Electric Motor Controller Learning Data Correction

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Solution Overview

Problem

Conventional learning control methods for electric motors in machining processes, such as cam grinding, struggle to maintain positional deviation convergence when repeatability of the target-position command is lost due to changes in cutting or depth-setting operations, especially when disturbances like torque ripple occur, limiting precise control in versatile machining applications.

Innovation Solution

A controller with a learning control unit that determines and corrects positional deviations using first and second learning data, stored in periodic manners corresponding to different learning periods, and incorporates a learning-data correcting section to address local changes and disturbances, ensuring accurate synchronization of the grinding head's motion with the work spindle rotation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional learning control is used with a single learning period, then the control is simple, but positional deviation convergence is lost when repeatability of the target-position command is lost due to changes in cutting operations

Engineering Contradiction:
Improvepositional deviation convergenceVSAvoidlearning control structure
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The learning control is segmented into multiple learning sections (first learning section for periodic disturbances at a first learning period, second learning section for local changes at a second learning period). Each section handles specific types of deviations independently, allowing the system to maintain convergence reliability across different operational conditions without requiring a single complex learning mechanism.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The learning control system dynamically switches between different learning periods based on the type of deviation being corrected. The controller adapts the learning period according to the operational phase - using the first learning period for regular periodic disturbances and the second learning period for local changes during cutting operations, thereby maintaining reliability across dynamic conditions.

Inventive Principle:
Principle #15Dynamics

2Measurement precision

If the learning control corrects all positional deviations uniformly, then the control logic is simple, but it cannot distinguish between periodic disturbances and local changes with different periods

Engineering Contradiction:
Improvedeviation analysis accuracyVSAvoidlearning control unit
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The learning control unit is divided into multiple learning sections, each dedicated to analyzing deviations within a specific learning period. The first learning section handles periodic disturbances with the first learning period, while the second learning section handles local changes with the second learning period. This segmentation enables precise differentiation and correction of different deviation types without requiring a single complex analysis mechanism.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Instead of attempting to correct all positional deviations with a single learning period, the system applies partial learning actions tailored to specific deviation types. The first learning section corrects periodic disturbances, while the second learning section corrects local changes. This partial action approach achieves measurement precision by focusing each learning section on its specific deviation type rather than trying to handle all deviations uniformly.

Inventive Principle:
Principle #16Partial or excessive action

3Manufacturing precision

If a single learning period is used for all corrections, then the control cycle is fast, but corrections are inaccurate when multiple types of disturbances with different periods are present

Engineering Contradiction:
Improvemachining precisionVSAvoidlearning control cycle
Core Design Contradiction:
Manufacturing precisionVSLoss of time

Solution Approach 1:

The learning control cycle is segmented into parallel processing paths with different learning periods. The first learning section operates with the first learning period to correct periodic disturbances, while the second learning section operates with the second learning period to correct local changes. This segmentation enables accurate correction of multiple disturbance types simultaneously, achieving manufacturing precision without requiring a single extended learning cycle.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The multiple learning sections operate continuously and independently, with each section continuously correcting its specific type of deviation. The first learning section continuously corrects periodic disturbances while the second learning section continuously corrects local changes. This continuous parallel action ensures manufacturing precision is maintained without interruption, avoiding the time loss that would occur if a single learning cycle had to complete all corrections sequentially.

Inventive Principle:
Principle #20Continuity of useful action

4Reliability

If the controller stores all positional deviation data without correction, then the data storage is simple, but the learning data contains influences of local changes that reduce control accuracy

Engineering Contradiction:
Improvelearning control accuracyVSAvoidlearning-data correcting section
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The learning-data correcting section extracts and removes the influence of local changes from the positional deviation data before storing it as learning data. By separating the local change component (handled by the second learning section) from the periodic disturbance component (handled by the first learning section), the system stores cleaner, more accurate learning data that improves control reliability without requiring complex filtering mechanisms.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The learning-data correcting section performs preliminary correction of positional deviation data by removing local change influences before the data is stored and used for future control. This preliminary action ensures that the learning data stored in memory is already corrected and ready for accurate control applications, improving reliability without requiring complex real-time correction during the control cycle.

Inventive Principle:
Principle #10Preliminary action

Data Source

PatentUS7479750B2Controller for electric motor
Publication Date: 2009.01.20 FANUC LTD
  • US7479750B2 patent drawing
  • US7479750B2 patent drawing
  • US7479750B2 patent drawing

AI summary

A controller including a learning control unit for determining learning data based on a positional deviation between a target-position command commanding superimposed-type motion including repetitive motion and a positional fed-back variable obtained from an output portion of an electric motor; and an operation control section for controlling the electric motor based on a corrected positional deviation. The learning control unit includes a first learning section for periodically determining, based on the positional deviation, and storing, first learning data according to a first learning period; a learning-data correcting section for correcting the first learning data to eliminate an influence of a local change included in the target-position command or the positional fed-back variable and periodically arising according to a period different from the first learning period; and a positional-deviation correcting section for correcting the positional deviation by using corrected learning data.