Digital High-Resolution Controller Kinematic Energy Control

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Solution Overview

Problem

Conventional electronic positioners face limitations in achieving high resolution and stability due to mechanical wear, overheating, and inefficiencies in controlling actuators, particularly in maintaining precise valve positions and handling varying fluid viscosities.

Innovation Solution

A kinematic control algorithm that adapts to actual motor motion and mechanical conditions by supplying energy in discrete quantities based on observed motion, reducing deadband and backlash, and incorporating electronic braking to achieve precise positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional electronic positioners use traditional control algorithms, then the system structure is simple, but the positioning resolution and stability are limited due to mechanical wear, deadband, and backlash

Engineering Contradiction:

Improvepositioning resolutionVSAvoidcontrol algorithm complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical positioning control with an energy-based control system that supplies discrete energy packets to the motor. This substitution eliminates the need for complex mechanical feedback mechanisms and reduces the impact of mechanical wear, deadband, and backlash on positioning resolution. The controller monitors motor motion and adjusts energy supply accordingly, achieving high-resolution control through energy management rather than mechanical adjustment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements a feedback mechanism where the controller monitors the actual motion of the motor and uses this information to adjust subsequent energy supply. By observing motor motion and comparing it to desired positioning, the system can compensate for mechanical imperfections like deadband and backlash, thereby improving positioning resolution without requiring overly complex mechanical structures.

Inventive Principle:

Principle #23Feedback

2Stability of the object's composition

If the motor operates continuously to maintain positioning, then the positioning stability is improved, but the motor overheats and reliability decreases

Engineering Contradiction:

Improvepositioning stabilityVSAvoidmotor temperature

Core Design Contradiction:

Stability of the object's compositionVSTemperature

Solution Approach 1:

The patent employs periodic energy supply to the motor rather than continuous operation. The controller supplies discrete energy packets at intervals, allowing the motor to rest between activations. This periodic operation maintains positioning stability by making adjustments only when necessary, while significantly reducing cumulative heat generation and improving motor reliability.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The patent converts the potential harm of motor overheating into a benefit by using the motor's natural cooling periods between operations. By carefully timing energy supply to coincide with periods when the motor has cooled sufficiently, the system maintains positioning stability without causing excessive temperature rise, effectively turning the cooling requirement into a design advantage.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Measurement precision

If the controller uses high-frequency adjustments to maintain precision, then the positioning accuracy is improved, but the motor experiences excessive cycling and reduced lifespan

Engineering Contradiction:

Improvepositioning accuracyVSAvoidmotor lifespan

Core Design Contradiction:

Measurement precisionVSDuration of action of moving object

Solution Approach 1:

The patent applies partial energy packets to the motor rather than full-power continuous operation. By supplying just enough energy to achieve the desired positioning adjustment and then stopping, the system maintains high positioning accuracy while minimizing the total operational time of the motor. This partial action approach reduces wear and extends motor lifespan.

Inventive Principle:

Principle #16Partial or excessive action

4Manufacturing precision

If the positioner uses mechanical brakes to prevent overshoot, then the positioning precision is improved, but the mechanical wear increases and maintenance requirements increase

Engineering Contradiction:

Improvepositioning precisionVSAvoidmaintenance requirements

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces mechanical braking systems with an energy-based control approach. Instead of using mechanical friction to prevent overshoot, the controller monitors motor motion and adjusts energy supply timing and magnitude to achieve precise positioning without mechanical contact. This substitution eliminates mechanical wear associated with brakes while maintaining positioning precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS7466100B2Digital high-resolution controller

Publication Date: 2008.12.16 PEAKTRONICS INC

AI summary

Kinematic control of an electronic positioner and its associated actuator is effected through a control algorithm that delivers energy to the actuator based on observed motion produced by a previous delivery of energy. The algorithm achieves control based on a desired or user-specified resolution. Electronic braking between energy delivery intervals improves the speed at which the desired position is achieved. Temperature of the force producing mechanism is determined, as by monitoring energy consumed, and used to control how power is delivered to the actuator.