Dual-Channel STO Circuit Control Without Timing Synchronization
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Solution Overview
Problem
Existing motor control systems with dual-channel safe torque off (STO) circuits face high production costs due to the need for two switches and a timing synchronization mechanism in self-detection circuits, which can lead to electrical short circuits and misjudgments.
Innovation Solution
A motor control system with a dual-channel structure using first and second STO circuits connected through photocoupler circuits, where a pulse control module issues pulse signals to control the on/off states of these circuits, eliminating the need for additional timing synchronization mechanisms and self-detection circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dual-channel self-detection circuits with two switches and timing synchronization mechanism are used, then safety function is improved, but production cost and device complexity increase
Solution Approach 1:
The patent extracts and removes the timing synchronization mechanism and self-detection circuits from the dual-channel STO system. By eliminating these complex components, the system achieves safety validation through a simpler architecture where two independent STO circuits directly control their respective driving units without requiring coordinated timing or additional detection hardware.
Solution Approach 2:
The patent makes each STO circuit universally applicable to its corresponding driving unit without requiring additional specialized components. The first STO circuit controls the first driving unit and the second STO circuit controls the second driving unit, with each circuit serving multiple functions (safety control, validation, and operation) that previously required separate dedicated components.
2Reliability
If dual-channel self-detection circuits with two switches are used, then safety function is improved, but production cost increases
Solution Approach 1:
The patent extracts and removes the expensive timing synchronization mechanism and self-detection circuits from the system. This elimination of redundant components directly reduces production costs while maintaining the essential safety function through the direct control architecture where STO circuits independently manage their corresponding driving units.
3Stability of the object's composition
If timing synchronization mechanism is used in self-detection circuit, then control coordination is improved, but response time and productivity deteriorate
Solution Approach 1:
The patent implements preliminary action by having the two independent STO circuits continuously monitored and ready to act immediately upon receiving abnormal signals. Instead of requiring timing synchronization to coordinate response, each circuit is pre-configured to independently and instantly respond to faults, eliminating delays associated with synchronization mechanisms and thereby improving response time and productivity.
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
Reduces production costs and avoids electrical short circuits and misjudgments by directly controlling the STO circuits, enhancing safety and response time while maintaining circuit independence and time independence.
Implementation Method 1
a first photocoupler circuit and a second photocoupler circuit... a photodiode of the first photocoupler circuit and a phototransistor of the second photocoupler circuit are connected with each other in series
Implementation Method 2
The first filter circuit is electrically connected with the first photocoupler circuit... The second filter circuit is electrically connected with the third photocoupler circuit
Data Source
AI summary
A motor control system includes a first STO circuit, a second STO circuit and a pulse control module. The first STO circuit includes a first filter circuit, a first STO switch, a first photocoupler circuit and a second photocoupler circuit. The first and second photocoupler circuits are connected in series. The first STO switch and the first filter circuit are connected with the first photocoupler circuit. The second STO circuit includes a second filter circuit, a second STO switch, a third photocoupler circuit and a fourth photocoupler circuit. The third and fourth photocoupler circuits are connected in series. The second STO switch and the second filter circuit are connected with the third photocoupler circuit. The pulse control module issues a pulse signal to the second and the fourth photocoupler circuits and detects whether the first or the second STO circuit is abnormal.