Machine Positioning Control via Braking Distance Calculation
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Solution Overview
Problem
Existing machine positioning systems, such as those in robots and machine tools, face challenges in achieving precise positioning due to the intervention of limit controllers, which reduce the setpoint position variable when physical limits like force or pressure are exceeded, causing the element to stop short of the target location, leading to longer processing times and increased costs.
Innovation Solution
A method and facility that determine an expected setpoint position variable by extrapolation from the modified setpoint position variable, calculate the braking distance, and initiate a braking process when the braking distance corresponds to a target location reduced by the expected setpoint position variable, allowing precise control and adjustment of the setpoint position variable to ensure accurate positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a limit controller reduces the setpoint position variable when physical limits are exceeded, then force or pressure limits are respected, but positioning precision deteriorates causing the element to stop short of the target location
Solution Approach 1:
The system performs preliminary calculation of the braking distance based on the current state and expected setpoint position variable. The limit controller proactively reduces the setpoint position variable by an amount corresponding to this calculated braking distance, ensuring the element will stop precisely at the target location rather than short of it. This preliminary adjustment resolves the contradiction by anticipating the stopping point and compensating in advance.
Solution Approach 2:
The system continuously monitors the actual position, velocity, and acceleration of the element, and uses this feedback to dynamically calculate the expected setpoint position variable and braking distance. The limit controller adjusts the setpoint position variable based on this real-time feedback, creating a closed-loop control system that maintains positioning precision while respecting force and pressure limits.
2Manufacturing precision
If manual control or reduced displacement speed is used to achieve precise positioning, then positioning accuracy is maintained, but processing time increases leading to higher costs
Solution Approach 1:
The system replaces manual control operations with an automated control algorithm that calculates the braking distance and adjusts the setpoint position variable accordingly. This substitution of mechanical/manual positioning with computational control achieves precise positioning automatically without requiring operators to slow down the displacement speed, thus maintaining both positioning accuracy and efficient processing times.
Solution Approach 2:
The system dynamically changes the setpoint position variable parameter based on real-time calculations of the braking distance and expected position. Instead of using a fixed or manually adjusted position command, the controller continuously adapts this parameter to ensure the element reaches the exact target location, eliminating the need for reduced speeds or manual intervention while maintaining precision.
3Productivity
If the element is displaced at higher speed to reduce processing time, then productivity increases, but force and pressure limits are more likely to be exceeded requiring limit controller intervention
Solution Approach 1:
The system dynamically adjusts the setpoint position variable based on the current displacement speed and calculated braking distance. When displacing at higher speeds to maintain productivity, the controller calculates a larger braking distance and相应地 reduces the setpoint position variable by a greater amount. This dynamic adaptation allows high-speed operation while ensuring force and pressure limits are never exceeded, as the limit controller intervention is anticipatory rather than reactive.
Data Source
AI summary
There is described a method and a device for positioning an element of a machine. A setpoint position variable is generated, said setpoint position variable is reduced by means of a limiting variable and a modified setpoint position variable which is forwarded as a setpoint variable to a controller for positioning the element is formed in this manner. An expected setpoint position variable is determined from the modified setpoint position variable, the braking distance of the element is determined from the expected setpoint position variable, and a braking process of the element is initiated if the braking distance matches a target position which is reduced by the expected setpoint position variable. An element of a machine can so be positioned with accuracy.