Brushless Synchronous Motor Feed-Forward Control for Fluid Jet Cutting
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Solution Overview
Problem
Fluid jet cutting systems using servo-loop controlled motors are expensive and require costly control circuitry, and existing feedback systems often have limitations in precision and accuracy due to loosely coupled actuation systems.
Innovation Solution
A brushless synchronous motor drive system with a friction drive arrangement and a feed-forward control system that adjusts the number of motor drive increments based on observed coupling between the drive wheel and sensor, allowing for higher precision and accuracy in nozzle movement through a combination of feedback and feed-forward control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If servo-loop controlled motors are used to move the cutting nozzle, then positioning accuracy is improved, but system cost and control circuitry complexity increase
Solution Approach 1:
The patent replaces the complex servo-loop control system with a brushless synchronous motor driven by a microcontroller implementing feed-forward control algorithms. This substitution eliminates the need for expensive servo control circuitry while maintaining positioning accuracy through software-based motion control and mathematical modeling of the friction drive mechanics.
Solution Approach 2:
The invention uses a cost-effective brushless synchronous motor with simple drive electronics instead of expensive servo motors. The system accepts some limitations in the feedback system and compensates through feed-forward control, effectively using a cheaper component solution to achieve the required performance.
2Measurement precision
If feedback systems are used in loosely coupled actuation systems, then positioning control is provided, but precision and accuracy are limited due to coupling variations
Solution Approach 1:
The patent implements feed-forward control that pre-calculates and compensates for expected positioning errors based on the commanded motion. By anticipating and correcting for coupling variations before they affect positioning accuracy, the system overcomes the limitations of the loosely coupled friction drive arrangement.
Solution Approach 2:
The system combines feedback from a position sensor with feed-forward control algorithms. The feedback provides actual position information while the feed-forward component proactively compensates for expected errors due to friction drive coupling variations, achieving higher precision than feedback alone could provide.
Data Source
AI summary
A drive system, such as for a fluid jet cutting system, includes a brushless synchronous motor configured to drive movement through a loosely coupled transmission, a sensor configured to sense movement, and a control system configured to drive the brushless synchronous motor responsive to previously measured drive coupling.