Motion Control System Dynamic Gain Adjustment
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Solution Overview
Problem
Current motion control systems in industrial environments face inefficiencies due to excessive power consumption and heat generation, largely because they do not adequately account for tuning values and external disturbances such as friction and temperature variations, leading to suboptimal energy usage and performance.
Innovation Solution
A motion control system that optimizes power efficiency by implementing non-overlapping performance parameters over time, including maximum position error, velocity, and thermal capacity, using a motion planner and drive with closed-loop feedback to adjust tuning parameters and power delivery in real-time, thereby minimizing energy consumption while maintaining performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If higher gain values are used to compensate for external disturbances and system variances, then performance and reliability are improved, but energy consumption increases
Solution Approach 1:
The patent applies dynamics by making the gain values adjustable and time-varying rather than fixed. The motion planner dynamically modifies gain values based on the current phase of the motion profile and real-time system state, allowing the control system to adapt its responsiveness to match actual performance needs at different moments in the motion cycle.
Solution Approach 2:
The patent implements parameter changes by systematically varying gain values (such as PID controller gains) throughout the motion execution. Different gain parameters are adjusted according to the motion phase, enabling the system to achieve high performance when needed while reducing energy consumption during phases where full performance is not required.
2Reliability
If greater current is provided to overcome system variances and external disturbances, then reliability and performance are improved, but power consumption and heat generation increase
Solution Approach 1:
The system dynamically adjusts current delivery by modifying gain values in real-time based on the motion phase and actual system performance. This prevents continuous high current delivery even when full performance is not required, thereby reducing unnecessary power consumption and heat generation while maintaining reliability when needed.
Solution Approach 2:
The motion control system performs self-optimization by using feedback from the actual motion execution to automatically adjust gain values and current delivery. The system monitors its own performance and adapts its power consumption characteristics without external intervention, achieving reliability while minimizing energy loss.
3Device complexity
If traditional sizing calculations are performed without considering tuning values and motion profiles, then device complexity is reduced, but manufacturing precision and energy efficiency deteriorate
Solution Approach 1:
The patent applies preliminary action by performing comprehensive sizing calculations that incorporate tuning values and motion profile characteristics before the actual motion execution. This upfront analysis ensures that the motor and drive are correctly sized to achieve the desired performance and energy efficiency without requiring complex real-time adjustments.
4Reliability
If continuous high performance control is maintained throughout the motion profile, then reliability is improved, but energy consumption increases
Solution Approach 1:
The system transitions from static to dynamic control by continuously adjusting gain values according to the motion phase. During phases where high performance is critical, full control authority is maintained, while during less critical phases, gain values are reduced to minimize energy consumption, achieving a dynamic balance between reliability and efficiency.
Solution Approach 2:
The control system applies periodic modulation of gain values synchronized with the motion profile phases. This periodic adjustment allows the system to deliver high performance during critical intervals while reducing power consumption during non-critical intervals, maintaining overall reliability while improving energy efficiency.
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
This approach results in a motion control system with high performance and low power consumption, reduced operating temperatures, and improved sizing accuracy, leading to more efficient and cost-effective industrial operations.
Implementation Method 1
a drive having closed loop feedback adapted to power an electromagnetic actuator for carrying out the physical motion for the load
Data Source
AI summary
Aspects of the present invention provide a motion control system implementing an electronic motion profile for a load that is highly optimized for power efficiency by implementing several performance parameters that are non-overlapping with respect to time. Each performance parameter may characterize an acceptable level of performance or error with respect to the electronic motion profile. Performance parameters may include, for example, maximum position error, maximum velocity error, maximum error for regions or sections of the electronic motion profile, position settling time, position repeatability, position accuracy, position bandwidth, velocity bandwidth, acceleration time, motor thermal capacity, motor temperature and drive temperature.