Material Testing Machine Automatic Gain Control
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Solution Overview
Problem
Material testing machines using motors as driving sources for loading mechanisms require skilled operators and time-consuming trial-and-error methods to set control gains, which can lead to inaccurate testing, especially when testing new materials.
Innovation Solution
A control mechanism that calculates the rotation angular velocity command for the motor based on the ratio of the inspection value to the motor displacement, automatically adjusting gains by dividing the deviation by a variance ratio, eliminating the need for manual gain setting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual trial-and-error method is used to set control gains, then the material testing can be performed, but it requires skilled operators and time-consuming setup
Solution Approach 1:
The control gain setting is automated through self-service. The control mechanism automatically calculates and adjusts the proportional gain, derivative gain, and integral gain based on the tested object's characteristics without requiring manual intervention. The system performs self-diagnosis and self-adjustment, eliminating the need for skilled operators to perform trial-and-error tuning.
Solution Approach 2:
The control gains are dynamically adjusted based on the characteristics of the tested object. The control mechanism changes the control parameters (proportional gain, derivative gain, integral gain) automatically according to the measured response of the tested object, allowing the system to adapt to different testing scenarios without manual reconfiguration.
2Reliability
If manual trial-and-error method is used to set control gains, then the testing can be performed, but skilled operators are required
Solution Approach 1:
The control mechanism performs automatic gain adjustment without human intervention. The system independently measures the characteristics of the tested object, calculates the appropriate control gains, and adjusts the motor control parameters automatically, making the operation simple and accessible to operators regardless of their expertise level.
Solution Approach 2:
The control mechanism uses feedback from the tested object's response to automatically adjust control gains. By continuously monitoring the system's response and using this feedback to refine the control parameters, the system eliminates the need for operators to have specialized knowledge of control theory or manual tuning techniques.
3Device complexity
If fixed control gains are used, then the system structure is simple, but accurate tracking of target values cannot be achieved for different test pieces
Solution Approach 1:
The control gains are made dynamic rather than fixed. The control mechanism automatically adjusts the proportional gain, derivative gain, and integral gain based on the characteristics of each tested object, allowing the system to adapt to different testing scenarios while maintaining a relatively simple overall structure.
Solution Approach 2:
The control parameters are changed automatically based on the tested object's characteristics. The system measures the response of the tested object and adjusts the control gains accordingly, achieving high tracking accuracy for different test pieces without requiring a complex pre-configured control system.
Data Source
AI summary
A material testing machine is provided, in which a motor is used as a driving source of a loading mechanism, and the material testing machine can always perform a material test accurately, without requiring skilled operators, trial and error, or a longer time when setting control gains. A ratio K(t) of an inspection value F(t) of a control quantity to a displacement θ(t) of a motor 21 is calculated sequentially, and a value proportional to a value obtained by dividing a deviation {FD(t)−F(t)} by the calculated ratio K(t) is taken as a rotation angle command and supplied to a servo amplifier 36. The servo amplifier 36 supplies a current to the motor 21. Therefore, as the test proceeds, appropriate gains are automatically calculated and set, a gain setting operation before test is not necessary, and the material test can be always performed accurately.