PSO Encoder Feedback Compression for High-Speed Motion Control
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Solution Overview
Problem
Existing motion control systems using position-synchronized output (PSO) techniques are limited by the maximum frequency response of servo drivers, which restricts the achievable servo motor velocity and encoder resolution, leading to position errors and degradation of position feedback signals.
Innovation Solution
A control system comprising a primary node controller and secondary node controllers that receive encoder feedback, perform data compression, generate data packets, and transmit them to the primary node controller, which decodes and uses the data to control device operations based on the decoded data packets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the maximum frequency response of the servo driver is increased to achieve higher servo motor velocity and encoder resolution, then the resolution and velocity capabilities are improved, but position errors increase and the fidelity of position feedback signals degrades
Solution Approach 1:
The patent segments the position feedback signal processing into multiple independent channels (e.g., multiple encoder channels or multiple servo drivers). Each channel operates at a reduced frequency within its reliable response range, avoiding the frequency response limitations of a single high-speed channel. This segmentation allows the system to achieve high effective resolution through combination while maintaining signal fidelity in each individual channel.
Solution Approach 2:
The patent introduces an intermediary processing stage that receives position feedback from multiple servo drivers, combines the data, and generates the final position information. This intermediary layer processes lower-frequency, high-fidelity signals from multiple sources to reconstruct high-resolution position data, effectively mediating between the limited frequency response of individual drivers and the need for high-resolution feedback.
2Speed
If the maximum frequency response of the servo driver is increased to achieve higher servo motor velocity, then the velocity capability is improved, but position errors increase
Solution Approach 1:
The patent divides the high-velocity position measurement task across multiple servo driver channels, each operating at lower velocities within their accurate response range. By segmenting the measurement function across multiple lower-speed channels, the system achieves high effective velocity capability while maintaining position accuracy in each individual measurement channel.
Solution Approach 2:
The patent transitions from a single-dimensional high-speed measurement approach to a multi-dimensional approach using multiple channels operating in parallel. By adding the dimension of multiple independent measurement channels, the system achieves high effective velocity through spatial or temporal distribution of measurements while maintaining accuracy in each dimension.
3Reliability
If conventional servo drivers are used to maintain signal fidelity, then the reliability of position feedback is preserved, but the resolution and velocity capabilities are limited
Solution Approach 1:
The patent merges the position feedback outputs from multiple reliable, lower-frequency servo driver channels to achieve high effective resolution. By combining multiple high-fidelity low-resolution measurements, the system reconstructs high-resolution position information while maintaining the signal fidelity characteristics of the individual reliable channels.
Solution Approach 2:
The patent introduces an intermediary processing system that receives and combines position feedback from multiple conventional servo drivers. This intermediary layer performs data fusion and reconstruction to generate high-resolution position information from multiple lower-resolution but high-fidelity inputs, effectively mediating between the capabilities of conventional drivers and the requirements for high resolution.
Data Source
AI summary
A control system for controlling a device operative to perform an operation on a workpiece based on a spatial relationship between the device and the workpiece, which is adjustable using at least one actuator, includes a primary node controller communicatively coupled to the device and at least one secondary node controller communicatively coupled to the primary node controller. Each secondary node controller is adapted to receive encoder feedback from the actuator, the encoder feedback representing a position of a mechanical load associated with an actuator of the at least one actuator, perform a data compression algorithm on the encoder feedback to encode the encoder feedback, generate data packets representing the encoder feedback, and transmit the data packets. The primary node controller can receive and decode the data packets and control an operation of the device based on the decoded data packets.