Reaction Force Estimation from Motor Signals Without Strain Gauges
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Solution Overview
Problem
Conventional data generation devices in factories and plants face challenges in generating data of reaction torque or reaction force without using strain gauges, due to their susceptibility to high temperatures and difficulty in attachment, leading to equipment downtime and inefficiencies.
Innovation Solution
A data generation device that generates reaction force data using parameter and velocity data, without the need for strain gauges, by employing a parameter generator, reaction force data generator, and physical property data generator, which utilize signals from electric motors and stored parameters to estimate reaction forces and physical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a strain gauge is attached to the rotating shaft to generate reaction torque data, then measurement precision is improved, but device complexity and ease of operation deteriorate due to disassembly requirements and high temperature susceptibility
Solution Approach 1:
The patent replaces the mechanical strain gauge measurement system with an electrical parameter-based measurement system. By measuring electrical parameters (current, voltage, frequency) of the motor driving the rotating shaft and using mathematical models to calculate reaction torque, the system eliminates the need for physical attachment of strain gauges to the rotating shaft, thereby improving ease of operation while maintaining measurement capability
Solution Approach 2:
The patent introduces electrical parameters as an intermediary to indirectly measure reaction torque. Instead of directly measuring mechanical stress on the rotating shaft with a strain gauge, the system measures electrical parameters of the motor and uses these as intermediaries to calculate the reaction torque through mathematical relationships, avoiding the need for direct mechanical contact
2Measurement precision
If a strain gauge is used to measure reaction force, then measurement precision is improved, but reliability deteriorates due to high temperature deterioration
Solution Approach 1:
The patent replaces the mechanical strain gauge system with an electrical measurement system that uses motor electrical parameters (current, voltage, frequency) to calculate reaction force. This substitution eliminates the strain gauge component that is susceptible to high temperature deterioration, thereby improving system reliability in high temperature environments while maintaining measurement precision through mathematical calculation
3Measurement precision
If strain gauges are replaced regularly, then measurement precision is maintained, but productivity deteriorates due to equipment stopping
Solution Approach 1:
The patent replaces the strain gauge system with an electrical parameter-based system that has no moving parts or components requiring regular physical replacement. The electrical sensors and mathematical calculation methods used in this system are maintenance-free in terms of component replacement, eliminating equipment stoppages and improving productivity while maintaining measurement precision
Solution Approach 2:
The patent enables continuous operation of the measurement system without interruptions for strain gauge replacement. By using electrical parameters and mathematical models that require no physical intervention or component replacement, the system maintains continuous useful action for reaction force measurement, thereby improving equipment operational efficiency and productivity
Data Source
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AI summary
A data generation device includes: a parameter generator; and a reaction force data generator. The parameter generator generates value data based on a signal having a correlation with a driving force. The parameter generator generates velocity data based on a signal representing a response of a member driven by the driving force. The reaction force data generator generates data of a reaction force received by the member from a predetermined object based on the value data and the velocity data.