Multi-Amplifier Servo Motor Wiring Error Detection
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Solution Overview
Problem
Existing wiring error detection devices are unable to detect errors in servo motors with multiple independent windings connected to multiple servo amplifiers, as they can operate normally despite wiring issues due to the compensation by other functioning amplifiers.
Innovation Solution
A wiring error detection device that includes a control amplifier selection unit, command generation unit, servo control unit, and wiring error checking unit to compare torque command values and electric current feedback values across different amplifier configurations to identify wiring errors in motors controlled by multiple amplifiers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a motor is controlled by multiple independent amplifiers with multiple windings, then the motor can operate with higher reliability and torque capability, but wiring errors cannot be detected because other amplifiers compensate for the faulty ones
Solution Approach 1:
The patent segments the motor control into multiple independent amplifier channels, each controlling a specific winding. By isolating and independently controlling each amplifier-winding pair, the system can identify which specific channel has a wiring error through comparative analysis, resolving the detection problem caused by redundant amplifiers compensating for each other.
Solution Approach 2:
The patent changes operational parameters by controlling motors to rotate in different directions and at different speeds under different amplifier configurations. By comparing torque command values and current feedback values across these varied operational states, the system can detect inconsistencies that indicate wiring errors, overcoming the masking effect of redundant amplifiers.
2Power
If the motor is controlled by multiple amplifiers to achieve higher torque, then the motor can perform better, but the system complexity increases making wiring error detection more difficult
Solution Approach 1:
The patent creates a universal detection methodology that works across different motor configurations (single motor, multiple motors, different winding arrangements). The same comparative analysis approach between torque command values and current feedback values applies regardless of the specific system configuration, simplifying the detection process despite varying system complexities.
Solution Approach 2:
The patent implements a feedback mechanism where current feedback values from motors are continuously compared against torque command values. This closed-loop comparison provides automatic detection of wiring errors without requiring additional complex hardware, leveraging existing feedback channels to enhance system safety.
3Measurement precision
If existing wiring error detection methods are used comparing position feedback with position commands, then simple wiring errors can be detected, but they fail to detect wiring errors in motors with multiple independent windings controlled by multiple amplifiers
Solution Approach 1:
The patent transitions from static position comparison to dynamic operational analysis. By examining torque command values and current feedback values during actual motor operation with varying speeds and directions, the system adapts to detect wiring errors in multi-winding motors, making the detection method versatile across different motor types and operational states.
Data Source
AI summary
A wiring error detection device having a control amplifier selection unit that, in order to control a motor using some of a plurality of amplifiers, determines two or more selection patterns by selecting and combining amplifiers for the control; a command generation unit that generates, for each selection pattern determined by the control amplifier selection unit, a command for causing the motor to perform a predetermined operation; a servo control unit that calculates torque command values for controlling the motor, on the basis of the selection patterns and a command from the command generation unit; and a wiring error checking unit that compares the torque command values or the current feedback values of the motor that correspond to the two or more selection patterns with each other to determine the presence or absence of a wiring error in the system formed by the amplifiers and the motor.