Roller Conveyance Tension Control Gain Auto-Adjustment
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Solution Overview
Problem
Conventional apparatuses for controlling conveyance between rollers require significant labor and time to adjust the tension control gain, often necessitating trial and error, and even with automated methods like genetic algorithms, determining an optimal control gain is time-consuming and requires skilled operation, especially under varying conditions.
Innovation Solution
An apparatus that includes a tension control-amount detector, speed-shaft and tension-shaft speed controllers, a synchronous-speed-command generation unit, a tension-control calculation unit, a binary output unit, and a gain calculation unit to automatically adjust the proportional and integral gains based on tension deviation oscillations, allowing for rapid setting of appropriate tension control gains across different conveyance speeds without operator expertise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an operator manually adjusts the control gain by trial and error while observing tension fluctuation, then the tension control can be adjusted, but a lot of labor and time is required for adjustment
Solution Approach 1:
The system performs self-adjustment of control gains through automatic identification of the control object model and automated optimization using genetic algorithms, eliminating the need for operator intervention and trial-and-error adjustment
Solution Approach 2:
The manual mechanical adjustment process is replaced with an automated computational system that uses model identification and genetic algorithms to automatically determine optimal control gains
2Reliability
If an operator manually adjusts the control gain by trial and error, then the tension control can be adjusted, but performance of stability differs depending on the level of skill of the operator
Solution Approach 1:
The system automatically identifies the control object model and optimizes control parameters without requiring operator expertise, ensuring consistent performance regardless of operator skill level
Solution Approach 2:
The system automatically determines optimal control parameters (proportional gain, integral gain, derivative gain) through model identification and genetic algorithm optimization, eliminating variability caused by manual parameter tuning
3Measurement precision
If response simulation is performed while changing the control gain to find an optimum value, then the control gain can be optimized, but a long time is required for determination of the control gain
Solution Approach 1:
The system performs model identification in advance to create an accurate control object model, which enables rapid optimization without requiring repeated time-consuming simulations during actual adjustment
Solution Approach 2:
Time-consuming trial-and-error simulation is replaced with automated genetic algorithm optimization that efficiently searches the parameter space to find optimal control gains
4Measurement precision
If a software to perform accurate identification of a control object, response simulation, or seeking using a genetic algorithm is constructed, then accurate control can be achieved, but a difficult case may be caused from the technical viewpoint or the viewpoint of computer cost
Solution Approach 1:
Complex software for model identification and optimization is replaced with a hardware-based automatic identification unit that directly measures system characteristics and computes optimal parameters
Solution Approach 2:
The system automatically performs control object identification and parameter optimization without requiring complex external software or manual intervention
Data Source
AI summary
An apparatus for controlling conveyance between rollers includes: a tension-control-amount-detector; a speed-shaft-speed-controller; a tension-shaft-speed-controller; a synchronous-speed-command-generation-unit synchronizing the speed-shaft speed command with a tension-shaft reference speed command; a tension-control-calculation-unit outputting a tension-control correction value based on proportional compensation based on a proportional gain, and integral compensation based on an integral gain; an adjustment-execution-command-generation-unit outputting an adjustment execution command during an automatic adjustment period; a binary-output-unit outputting one of positive and negative values of the additional-value amplitude as an additional value in adjustment during the automatic adjustment period; a tension-shaft-speed-command-generation-unit outputting a tension-shaft speed command based on the tension-shaft reference speed command, the tension-control correction value and the additional value in adjustment; and a gain-calculation-unit calculating a proportional gain and an integral gain based on a period and an amplitude of the tension control deviation for the automatic adjustment period.