Inter-roller conveyance control gain adjustment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional inter-roller conveyance control devices require time-consuming trial and error to find appropriate control gains, and their response performance deteriorates when conveyance conditions such as speed or roller diameter change.
Innovation Solution
An inter-roller conveyance control device with a control tension detector, tension control calculation unit, adjustment execution command generator, gain calculation unit, and gain table that automatically adjusts control gains based on real-time tension deviations and conveyance conditions, allowing immediate adjustment to optimal values without repeated searches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the control gain is manually adjusted through trial and error by a user, then the control gain can be set to achieve stable conveyance, but it takes much time and effort and causes variations in stability depending on user proficiency
Solution Approach 1:
The control device automatically adjusts its own control gain through the gain calculation unit that computes optimal values based on detected tension deviations and conveyance conditions, eliminating the need for manual trial-and-error adjustment by users while ensuring consistent stable conveyance
Solution Approach 2:
The system uses feedback from the control tension detector that continuously monitors tension deviations, and the gain calculation unit processes this feedback information to automatically determine and adjust the optimal control gain, creating a closed-loop self-adjusting mechanism
2Extent of automation
If the control gain is automatically adjusted by gradually reducing it during initial conveyance operation, then the adjustment process is automated, but the range of reduction cannot be determined and needs to be set to a value smaller than necessary, requiring repeated operations to search for appropriate gain
Solution Approach 1:
The gain calculation unit calculates optimal control gain values by analyzing the relationship between tension deviations and conveyance conditions, dynamically adjusting the control parameter based on actual system behavior rather than using fixed gradual reduction patterns, thereby determining the appropriate gain range in a single operation
Solution Approach 2:
The system performs preliminary analysis of tension deviation characteristics and conveyance conditions to pre-calculate the optimal control gain before actual conveyance operations begin, allowing immediate use of appropriate gain values without requiring repeated search operations
3Reliability
If the automatic adjustment is performed only once at initial conveyance operation, then the response performance is set well initially, but it becomes unsatisfactory when conveyance conditions such as speed or roller diameter change
Solution Approach 1:
The control system transitions from static fixed gain to dynamic adaptive gain by continuously monitoring conveyance conditions (speed, roller diameter) and automatically recalculating optimal control parameters through the gain calculation unit, allowing the system to adapt its control characteristics to changing operational conditions
Solution Approach 2:
The gain calculation unit serves multiple functions by handling both initial gain setup and ongoing gain adjustments for various conveyance conditions, making the control system universally applicable across different operating scenarios without requiring separate adjustment procedures
Data Source
AI summary
An inter-roller conveyance control device conveying an object to be conveyed between a speed shaft roller driven by a speed shaft motor and a tension shaft roller driven by a tension shaft motor while providing tension to the object includes a gain table that stores a plurality of pairs of a conveyance condition variable changing while the object to be conveyed is conveyed and affecting an appropriate value of a control parameter and a control parameter candidate value that is an appropriate control parameter where, when the conveyance condition variable is changed, the device performs calculation on the basis of the conveyance condition variable and a gain calculation result and writes, into the gain table, the control parameter candidate value and the conveyance condition variable in association with each other when the calculation is completed.