Industrial Machine Joint Torque Control for Runaway Prevention
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Solution Overview
Problem
Industrial machines, such as mining equipment, can experience a runaway state due to operating variability and excessive loading, leading to potential damage from loss of control authority over joints.
Innovation Solution
A system and method that monitors joint parameters of industrial machines, increasing the torque limit when parameters exceed a threshold to prevent a runaway state by applying additional force or torque during deceleration, utilizing a processor, sensor, motor driver, and motor to limit torque to a second value.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a default torque limit is applied to the joint, then the machine operates safely under normal conditions, but the machine loses control authority when excessive loading occurs
Solution Approach 1:
The torque limit is made dynamic rather than static. The controller continuously monitors joint parameters and adjusts the torque limit in real-time based on the operational state. When excessive loading is detected through sensor feedback, the torque limit increases from a first value to a second value, allowing the joint to overcome the excessive load and maintain control authority.
Solution Approach 2:
The system implements feedback control by continuously monitoring joint parameters through sensors and using this information to adjust the torque limit. The controller receives feedback about the operational state and modifies the torque limit accordingly, creating a closed-loop control system that adapts to changing conditions and prevents runaway states.
2Reliability
If the torque limit is increased to prevent runaway states, then control authority is maintained during excessive loading, but the risk of damage increases under normal operating conditions
Solution Approach 1:
The torque limit dynamically adapts to operational conditions rather than remaining at a high fixed value. Under normal conditions, the torque limit remains at a safe first value that prevents damage. When excessive loading is detected through sensor feedback, it temporarily increases to a second value to maintain control authority, then returns to the first value when conditions normalize.
Solution Approach 2:
Feedback control ensures the torque limit only increases when actually needed. The controller continuously monitors joint parameters and only adjusts the torque limit upward when sensors detect conditions indicating excessive loading. This prevents unnecessary torque increases that could cause damage while still providing protection when truly needed.
3Reliability
If joint parameters are continuously monitored to detect runaway potential, then early intervention is possible, but system complexity increases
Solution Approach 1:
The monitoring system uses the machine's existing sensors and control infrastructure to detect runaway conditions. Rather than adding entirely new monitoring equipment, the system leverages available sensor data about joint parameters, using these existing resources to identify when torque limit adjustment is needed.
Solution Approach 2:
The system uses feedback from existing sensors to monitor joint parameters and detect runaway potential. This approach integrates monitoring into the existing control loop rather than requiring separate complex monitoring infrastructure, reducing overall system complexity while maintaining effective runaway prevention.
Data Source
AI summary
A system and method for preventing a run-away state of an industrial machine. Joints of the industrial machine are monitored in order to determine if the industrial machine is in danger of entering a run-away state. If a joint parameter exceeds a threshold value, which is indicative of the potential to enter a run-away state, then a force or torque limit is increased so that the industrial machine has additional force or torque to slow down the industrial machine when decelerating. This additional torque prevents the industrial machine from entering the run-away state.