Motor With Integrated PLC for Automation Response Time
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Solution Overview
Problem
Conventional electrical rotating machines face performance and reliability issues due to extensive wiring and long data transmission delays, leading to increased costs and reduced system efficiency in large industrial and commercial settings.
Innovation Solution
Integration of programmable logic controllers (PLCs) directly within or proximate to the motors/drives, enabling local processing and direct communication between motors and sensors, reducing the need for lengthy data transmission to a central control unit and facilitating immediate response to sensor feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a central control unit is used to control electrical rotating machines, then system automation and control capability are improved, but system response time deteriorates due to long data transmission delays
Solution Approach 1:
The patent divides the centralized control system into distributed intelligent units by integrating PLCs directly into individual motors. Each motor becomes an independent control node that can process sensor data and execute control decisions locally, eliminating the need for all data to travel to a central control unit. This segmentation of control functions resolves the contradiction by maintaining automation while drastically reducing response time.
Solution Approach 2:
The patent transitions from a hierarchical centralized control architecture to a distributed peer-to-peer network architecture. By changing the dimensional structure of the control system from top-down to distributed mesh network, motors can communicate directly with each other and with sensors without funneling all data through a central point, thereby maintaining automation capability while reducing transmission delays.
2Area of stationary object
If extensive wiring is used to connect central control unit to distributed components, then system coverage and control reach are improved, but system reliability and cost deteriorate
Solution Approach 1:
The patent segments the control system into autonomous motor units with integrated PLCs that can operate independently. This eliminates the need for extensive wiring to a central control unit, as each motor only needs local sensor connections and can communicate with other motors through a simplified network. The segmentation reduces wiring complexity while maintaining system coverage through peer-to-peer communication.
Solution Approach 2:
The patent introduces a communication network as an intermediary that replaces extensive physical wiring. Instead of running long data wires from every sensor and motor to a central control unit, the network allows motors to exchange information directly. This intermediary solution maintains system coverage while dramatically reducing wiring requirements and improving reliability.
3Area of stationary object
If extensive wiring is used to connect central control unit to distributed components, then system coverage and control reach are improved, but system cost increases
Solution Approach 1:
The patent segments the control functionality into integrated PLC units within each motor, eliminating the need for extensive wiring infrastructure. This segmentation reduces material costs (less wire, fewer connectors) and installation costs while maintaining the ability to cover large areas through wireless or simplified network communication between distributed motor units.
Solution Approach 2:
The patent uses a communication network as an intermediary to replace costly extensive wiring. The network infrastructure requires minimal physical connections compared to traditional control wiring, significantly reducing material and installation costs while maintaining full system coverage and control capability across distributed locations.
Data Source
AI summary
A system, in one embodiment, includes a drive having a housing, a stator disposed in the housing, a rotor disposed in the stator, and a programmable logic controller disposed inside, mounted on, or in general proximity to the housing. In another embodiment, a system includes a network, a first motor having a first integral programmable logic controller coupled to the network, and a second motor having a second integral programmable logic controller coupled to the network. In a further embodiment, a system includes a rotary machine having a rotor and a stator disposed concentric with one another, a microprocessor, memory coupled to the microprocessor, a power supply coupled to the microprocessor and the memory, and a machine sensor coupled to the microprocessor.