Motor State Acquisition via Rotor Flux Reduction Timing
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Solution Overview
Problem
Current motor information acquisition systems fail to detect extremely small changes in the state of bearings and ball screws in machine tools, limiting the effectiveness of failure prediction and diagnosis.
Innovation Solution
A motor information acquisition system that includes a motor control device, a timing generation section, a rotor magnetic flux reduction command output section, and a motor information acquisition section, which generates acquisition timing based on control data and reduces the magnetic flux density of the motor's rotor to detect subtle changes in operational state, allowing for the collection of waveform data representing the motor's operation state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the motor operates under normal magnetic flux density conditions, then the motor maintains sufficient driving force and operational stability, but extremely small state changes in machine tool components (bearings, ball screws) cannot be detected
Solution Approach 1:
The system periodically reduces the magnetic flux density of the motor rotor at specific intervals during operation. The timing generation section generates acquisition timing based on control data, and when this timing is reached, the rotor magnetic flux reduction command output section outputs a command to reduce the magnetic flux density. This periodic reduction allows for periodic detection of component states without continuously compromising motor performance.
Solution Approach 2:
The system performs preliminary action by reducing the magnetic flux density before actual component failure occurs. The timing generation section predicts appropriate acquisition timing based on control data, and the system proactively reduces flux density at these predicted moments to detect early signs of component degradation before they develop into actual failures.
2Measurement precision
If the magnetic flux density is reduced to detect small state changes, then detection sensitivity improves, but the motor's operational stability and driving capability deteriorate
Solution Approach 1:
The magnetic flux density is reduced only periodically at specific acquisition timing moments rather than continuously. The timing generation section determines when reduction should occur based on control data, ensuring that flux reduction happens only at appropriate intervals when detection is needed, while maintaining normal flux levels during other operational phases.
Solution Approach 2:
The system dynamically adjusts the magnetic flux density based on operational conditions. The rotor magnetic flux reduction command output section outputs commands to reduce flux density only when the timing generation section determines acquisition timing is reached, making the flux density dynamic rather than static, allowing optimization between detection sensitivity and operational stability.
3Measurement precision
If traditional motor information acquisition systems are used, then the system structure remains simple, but extremely small changes in bearing and ball screw states cannot be detected
Solution Approach 1:
The motor control device is given multiple functions: it not only controls the motor operation but also reduces the rotor magnetic flux density and acquires detection information at specific timing. The timing generation section and rotor magnetic flux reduction command output section are integrated into the existing motor control system, allowing the same hardware to serve both control and diagnostic functions without adding separate dedicated detection equipment.
Solution Approach 2:
The system merges the motor control function with the diagnostic detection function. The timing generation section generates acquisition timing based on control data, and the rotor magnetic flux reduction command output section uses this timing to coordinate flux reduction with the motor control operations, combining multiple functions into an integrated system rather than separate independent subsystems.
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
Enables the detection of extremely small state changes in machine tool components, improving failure prediction and diagnosis by capturing waveform data during reduced magnetic flux conditions, without the need for test operations, thereby enhancing monitoring and maintenance capabilities.
Implementation Method 1
a rotor magnetic flux reduction command output section configured to output a command for reducing a magnetic flux density of a rotor of the motor to the motor control device when the acquisition timing is reached
Data Source
AI summary
A motor information acquisition system is provided that acquires information representing an operation state of a motor included in a machine tool in order to monitor a state of the machine tool and that includes a motor control device configured to control the motor based on control data, a timing generation section configured to generate acquisition timing of the information representing the operation state of the motor based on the control data, a rotor magnetic flux reduction command output section configured to output a command for reducing a magnetic flux density of a rotor of the motor to the motor control device when the acquisition timing is reached, and a motor information acquisition section configured to acquire information representing the operation state of the motor when the magnetic flux density of the rotor is reduced by the command.