Motion Control System Sizing for Energy Efficiency

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Solution Overview

Problem

Current motion control systems face inefficiencies due to incomplete consideration of tuning parameters and external disturbances, leading to excess energy consumption and heat, as sizing calculations often rely on 'backwards open loop' methods that do not account for gain values and motion profiles, resulting in suboptimal power and energy usage.

Innovation Solution

A simulation-based approach that considers motion profiles and performance parameters to optimize the configuration of hardware elements like drives and motors, allowing for flexible power consumption adjustments while maintaining performance, using a graphical user interface to analyze and iteratively change settings for maximum efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If higher gain values are used in PID controllers to improve performance, then manufacturing precision and reliability are improved, but energy consumption increases

Engineering Contradiction:

Improveposition accuracyVSAvoidenergy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent implements dynamic gain scheduling where PID controller gains are adjusted in real-time based on system state (position error magnitude, velocity, acceleration requirements). During high-precision positioning phases, higher gains are applied, while during low-precision or steady-state phases, gains are reduced, optimizing the trade-off between positioning accuracy and energy consumption throughout the motion cycle

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system dynamically changes controller parameters (PID gains, feedforward gains) based on motion profile requirements and system state. The motion planner modifies gain values adaptively during different phases of motion execution, allowing high precision when needed while minimizing energy consumption during less critical phases

Inventive Principle:

Principle #35Parameter changes

2Reliability

If greater current is provided to overcome system variances and disturbances, then reliability and manufacturing precision are improved, but energy consumption and heat generation increase

Engineering Contradiction:

Improvesystem stabilityVSAvoidexcess energy consumption

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The system employs closed-loop feedback where the motion controller continuously monitors actual position, velocity, and acceleration, comparing them against the motion profile. Feedback from encoders and system sensors allows the controller to detect disturbances and adjust control signals dynamically, maintaining stability and precision without requiring excessive current margins

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The motion planner performs preliminary calculation of required torque and current based on the motion profile, load characteristics, and friction models before execution. This allows the system to provide exactly the right amount of current needed for each phase of motion, avoiding excess current provision while maintaining reliability

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If backwards open loop sizing calculations are used, then device complexity is reduced, but manufacturing precision and energy efficiency deteriorate

Engineering Contradiction:

Improvecalculation methodVSAvoidsizing accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent replaces manual or simplified open-loop sizing calculations with automated simulation-based sizing performed by software tools. The motion controller executes virtual simulations of the motion profile, measuring actual performance metrics (position error, velocity tracking, energy consumption) and using this data to automatically determine optimal component specifications, achieving high sizing accuracy through computational methods rather than manual calculation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Manufacturing precision

If tighter performance parameters are enforced throughout the entire motion profile, then manufacturing precision is improved, but energy consumption increases

Engineering Contradiction:

Improveposition accuracyVSAvoidpower consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The motion controller applies different performance requirements to different segments of the motion profile. Tighter position accuracy and gain values are applied only to critical segments where high precision is needed, while less critical segments use relaxed parameters. This localized approach to performance optimization reduces overall energy consumption while maintaining necessary precision at key positions

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP2846207B1Sizing and tuning methodology for optimized motion control components and energy efficiency

Publication Date: 2017.10.18 ROCKWELL AUTOMATION TECH INC

AI summary

Aspects of the present invention provide a tool for simulating a motion control system that simulates performance and energy for a given configuration. The simulation analysis considers a motion profile and one or more corresponding performance parameters, and the resulting configuration provides hardware elements, such as drives and motors, and settings of those elements. The simulation allows optimization for energy efficiency, as opposed to only speed or accuracy.