Multi-Mover Direct Drive Position Control Without Full Encoder Arrays
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Solution Overview
Problem
The existing multi-mover direct drive transmission systems require complex structures and expensive encoder arrays, especially for stators that only need simple transition instead of positioning, leading to high costs and difficult assembly processes.
Innovation Solution
A multi-mover direct drive transmission system with a stator unit featuring alternating feedback and transition segments, where hall elements on transition segments generate signals to calculate electrical angles and drive currents, eliminating the need for expensive encoder arrays by using a simple and easy-to-implement motion control method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If encoder arrays are used on all stators for position identification, then positioning precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent applies different sensor types to different functional segments: encoder arrays are used only on feedback segments where precise positioning is required, while Hall elements are used on transition segments where only simple transition control is needed. This local differentiation optimizes both precision and complexity by matching sensor capabilities to actual functional requirements of each segment type.
2Measurement precision
If encoder arrays are installed on all stators, then positioning accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The patent implements a cost-optimized sensor distribution strategy where expensive encoder arrays are deployed only on feedback segments requiring high positioning accuracy, while cheaper Hall elements are used on transition segments. This local quality approach significantly reduces overall system cost while maintaining positioning accuracy where it is truly needed for production operations.
3Loss of information
If encoder arrays are used on all stators, then position feedback is improved, but assembly difficulty increases
Solution Approach 1:
The patent reduces assembly complexity by using simpler Hall elements on transition segments where full encoder arrays are not needed. This local differentiation in sensor complexity directly translates to easier assembly processes, fewer calibration steps, and reduced installation time for those segments while maintaining adequate position feedback through the Hall element magnetic field detection.
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
The system achieves a simple structure with fewer components, enabling easy assembly and efficient motion control without the need for encoder arrays, reducing costs and complexity while maintaining accurate position correction.
Implementation Method 1
A magnetic field variation is produced when the mover unit moves to a magnetic field range of one of the coil windings, and one of the hall elements within the magnetic field range outputs a hall signal according to a magnetic field variation detected
Implementation Method 2
The magnet is arranged directly opposite to and spaced from the coil winding, and the coil winding drives the magnet to cause the mover to move
Data Source
AI summary
A multi-mover direct drive transmission system, including: stator unit formed by stator segments and includes frame and coil windings; mover units movable relative to the stator unit and each includes mover slidably connected to the stator unit and movable relative to the frame, and magnet fixed to the mover; and actuators. The magnet is arranged opposite to and spaced from the coil winding, and the coil winding drives the magnet to drive the mover. The frame includes feedback segments and transition segments. The stator unit further includes hall elements. The hall element outputs a hall signal according to a magnetic field variation detected. The actuator calculates an electrical angle and calculates a drive current, the coil winding drives the magnet to move to realize position correction. The multi-mover direct drive transmission system has a simple structure, a small number of components, and is simple and easy-to-implement the motion control method.