Distributed Multi-Axis Servo Control for Precise Motor Synchronization

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Solution Overview

Problem

Existing multi-axis servo control systems face limitations in synchronization due to communication cycle constraints of field buses, leading to poor synchronization and limited expandability and replaceability of motor control.

Innovation Solution

A decentralized multi-axis servo control system with distributed processing, where current commands are handled by drive units and position commands by control units, utilizing high-speed local buses for precise control and enabling modular operation modes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a single independent servo drive controls multiple motors, then the system can drive more motors with one drive unit, but the upper limit of motor count or rated output is limited due to output current constraints

Engineering Contradiction:
Improvemotor control capabilityVSAvoidoutput current
Core Design Contradiction:
Adaptability or versatilityVSPower

Solution Approach 1:

The patent segments the control function by introducing a master controller that handles high-level coordination and multiple slave controllers that handle individual motor control. This segmentation allows the system to control more motors than a single drive unit could handle independently, as each slave controller manages a subset of motors while the master controller coordinates them all, effectively overcoming the output current limitation of individual drive units.

Inventive Principle:
Principle #1Segmentation

2Manufacturing precision

If each servo drive controls a single motor independently, then control precision is maintained, but synchronization is limited by field bus communication cycle

Engineering Contradiction:
Improvecontrol precisionVSAvoidsynchronization delay
Core Design Contradiction:
Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent merges the control functions by implementing a coordinated control system where the master controller and slave controllers work together as an integrated system. The slave controllers receive coordination commands from the master controller and execute them locally, combining the benefits of centralized coordination (for synchronization) and distributed execution (for precision), thereby reducing synchronization delays while maintaining control precision.

Inventive Principle:
Principle #5Merging (Combining)

3Device complexity

If a single servo drive controls multiple motors, then system complexity is reduced, but expandability and replaceability are poor

Engineering Contradiction:
Improvecontrol system structureVSAvoidexpandability and replaceability
Core Design Contradiction:
Device complexityVSAdaptability or versatility

Solution Approach 1:

The patent segments the control system into modular master and slave controller units that can be independently configured and replaced. Each slave controller can be assigned to control specific motors, and the modular architecture allows easy expansion by adding or removing slave controllers without affecting the entire system, thereby improving both expandability and replaceability while maintaining manageable system complexity.

Inventive Principle:
Principle #1Segmentation

4Manufacturing precision

If decentralized control is implemented with multiple controllers, then calculation burden is reduced and precision is improved, but system structure becomes more complex

Engineering Contradiction:
Improvecontrol precisionVSAvoidcontrol unit structure
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent segments the control calculations between the master controller (handling coordination and timing) and slave controllers (handling motor-specific control algorithms). This segmentation distributes the calculation burden across multiple units, allowing each controller to focus on specific tasks and thereby improving overall control precision while keeping individual controller structures simple and manageable.

Inventive Principle:
Principle #1Segmentation

Data Source

PatentEP4169672B1Multi-axis servo control system
Publication Date: 2026.05.06 DELTA ELECTRONICS INC(CN)
  • EP4169672B1 patent drawingFigure 1~2
  • EP4169672B1 patent drawingFigure 3
  • EP4169672B1 patent drawingFigure 4

AI summary

A multi-axis servo control system includes a plurality of motors (200) and a plurality of drive control apparatuses (100). The drive control apparatuses (100) are connected to each other through an external field bus (300). Each drive control apparatus (100) includes a control unit (10) and a plurality of drive units (20). The drive units (20) are connected to the control unit (10) in series by a plurality of local buses (400) to form a series-connected communication loop of sequentially transmitting data. Each drive unit (20) controls at least one of the motors (200). The control unit (10) receives multi-axis position commands through the external field bus, and the drive units (20) correspondingly receive multi-axis commands through the local buses (400) so as to control the motors (200) in a decentralization manner.