Electronic Cam Return Control for Power-Restored Axis Synchronization
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Solution Overview
Problem
In electronic cam control systems, the slave axis often deviates from its intended position during a power outage or maintenance, requiring manual intervention to return to the corresponding master axis position upon power restoration, which is inconvenient and inefficient.
Innovation Solution
A controller that recalculates the reference positions of the axes after power restoration, enabling the slave axis to automatically return to the master axis position, with an information provider displaying a state screen showing the relationship between the axes and allowing user input for control, thus facilitating automatic alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operation is used to move the slave axis to the position corresponding to the master axis after power disconnect, then the slave axis can be returned to the correct position, but the operation convenience deteriorates due to requiring manual intervention
Solution Approach 1:
The controller automatically detects power disconnect events and autonomously calculates the position corresponding to the master axis using stored electronic cam profile data. The system self-corrects the slave axis position without requiring manual intervention, making the system serve itself after power restoration
Solution Approach 2:
The controller pre-stores the electronic cam profile and reference positions in memory before power disconnect occurs. This preliminary preparation enables the system to quickly recalculate and restore synchronization after power restoration, avoiding the need for manual position matching
2Ease of operation
If the slave axis position is not corrected after power disconnect, then the operation simplicity is maintained, but the position accuracy deteriorates as the slave axis deviates from the intended position
Solution Approach 1:
The controller continuously monitors the positions of both master and slave axes, comparing actual positions against the stored electronic cam profile. After power disconnect, the system uses this feedback mechanism to calculate the correct slave axis position based on the master axis position and profile data, then automatically corrects any deviation
3Ease of operation
If automatic return control is implemented, then the ease of operation improves by eliminating manual intervention, but the device complexity increases due to additional control functions
Solution Approach 1:
The controller integrates multiple functions into a single device: it serves as both the emergency stop controller and the automatic position recovery controller. The same processor that controls the electronic cam system also handles power disconnect detection and automatic position recalculation, eliminating the need for separate manual intervention systems
Data Source
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Figure 2A~2B
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AI summary
A controller for performing synchronization control over the master axis and the slave axis to follow an electronic cam profile includes a reference position calculator that, in response to power being restored after a power disconnect, obtains a position of the master axis and calculates reference positions of the master axis and the slave axis based on the obtained position of the master axis, a position of the master axis at cam synchronization, and the electronic cam profile, and a return control unit that performs return control to determine a position of the slave axis corresponding to a current position of the master axis based on the current position of the master axis, the electronic cam profile, and the reference positions of the master axis and the slave axis calculated by the reference position calculator, and that moves the slave axis to the determined position.