sine wave is applied from the controller to the load; and A processing unit that receives, from the frequency response analysis unit, the result of analyzing the sensed current to perform quality determination on the controller.

2. The production equipment according to claim 1, wherein, The frequency response analysis unit analyzes the received sensed current by performing a fast Fourier transform.

3. The production equipment according to claim 1, wherein, The frequency response analysis unit performs a fast Fourier transform using the received sensed current and the sine wave sent to the controller.

4. The production equipment according to claim 1, wherein, The sine wave is a sine wave with variable frequency, and a signal with one of the variable frequencies is output for one or more cycles, or a signal with continuously changing frequency is output for one or more cycles.

5. The production equipment according to claim 1, wherein, The controller receives the sine wave from the frequency response analysis unit, converts the sine wave into a voltage signal, and applies the voltage signal to the load.

6. The production equipment according to claim 1, wherein, The processing unit uses the result of analyzing the sensed current to perform quality determination on the controller or the load.

7. The production equipment according to claim 1, wherein The processing unit uses the result of analyzing the sensed current to determine the cause of the failure of the load.

8. The production equipment according to claim 1, wherein, The processing unit calculates the control parameters of the controller using the result of analyzing the sensed current while performing quality determination or after performing quality determination, and sends the control parameters to the controller.

9. The production equipment according to claim 8, wherein The control parameters of the controller include the PI control parameters, PID control parameters, or filtering coefficients of the controller.

10. The production equipment according to claim 1, wherein, The processing unit controls the frequency response analysis unit by sending a mode entry signal to the frequency response analysis unit.

11. The production equipment according to claim 1, wherein, The frequency response analysis unit sends the sine wave to the controller using communication or a digital-to-analog converter DAC.

12. The production equipment according to claim 1, wherein, The load includes an actuator.

13. A production method for performing quality determination, comprising the following steps: Sending a mode entry signal to the frequency response analysis unit; Generating, by the frequency response analysis unit, a sine wave of variable frequency and sending the sine wave to a controller connected to a load; Receiving, from the controller, a sensed current that senses the current output from the load, wherein the sine wave is applied to the load; Analyzing, by the frequency response analysis unit, the received sensed current; Receiving, from the frequency response analysis unit, the result of analyzing the sensed current; and Performing quality determination on the controller or the load using the result of analyzing the sensed current.

14. The production method according to claim 13, wherein, The step of analyzing the received sensed current is performed by performing a fast Fourier transform using the received sensed current and the sine wave sent to the controller.

15. The production method according to claim 13, wherein The sine wave is a sine wave with variable frequency, and a signal with one of the variable frequencies is output for one or more cycles, or a signal with continuously changing frequency is output for one or more cycles.

16. The production method according to claim 15, further comprising the following steps performed while performing quality determination or after performing quality determination: Calculating the control parameters of the controller; and Sending the calculated control parameters to the controller.

17. The production method according to claim 16, wherein The step of calculating the control parameters of the calculation controller uses the result of analyzing the sensed current to calculate the PI control parameters, PID control parameters or filtering coefficient of the controller.

18. The production method according to claim 15, wherein, The step of performing quality determination on the controller or the load uses the result of analyzing the sensed current to determine the cause of the failure of the load.

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