Linear Actuator Control with Vibration Damping
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Solution Overview
Problem
Existing control methods for linear drives restrict movement to a single carrier per segment, limiting efficiency in applications like the packaging industry, and fail to adequately dampen mechanical vibrations during carrier transfer between segments.
Innovation Solution
A control method that determines a commutation angle as the sum of a base angle and a damping angle, with correction values from upstream and downstream segments, to optimize vibration damping and allow multiple carriers to be moved simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If regulated operation with single carrier per segment is used, then vibration damping is achieved, but productivity is limited due to inability to move multiple carriers simultaneously
Solution Approach 1:
The system dynamically switches between regulated operation mode (for vibration damping when single carrier is present) and controlled operation mode (for high-speed multi-carrier transport). The control device adapts the operating mode based on the number of carriers in each segment, enabling both vibration damping and high productivity to be achieved at different times.
Solution Approach 2:
The system periodically alternates between regulated operation and controlled operation based on carrier presence detection. When a carrier enters a segment, the system switches to regulated operation for vibration damping during transfer, then returns to controlled operation for efficient multi-carrier movement, creating a periodic cycle that balances both requirements.
2Productivity
If controlled operation with multiple carriers per segment is used, then productivity is improved, but mechanical vibrations occur during carrier transfer
Solution Approach 1:
The system applies preliminary anti-action by detecting when a carrier is present in a segment and proactively switching from controlled operation to regulated operation before significant vibrations can occur. This preventive switching eliminates the harmful vibrations that would otherwise be generated during carrier transfer in multi-carrier scenarios.
Solution Approach 2:
The control device uses feedback from carrier detection signals to determine when to switch between operating modes. When a carrier is detected in a segment, the system receives feedback and transitions to regulated operation mode, thereby automatically responding to conditions that would generate vibrations and eliminating the need for manual intervention.
3Reliability
If longitudinal current is increased to ensure carrier movement, then reliability of carrier movement is improved, but mechanical vibrations are intensified
Solution Approach 1:
The system changes the current control parameters by switching between two distinct current strategies: controlled operation uses sufficient longitudinal current for reliable carrier movement, while regulated operation uses precisely dimensioned cross-current for vibration-free transfer. The parameter change is triggered by carrier detection, allowing the system to optimize current application based on real-time conditions.
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
Enables efficient movement of multiple carriers and effective damping of mechanical vibrations, enhancing operational efficiency and reducing mechanical oscillations during carrier transfer.
Implementation Method 1
the segments are supplied with respective currents of a three-phase system... the converters are controlled by a respective control device... determining a commutation angle as the sum of a base angle and a damping angle
Data Source
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AI summary
Segments (2) of a primary part (1) of a linear drive are connected to a supply voltage (U) by means of inverters (3) and thereby supplied with currents (IR, IS, IT) of a three-phase system. Control units (4) of the inverters (3) update a basic commutation angle (ε1) based on a speed setpoint (v*). They determine a longitudinal current (ID) and a transverse current (IQ) based on the currents (IR, IS, IT) and a commutation angle (ε), which are referenced to a secondary part (11, 11') of the linear drive. The control units (4) supply a transverse current setpoint (IQ*) and the transverse current (IQ) to a transverse current controller (13), which determines a transverse voltage setpoint (UQ*) from this. Furthermore, they supply a longitudinal current setpoint (ID*) and the longitudinal current (ID) to a longitudinal current controller (15), which determines a longitudinal voltage setpoint (UD*) from it.Based on the longitudinal voltage setpoint (UD*), the transverse voltage setpoint (UQ*), and the commutation angle (ε), they determine data characteristic of the voltages (UR*, US*, UT*) of a three-phase voltage system to be output by the converters (3) to the segments (2). The commutation angle (ε) is the sum of the basic commutation angle (ε1) and the damping commutation angle (ε2) plus a first and/or a second correction value (ε3, ε4). The damping commutation angle (ε2) is determined using at least the longitudinal voltage setpoint (UD*) and/or the transverse voltage setpoint (UQ*). The first/second correction value (ε3, ε4) is received by the control unit (4) from the upstream/downstream control unit (4). The control unit (4) determines a first/second correction value (ε5, ε6) which it transmits to the upstream/downstream control unit (4).