Motor Driver Master-Slave Synchronization for Power Failure
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Solution Overview
Problem
In the textile industry, equipment such as spindles and winding machines struggle to stop simultaneously when power is abnormal, leading to potential damage or knotting due to mismatched deceleration of driving signals from motors.
Innovation Solution
A motor driving system with a controller, multiple motors, and motor drivers forming a common-DC-bus structure, where one motor driver is designated as the master to activate a deceleration energy backup function, maintaining the frequency ratio of driving signals to ensure all motors stop at the same time during power abnormalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If motors are driven independently without coordinated control during power abnormality, then each motor can operate freely, but the motors will stop at different times causing equipment damage or yarn knotting
Solution Approach 1:
The patent merges multiple motor driver controls into a unified master-slave architecture. One driver is designated as master and others as slaves, all sharing a common DC bus. The master driver coordinates the deceleration of all motors by controlling the slave drivers, ensuring they stop simultaneously. This consolidation reduces control complexity while improving reliability during power abnormalities.
Solution Approach 2:
The common DC bus acts as an intermediary energy storage and transfer medium between the motors. During power abnormality, the DC bus maintains voltage stability and enables the master driver to control slave drivers for coordinated deceleration. This intermediary structure facilitates synchronized motor stopping without requiring complex direct communication between all driver pairs.
2Reliability
If power supply is unstable or abnormal, then motors may stop freely without coordination, but maintaining frequency ratio requires active control to prevent damage
Solution Approach 1:
The system pre-establishes frequency ratio relationships between driving signals of different motors during normal operation. When power abnormality is detected, the master driver uses these pre-established ratios to automatically coordinate deceleration of all motors. This preliminary setup enables automatic coordinated stopping without real-time complex calculations, improving ease of operation during emergencies.
Solution Approach 2:
The master driver monitors the operational status of all slave drivers and adjusts their driving signals to maintain the predetermined frequency ratio during deceleration. This feedback mechanism ensures that even if motors have different inertias or load conditions, they will stop simultaneously by continuously adjusting control signals based on actual motor responses.
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 solution ensures that motors decelerate and stop in sync, preventing damage and maintaining the twist ratio, thus ensuring correct operation and avoiding yarn knotting during power fluctuations.
Implementation Method 1
The master driver activates a deceleration energy backup function to power and control the slave drivers through the common-DC-bus structure
Data Source
AI summary
A motor driving system includes a controller, motors and motor drivers. In the normal supplying state of a power supply, the controller controls the motor drivers. The motor drivers output driving signals for driving the motors respectively. In an abnormal state or a power-off state of the power supply, one of the motor drivers is set to be a master driver and the others are set to be slave driver. The master driver activates a deceleration energy backup (DEB) function, powers the slave drivers through a common-DC-bus structure, controls the slave drivers, and during deceleration maintains a ratio between frequencies of the driving signals, until all of the motors are decelerated to stop at the same time.