Adaptive Stepper Motor Current Control for Textile Machines
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Solution Overview
Problem
Textile machines producing cross-wound bobbins with multiple workstations and stepper motors face inefficiencies due to excessive energy consumption, as current settings are designed for the worst-case friction torque, leading to unnecessary power usage and increased component sizing.
Innovation Solution
Implement a method where stepper motors are connected to a power supply with limited output, and the target current magnitude is adjusted based on speed fluctuations, reducing power consumption by adapting to actual torque requirements rather than fixed settings, thereby optimizing energy use and minimizing unnecessary acceleration and braking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current settings are designed for the worst-case friction torque, then the stepper motors can overcome the maximum expected friction, but energy consumption increases unnecessarily
Solution Approach 1:
The patent applies dynamics by making the current setting adaptive rather than fixed. The control system continuously adjusts the current magnitude based on actual operating conditions (speed fluctuations, acceleration needs, friction variations), allowing the motor to use only the necessary current at each moment rather than maintaining a constant high current set for worst-case scenarios
Solution Approach 2:
The patent changes the parameter of current magnitude dynamically. Instead of using a fixed current setting designed for worst-case friction, the system varies the current parameter in real-time based on actual torque requirements, speed changes, and operational state, thereby reducing energy consumption while maintaining sufficient torque when needed
2Ease of operation
If a fixed current target value is used for all operating states, then control is simplified, but power consumption cannot be optimized
Solution Approach 1:
The system transitions from static to dynamic control by continuously adjusting the current target value based on actual speed fluctuations and operational needs. The control algorithm monitors speed deviations and automatically modifies current magnitude, maintaining simplicity in the control structure while achieving dynamic optimization of power consumption
Solution Approach 2:
The patent implements feedback control by monitoring actual speed and comparing it with the target speed. Based on speed fluctuations and the resulting torque requirements, the system adjusts the current target value accordingly. This closed-loop feedback mechanism enables energy optimization while keeping the control system relatively simple
3Force
If stepper motors are supplied with high current to handle maximum friction, then torque requirements are met, but heating increases
Solution Approach 1:
The system dynamically changes the current parameter to match actual torque requirements. By reducing the current magnitude when maximum friction is not present, the system maintains sufficient torque for actual conditions while significantly reducing I²R losses and associated heating in the motor windings
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces energy consumption, lowers heating in the textile machine, and allows for the use of power packs with lower nominal power, improving operational efficiency and reducing hardware costs.
Implementation Method 1
Stepper motors are preferably used as individual drives... by means of which a target value is set for the magnitude of the current... The magnitude of the current specifies the drive torque
Data Source
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AI summary
The method involves supplying electrical energy to stepper motors of multiple working locations (1) of a same type by a power supply (31) with a limited power. A variable e.g. current variation, of the stepper motors of handling devices (4) of the working locations representing rotational speed variations is detected. A reference value for an amount of current is adapted to the motors based on the variable. The power received from the power supply is limited. A power end stage is associated to each motor. The reference value is adjusted by the stage. An independent claim is also included for a textile machine producing cross-wound spools comprising working locations.