Integrated Robot Rectifier Control for Stable DC Bus Voltage
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Solution Overview
Problem
Conventional robot control systems face limitations due to separate rectifier control units with limited calculation power, complex and costly wired communication links, low-speed discrete IO interactions, and high voltage fluctuations in DC bus control, which affect performance and reliability.
Innovation Solution
Integration of motion control, rectifier control, and safety control units in a single chip, utilizing an on-chip data bus for supervision, higher calculation ability, and reduced size, which supports higher switching frequencies and eliminates wired communication links, while incorporating features like power consumption prediction and grid quality monitoring to stabilize voltage output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a separate rectifier control unit with MCU/DSP/DSC is used, then the rectifier control function is implemented, but the calculation power is limited and system complexity increases
Solution Approach 1:
The patent integrates the rectifier control unit, motion control unit, and safety control unit into a single integrated control chip. This merging eliminates the need for separate control units and wired communication links, thereby increasing calculation power while reducing system complexity and cost.
Solution Approach 2:
The integrated control chip performs multiple functions including rectifier control, motion control, safety control, and grid quality monitoring within a single device. This multi-functionality consolidates what would traditionally require multiple separate control units, improving calculation power while simplifying the overall system architecture.
2Reliability
If wired communication links and IO links are used between control units, then supervision is achieved, but the structure becomes complicated and cost increases
Solution Approach 1:
By integrating multiple control units into a single chip, the patent eliminates the need for external wired communication links and IO links. The on-chip communication pathways provide supervision and data exchange capabilities without the complexity and cost of external wiring.
3Reliability
If discrete IO terminals are used for safety controller interaction, then power source cutting capability is achieved, but communication speed is low
Solution Approach 1:
The integration of the safety control unit with other control units in the same chip enables high-speed on-chip communication for emergency stop and power source cutting operations, replacing the low-speed discrete IO terminals while maintaining the critical safety functionality.
4Stability of the object's composition
If feedback-based DC bus control is used, then control stability is achieved, but control performance is low and voltage fluctuation is high
Solution Approach 1:
The integrated control unit can predict power consumption based on motion control commands and proactively adjust rectifier control signals before voltage fluctuations occur. This preliminary action prevents voltage dips and improves control performance while maintaining stability, overcoming the reactive nature of traditional feedback-based control.
Data Source
AI summary
A robot control system, a robot control method, and a robot. The robot control system includes a motion control unit configured to perform motion control of a robot, and a rectifier control unit which includes an AC-DC control unit configured to generate a rectifier control signal for driving a rectifier power stage. The rectifier power stage is bcing configured to convert AC power from a grid into DC power. The robot control system also includes a safety control unit configured to generate a safety control signal for selectively turning on or off safety switches connected to an output of the rectifier power stage. The robot control system also includes a motor control unit configured to perform motor control of the robot.