Motor Control Parameter Switching for Lower-Energy Machining Cycles
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Solution Overview
Problem
Existing motor control devices struggle to reduce consumption energy for operations other than machining, such as tool changes, as they rely on a single parameter set for the entire machining program, leading to extended cycle times and increased energy consumption.
Innovation Solution
A motor control device that generates control signals based on optimized acceleration and deceleration time constants for each synchronous operation command, allowing for adjustable operation times and energy usage by extracting synchronous operation commands from the machining program and computing optimal parameters for each operation to minimize energy consumption and cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a single parameter set is used for the entire machining program, then the control system is simple to manage, but consumption energy cannot be reduced for operations other than machining such as tool changes
Solution Approach 1:
The machining program is divided into multiple operation types (machining operations and non-machining operations such as tool changes). Different parameter sets are assigned to different operation types, allowing optimization of energy consumption for each operation type while maintaining manageable system complexity through structured segmentation.
Solution Approach 2:
The system dynamically selects and switches between different parameter sets based on the current operation type. During machining operations, one parameter set is applied, while during non-machining operations like tool changes, a different parameter set is automatically selected, enabling adaptive energy optimization without requiring manual reconfiguration.
2Loss of energy
If smaller driving currents are set to reduce energy consumption, then energy loss decreases, but acceleration time and deceleration time are extended
Solution Approach 1:
The system changes the driving current parameters dynamically based on operation type. For non-machining operations like tool changes where time is less critical, smaller driving currents are used to minimize energy loss. For machining operations where productivity is important, larger driving currents are applied to maintain short acceleration and deceleration times, thus optimizing the trade-off between energy consumption and time for different operational contexts.
Data Source
AI summary
A motor control device that generates, based on acceleration time constant and deceleration time constant, a control signal for a motor driving a drive shaft includes a synchronous operation command extraction unit extracting, from within a machining program, blocks where set-point control is continuously commanded for the drive shafts that synchronize and extracting synchronous operation commands included in the blocks; an operation state computation unit computing, based on acceleration time constant and deceleration time constant, operation time and consumption energy associated with machining performed with the machining program; an optimum parameter computation unit computing, for each synchronous operation command, the acceleration time constant and the deceleration time constant that result in the operation time of the drive shaft being within allowable operation time for operation and the consumption energy being minimum as optimum parameters; and a motor control unit generating the control signal based on the optimum parameters.