Drive System Disturbance Compensation Using a Plant Model
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Solution Overview
Problem
Existing drive systems in industrial applications face challenges in achieving precise control and reduced wear due to disturbances, necessitating improved methods to suppress these disturbances.
Innovation Solution
A method involving a control unit with a first controller and a plant model that simulates the drive system's behavior, using a deterministic disturbance function to minimize setpoint-actual deviations, allowing the controller to operate ideally and independently of the system's state, thereby compensating for disturbances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional controller operates without disturbance compensation, then the control loop remains simple, but positioning accuracy and manufacturing precision deteriorate due to uncompensated disturbances
Solution Approach 1:
The control system is segmented into independent functional blocks: the first controller for primary control, the plant model for disturbance simulation, and the disturbance compensation unit. This modular segmentation allows each component to be optimized independently while maintaining overall system simplicity and achieving high positioning accuracy through coordinated operation of the segments.
2Manufacturing precision
If the controller continuously compensates for disturbances, then positioning accuracy improves, but computational effort and processing time increase
Solution Approach 1:
The plant model pre-calculates disturbance effects and compensation signals in advance based on the deterministic disturbance function, rather than computing complex compensations in real-time during operation. This preliminary action enables accurate disturbance compensation while minimizing computational processing time during actual control operations.
Solution Approach 2:
The system transforms the complex disturbance compensation problem into a parameter optimization problem by using a deterministic disturbance function with adjustable parameters. This allows the compensation to be achieved through parameter tuning rather than complex real-time calculations, reducing computational effort while maintaining positioning accuracy.
3Reliability
If the controller adapts to varying system states, then robustness against disturbances improves, but the controller design and operation become more complex
Solution Approach 1:
The plant model acts as an intermediary between the controller and the actual system disturbances. It provides a simplified deterministic representation of disturbance effects that the controller can easily handle, while still achieving robust compensation for real disturbances. This intermediary approach maintains controller simplicity while improving robustness.
Solution Approach 2:
Instead of directly dealing with complex real-world disturbances, the system uses a copied representation through the plant model with a deterministic disturbance function. This copy captures the essential disturbance characteristics in a simplified form that is easier to compensate for, achieving robustness without increasing controller complexity.
4Manufacturing precision
If a detailed plant model is used to accurately simulate system behavior, then disturbance compensation accuracy improves, but computational resources and processing complexity increase
Solution Approach 1:
The plant model uses a deterministic disturbance function with a limited set of adjustable parameters rather than a fully detailed physical model requiring extensive computation. This parameter-based approach achieves accurate disturbance compensation while minimizing computational resource consumption by focusing on the most influential disturbance characteristics.
Data Source
AI summary
The invention relates to a method (100) for operating a drive system (50) with an open-loop control unit (70) that has at least one first closed-loop controller (10). The drive system (50) forms a closed-loop control path (30) that belongs to the first closed-loop controller (10). The method (100) comprises a first step (110) in which the first closed-loop controller (10) is operated in an active operating state, wherein at least one first closed-loop controller input variable (12) is supplied and at least one first closed-loop controller output variable (14) is output. The method (100) also comprises a second step (120), in which a system model (40) is operated that replicates the behaviour of the closed-loop control path (30), wherein a disruptive function (41) is supplied. The method (100) also has a third step (130), in which a first system model output signal (42) is determined, which is combined with the first closed-loop controller output variable (14) to form a closed-loop control path input variable (16). The invention also relates to a computer program product (60) that can be used to carry out such a method (100) and an open-loop control unit (70) that is equipped with such a computer program product. The invention further relates to a correspondingly designed industry application (80).