Redundant Drive State Transmission for Noise-Tolerant Machine Tools
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Solution Overview
Problem
Existing data transmission systems in drive devices often misinterpret normal operating conditions as abnormal due to noise-induced data corruption, leading to premature device shutdown and reduced utilization rates, especially when a single circuit malfunctions.
Innovation Solution
A device with multiple independent data transmission mechanisms, each equipped with sensors, error detection codes, and reception units, where the controller determines the operational status based on matching error codes and judgment ranges across multiple data paths, ensuring continued operation unless all paths indicate an abnormality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single circuit is used to transmit data from the drive device, then the device complexity is reduced, but the reliability of data transmission deteriorates when noise or malfunction occurs
Solution Approach 1:
The patent divides the single data transmission path into multiple independent circuits (first circuit and second circuit). Each circuit independently transmits the same drive device data to the control device. This segmentation allows the system to tolerate failures in individual circuits while maintaining overall reliability through redundancy.
2Measurement precision
If error detection codes are assigned to all transmitted data, then the measurement precision of data integrity is improved, but the loss of time for processing and transmitting coded data increases
Solution Approach 1:
Instead of requiring all data transmission paths to succeed, the patent applies partial action by accepting data from multiple paths where only a threshold number (e.g., one out of two) needs to be valid. This reduces the stringent time-consuming verification requirements while maintaining data integrity through the error detection codes.
3Reliability
If the device stops operation when data deviation is detected, then the safety and reliability are improved, but the productivity deteriorates due to unnecessary shutdowns from data corruption
Solution Approach 1:
The control device implements feedback by comparing data received from multiple independent circuits and using error detection codes to validate each transmission. When data deviation is detected in one circuit, the system feedbacks this information and continues operation using valid data from other circuits, rather than immediately stopping, thus maintaining productivity while ensuring safety.
4Reliability
If multiple independent data transmission mechanisms are implemented, then the reliability of data transmission is improved, but the device complexity increases
Solution Approach 1:
The patent merges the functions of multiple data transmission circuits into a unified control system that processes data from all paths. The control device combines data from the first and second circuits, applies error detection codes, and makes unified decisions about device operation. This merging approach manages the complexity of multiple transmission paths through centralized intelligent processing.
Data Source
AI summary
A machine tool includes three mutually independent data transmission mechanisms. The data transmission mechanisms include respective transmission units which assign codes for detecting errors to data acquired from the output of sensors, and which transmit the data. A machine controller includes an operation judgment unit which judges whether operation of a feed axis motor is continued. The operation judgment unit judges that operation is continued when there are two pieces of data for which a relationship between the data and the code matches a rule, and the two pieces of data are within a predetermined judgment range. The operation judgment unit judges that the feed axis motor is stopped when at least one of the pieces of data for which the relationship matches the rule deviates from the judgment range.