Synchronized Motor Torque Correction for Load Balancing
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Solution Overview
Problem
In systems with multiple motors, mechanical errors and aging lead to uneven loads and positional displacements, causing increased power consumption and belt distortion, which complicates motor control and calculation processing, shortening motor lifespan and leading to apparatus malfunctions.
Innovation Solution
A motor control apparatus that includes conversion units to convert motor currents into torque currents, torque correction units to adjust instruction values based on synchronized motor currents, and motor control units to manage driving voltages, enabling equalization of torque currents and loads between motors, thereby stabilizing operation and reducing power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If sensorless field oriented control is used to estimate rotation speed without sensors, then device complexity is reduced, but measurement precision of rotation speed and position deteriorates
Solution Approach 1:
The patent implements a feedback mechanism where the estimated rotation speed from sensorless control is continuously refined by comparing actual motor performance with expected performance. The controller adjusts the rotation speed estimation based on feedback from current measurements and motor model predictions, improving measurement precision while maintaining sensorless operation.
Solution Approach 2:
The patent changes the parameters used for rotation speed estimation by utilizing multiple electrical parameters (current, voltage, frequency) and dynamically adjusting estimation algorithms based on operating conditions. This allows accurate speed estimation without physical sensors by adapting the estimation parameters to match actual motor behavior.
2Reliability
If torque correction is applied to equalize loads between motors, then reliability of motor operation is improved, but device complexity increases
Solution Approach 1:
The patent merges the torque correction function with the existing motor control unit by integrating load detection and correction algorithms into the standard control architecture. The same control unit that manages motor operation also performs load equalization, eliminating the need for separate correction hardware and reducing overall device complexity.
Solution Approach 2:
The motor control system performs self-diagnosis and self-correction by automatically detecting load imbalances and adjusting torque distribution without external intervention. The system monitors its own performance and applies corrections autonomously, improving reliability while avoiding additional control hardware.
3Manufacturing precision
If sophisticated calculation processing is used to correct belt distortion, then manufacturing precision of belt positioning is improved, but loss of time in calculation processing increases
Solution Approach 1:
The patent performs preliminary correction by detecting and compensating for belt distortion early in the operation cycle. The system pre-calculates correction values based on initial position measurements and applies them before significant distortion occurs, reducing the need for complex real-time calculations and minimizing processing time.
Solution Approach 2:
The patent simplifies calculations by changing the parameters used for distortion correction from complex geometric models to simplified electrical parameter-based measurements. By using current and voltage measurements to infer position and distortion, the system achieves accurate correction with minimal computation time.
Data Source
AI summary
A motor control apparatus that controls a first motor and a second motor that are synchronized includes a first motor control unit configured to control a driving voltage of the first motor based on the torque current instruction value, which is output based on a torque current of the first motor for the first motor, and a second motor control unit configured to control a driving voltage of the second motor based on the torque current instruction value, which is output based on a torque current of the second motor for the second motor, wherein the first torque correction unit or the second torque correction unit corrects the torque current instruction value for the first motor or the toque current instruction value for the second motor based on the torque current of the first motor and the torque current of the second motor.