Motor Controller Dual Communication Path for Sensor Data Processing
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Solution Overview
Problem
Motor control systems face increased physical and processing costs due to the need for multiple sensors, which leads to higher wire counts and communication traffic, especially in real-time sensing applications.
Innovation Solution
A motor control system with a dual communication path architecture, where a lower-level communication path connects multiple devices in series, allowing for efficient data exchange and processing, while reducing the load on the upper-level controller by performing predetermined processing on the motor controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors are connected through individual communication paths to the upper-level controller, then measurement precision and reliability are improved, but device complexity and physical costs increase due to higher wire counts
Solution Approach 1:
The patent combines multiple communication paths into a single shared communication line where sensors communicate in sequence. Instead of providing dedicated wires for each sensor to the upper-level controller, sensors are connected in series through a common bus, significantly reducing the total wire count while maintaining communication capability with all sensors.
Solution Approach 2:
The patent introduces an intermediate motor controller that segments the communication architecture into two levels: lower-level communication between sensors and motor controller, and upper-level communication between motor controller and upper-level controller. This segmentation allows sensors to communicate efficiently through the motor controller without requiring direct individual connections to the upper-level controller.
2Reliability
If multiple sensors are connected through individual communication paths, then reliability of data acquisition is improved, but processing costs and communication traffic increase
Solution Approach 1:
The motor controller serves as an intermediary device between sensors and the upper-level controller. It receives data from multiple sensors through the lower-level communication path, performs preliminary processing and filtering, then forwards only essential processed data to the upper-level controller through the upper-level communication path. This reduces communication traffic and processing burden on the upper-level controller while maintaining data reliability.
3Measurement precision
If real-time sensing is implemented with multiple sensors, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The motor controller is designed with multi-functionality, serving both as a motor control device and as a communication hub for multiple sensors. It handles motor control operations while simultaneously managing data acquisition from multiple sensors through the lower-level communication path, reducing the need for separate dedicated hardware for sensor management.
Data Source
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AI summary
A motor control system 1 includes a motor controller 20 to control a motor 30. An upper-level communication path 80 connects an upper-level communication port 24A of the motor controller 20 to an upper-level controller 10 that sends an instruction to the motor controller 20. A lower-level communication path 90 is connected to a lower-level communication port 24C of the motor controller 20 and connects a plurality of devices 40, 50, 60, 70 in series to each other. The devices 40, 50, 60, 70 include a rotational angle detector 40 and an output device 50, 60, 70. The rotational angle detector 40 detects a rotation angle of the motor 30. The output device 50, 60, 70 outputs associated information that is associated with the motor 20 and is different from the rotational angle or that is associated with an industrial device associated with the motor 30. The motor controller 20 performs a predetermined processing based on the rotational angle and the associated information, and sends a result of the predetermined processing to the upper-level controller 10.