Frequency Response Control Tuning for Motor Quality Determination

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Solution Overview

Problem

Existing production methods for control boards and motors face challenges in accurately determining quality due to fixed control parameters, variations in motor characteristics, and measurement errors, leading to incorrect judgments of product quality.

Innovation Solution

A production equipment and method that transmit a sine wave of variable frequency to a controller connected to a load, analyze the sensing current using a frequency response analysis unit, and calculate or set control parameters using a processing unit to perform quality determination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If quality determination is performed on control boards and motors separately with fixed control parameters, then the quality determination process is simplified, but the accuracy of quality judgment deteriorates due to parameter mismatches with actual products

Engineering Contradiction:

Improvequality determination processVSAvoidquality judgment accuracy

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The patent applies dynamics by transitioning from fixed control parameters to dynamically adjustable parameters. The system measures actual motor characteristics (resistance, inductance, frictional force) and automatically adjusts control parameters to match each specific motor-controller combination, enabling accurate quality determination that adapts to individual product variations

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent implements parameter changes by modifying control parameters based on measured motor characteristics. The system calculates optimal control parameters including position control gain, speed control gain, and current control gain specific to each motor-controller pair, thereby resolving the mismatch between fixed parameters and actual product variations

Inventive Principle:

Principle #35Parameter changes

2Productivity

If control parameters are fixed for each quality determination, then the determination process is faster, but control performance deteriorates due to sample variations, temperature changes, and aging

Engineering Contradiction:

Improvequality determination speedVSAvoidcontrol performance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies preliminary action by measuring motor characteristics and setting optimal control parameters before actual operation. The system performs characteristic value measurement and control parameter calculation in advance during quality determination, ensuring that each product starts with optimized parameters tailored to its specific characteristics

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements feedback by using measured motor characteristics to adjust control parameters. The system continuously adapts control parameters based on actual motor performance data, creating a closed-loop approach that maintains optimal control performance despite sample variations, temperature changes, and aging

Inventive Principle:

Principle #23Feedback

3Ease of manufacture

If separate quality determination is performed on control boards and motors, then each component can be individually tested, but the actual system performance cannot be accurately assessed due to interaction effects

Engineering Contradiction:

Improvecomponent testingVSAvoidsystem performance assessment

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The patent applies merging by combining the quality determination process for control boards and motors into a unified system-level test. The system measures characteristics of both components together and determines control parameters for the integrated system, capturing interaction effects that separate testing would miss

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent implements universality by creating a quality determination system that handles both control boards and motors simultaneously. The system performs multiple functions: measuring motor characteristics, analyzing controller responses, calculating optimal parameters, and assessing overall system performance in a single integrated process

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12204293B2Production equipment for performing control parameter setting and quality determination

Publication Date: 2025.01.21 LG INNOTEK CO LTD

AI summary

Production equipment according to an embodiment of the present invention, comprises: a frequency response analysis unit for transmitting a sine wave of a variable frequency to a controller connected to a load, receiving, from the controller, a sensing current for sensing a current output from the load to which the sine wave has been applied, and analyzing the received sensing current; and a processing unit for receiving, from the frequency response analysis unit, a result of analyzing the sensing current to thereby perform a quality determination of the controller or calculate a control parameter of the controller to transmit the result to the controller.