Motor Control Device Abnormality Alarm Mode
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Solution Overview
Problem
Existing motor control systems fail to effectively prevent recurring abnormalities due to incomplete investigation and reset processes, particularly for issues with high repeatability, leading to potential erroneous operations and machinery errors.
Innovation Solution
A motor control device with a control processing unit and abnormality determining unit that transitions from a normal mode to a specific abnormality alarm mode when an abnormality with high repeatability is detected, disabling reset and allowing only specific abnormality releasing processes to prevent recurrence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a simple alarm reset process is allowed for all abnormalities, then ease of operation is improved, but reliability deteriorates due to recurring abnormalities with high repeatability
Solution Approach 1:
The alarm abnormality releasing process is segmented into two distinct types: a first type that allows easy releasing by alarm releasing operations, and a second type that requires specific releasing operations. This segmentation enables differentiated handling based on abnormality characteristics, preventing simple resets for recurring issues while maintaining ease of operation for non-recurring alarms.
Solution Approach 2:
The system changes the parameter of alarm releasing difficulty based on the determined type of abnormality. For abnormalities with high repeatability (second type), the releasing parameter is set to require specific operations, whereas for other abnormalities (first type), the parameter allows simple alarm releasing operations. This dynamic parameter adjustment resolves the contradiction between ease of operation and reliability.
2Reliability
If operation is inhibited for all important abnormalities, then reliability is improved, but productivity deteriorates due to unnecessary inhibition of low-repeatability abnormalities
Solution Approach 1:
Abnormalities are segmented into two categories: those requiring operation inhibition (second type with high repeatability) and those allowing continued operation (first type). This segmentation ensures that only abnormalities with significant recurrence risk prevent motor operation, maintaining productivity while ensuring reliability for critical cases.
Solution Approach 2:
The operation inhibition parameter is changed based on the abnormality type determined by the determining unit. For second-type abnormalities, the parameter sets operation inhibition to prevent recurrence, while for first-type abnormalities, the parameter allows operation to continue. This conditional parameter adjustment balances reliability and productivity.
3Loss of information
If alarm history is stored without source removal, then loss of information is reduced, but reliability worsens due to repeated abnormalities occurring after reset
Solution Approach 1:
The determining unit provides feedback about the type of abnormality based on stored alarm history and determination results. This feedback mechanism enables the system to learn from past abnormalities and adjust the alarm releasing process accordingly, preventing simple resets for recurring issues while maintaining information storage for continuous improvement.
Data Source
AI summary
A motor control device includes: a control processing unit that controls driving of a motor based on a command signal input from a controller so as to command an operation of the motor and a detection signal which is a detection result of the operation of the motor; and an abnormality determining unit that detects an abnormality in the controller, the motor control device, and the motor based on the command signal, the detection signal, and a control signal generated in the motor control device and that determines a level of repeatability of the detected abnormality based on a predetermined criterion. The control processing unit transitions from a normal mode to a specific abnormality alarm mode when the abnormality determining unit determines that an specific abnormality having high repeatability has occurred.