Direct Drive Stator Control With Mode Switching to Cut Power Modules
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Solution Overview
Problem
Existing direct drive transmission systems require complex control operations due to the need to drive each coil separately, leading to increased manufacturing and use costs due to the large number of power modules required.
Innovation Solution
A method for controlling a direct drive system that integrates multiple coils into a single stator, with each stator driven by a separate actuator and controlled by a unified controller, allowing for switching between main and auxiliary drive modes based on position feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If each coil is driven separately under overall cooperative control, then the position of each transmission unit can be accurately controlled, but the control scheme becomes more complex and the number of power modules increases
Solution Approach 1:
The patent merges multiple independently controlled coils into a single stator assembly that is controlled by one actuator. Multiple windings are integrated into one stator structure, reducing the number of separate power modules and simplifying the control architecture while maintaining the ability to precisely control mover positions through unified actuator control
2Measurement precision
If each coil is driven separately under overall cooperative control, then the position of each transmission unit can be accurately controlled, but the number of power modules increases leading to increased manufacturing and use costs
Solution Approach 1:
The patent combines multiple coils into a single stator assembly with multiple windings, reducing the total number of power modules required. This integration lowers manufacturing costs and simplifies assembly while preserving precise position control capabilities through the unified actuator-stator-mover system
3Power
If multiple windings and coils are used in the direct drive transmission system, then the drive capability is enhanced, but the drive and control scheme becomes more complex
Solution Approach 1:
The patent integrates multiple windings into a single stator assembly that is controlled by one actuator, maintaining enhanced drive capability through multiple windings while simplifying the control scheme by eliminating the need for separate control of each coil
Solution Approach 2:
The single actuator controls multiple windings within the stator assembly, making the actuator a multi-functional control element that can drive multiple coils simultaneously, thereby reducing overall system complexity while preserving drive capability
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 simplifies control operations and reduces the number of power modules needed, thereby lowering manufacturing and operational costs while maintaining efficient movement of movers along a guide rail.
Implementation Method 1
outputting, by the actuator, a current to the winding of the stator corresponding to the actuator to cause the windings to drive the mover corresponding to the windings to move
Implementation Method 2
sensing a position of the second position feedback means through the first position feedback means, and acquiring position information of the mover relative to the stator
Data Source
AI summary
A method for controlling a direct drive system, including: S1: outputting, by the actuator, a current to the winding of the stator corresponding to the actuator to cause the windings to drive the mover corresponding to the windings to move in a single direction along the guide rail; S2: sensing a position of the second position feedback means through the first position feedback means, and acquiring position information of the mover relative to the stator; and S3: changing a drive mode of the actuator according to the position information, so that the actuator adjusts, according to the drive mode, magnitude of the current outputted to the windings of the stator corresponding to the actuator. The above solution can reduce a number of power modules used in the direct drive system, so as to reduce overall manufacturing and use costs of the direct drive system.