Servo Safety Control Device Using Encoder Monitoring
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Solution Overview
Problem
Existing servo systems lack a cost-effective method to integrate safety functions without requiring a complete system replacement, leading to high costs and waste of existing knowledge and customization.
Innovation Solution
A safety control device that monitors abnormalities in servo motor operations using encoder outputs and controls the supply of drive power through a branching output system, allowing for the shielding of power to the servo motor when abnormalities are detected, thereby preventing unsafe operation without needing to replace the entire system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dedicated servo controller with safety function is used, then safety is improved, but the entire servo system must be interchanged, increasing cost and losing accumulated knowledge
Solution Approach 1:
The safety control function is segmented from the main servo control system. A separate safety control device is introduced that independently monitors encoder outputs and controls the opening/closing unit, while the existing servo amplifier and motor continue to operate normally. This segmentation allows safety enhancement without replacing the entire servo system.
Solution Approach 2:
A safety control device acts as an intermediary component between the encoder and the opening/closing unit. It receives encoder outputs, processes safety-related information, and controls the opening/closing unit accordingly. This intermediary approach enables safety functionality to be added without modifying the core servo control architecture.
2Reliability
If the entire servo system is interchanged, then safety function is achieved, but cost increases and accumulated know-how is wasted
Solution Approach 1:
The safety control device is designed to work with existing encoder outputs without requiring preliminary system replacement. By utilizing the already-present encoder signals and adding a dedicated safety monitoring component, the system preserves accumulated knowledge while preemptively adding safety functionality.
Solution Approach 2:
The safety control device serves multiple functions: it monitors encoder outputs for safety abnormalities, controls the opening/closing unit, and maintains compatibility with existing servo systems. This multi-functionality allows one component to provide safety enhancement while preserving the value of the existing system.
3Reliability
If a safety control device is added, then safety is enhanced without system replacement, but additional components are introduced
Solution Approach 1:
The safety control functionality is extracted as a separate, dedicated device rather than being integrated into the existing servo amplifier. This extraction allows the safety function to be added independently, minimizing interference with the existing system architecture and reducing the need for additional complex integrations.
Data Source
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AI summary
This invention aims to achieve safety without interchanging an entire existing servo system to a servo system having the safety function, in a servo system including a servo motor, and a servo amplifier for controlling the drive of the servo motor based on the output of an encoder attached to the servo motor, a safety control device for monitoring presence of abnormality based on the output of the encoder, and shielding the supply of drive power to the servo motor if abnormality is present is arranged, and the monitoring content is set as setting information.