Industrial Motor Control Preview Timing for Flux Lag Reduction
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Solution Overview
Problem
Industrial machinery, particularly those using induction motors, face delays due to the first-order lag of magnetic flux, which increases preparation time when switching from speed control to position control, leading to inefficiencies and increased power consumption.
Innovation Solution
A control apparatus and system that calculates and outputs 'advanced preview commands' to anticipate and initiate the necessary preparation time for industrial machine operations, reducing waiting times by recording actual execution times and subtracting preparation time to determine the advanced preview command time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the magnetic flux is increased to improve spindle responsivity and torque output, then the spindle performance is improved, but power consumption and heat generation in the motor increase
Solution Approach 1:
The control apparatus performs preliminary action by increasing the magnetic flux in advance before the spindle control is switched from speed control to position control. This allows the magnetic flux to reach the desired level before it is actually needed, eliminating waiting time and improving spindle responsivity without requiring continuous high magnetic flux, thereby reducing overall power consumption.
2Force
If the magnetic flux is increased to improve spindle torque output, then the torque output is improved, but heat generation in the motor increases
Solution Approach 1:
The control apparatus increases the magnetic flux in advance before position control is required, allowing the spindle to have sufficient torque output when needed. By performing this action preliminarily and only temporarily maintaining high magnetic flux when actually required for position control, the overall heat generation is reduced compared to continuously maintaining high magnetic flux.
3Manufacturing precision
If the control is switched from speed control to position control requiring high torque, then the positioning precision is improved, but waiting time occurs due to magnetic flux being a first-order lag element
Solution Approach 1:
The control apparatus detects when position control is required and preliminarily increases the magnetic flux before the switching occurs. Since the magnetic flux is a first-order lag element that takes time to rise, this preliminary action ensures that the magnetic flux reaches the desired level before position control begins, eliminating waiting time and improving positioning precision.
4Stability of the object's composition
If the exciting current is ramped up to increase magnetic flux, then the magnetic flux rises, but the cycle time increases due to the lag in flux rise
Solution Approach 1:
The control apparatus performs preliminary action by increasing the exciting current and magnetic flux in advance before the control switching is required. This allows the magnetic flux to rise and stabilize at the desired level before position control begins, eliminating the lag effect and reducing cycle time, thereby improving productivity.
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 effectively shortens the preparation time for industrial machines to go into action, enhancing operational efficiency and reducing power consumption by proactively managing the magnetic flux and motor operations.
Implementation Method 1
The induction motor conducts vector control to control torque by using magnetic flux and torque current
Implementation Method 2
the increase in the magnetic flux causes an increase in power consumption and heat generation in the motor
Data Source
AI summary
A control apparatus records commands and information about execution time of industrial machinery. The control apparatus analyzes a program, and when a command that requires preparation time exists in the program, then calculates advanced preview command time by subtracting the preparation time from time to start the execution of the command based on the execution time previously recorded. The control apparatus outputs in advance the command requiring the preparation time when the advanced preview command time comes, so as to shorten the preparation time.