Servo Motor Torque Constant Correction for Magnetic Saturation
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Solution Overview
Problem
Current servo motor control systems lack precision in calculating the output of servo motors when magnetic saturation occurs, leading to inefficiencies and inaccuracies in power management, particularly in industrial machinery and machine tools where power peaks are high.
Innovation Solution
A servo motor control apparatus that includes a storage unit for predefined torque constants, a torque constant correction unit to adjust for magnetic saturation, and an output calculation unit that uses the corrected torque constant along with current and speed values to accurately calculate the servo motor's output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the current flowing through the winding is increased to increase torque, then the torque increases linearly in non-saturation state, but when magnetic saturation occurs the torque constant decreases and the actual output becomes smaller than calculated
Solution Approach 1:
The patent changes the torque constant parameter dynamically based on the operating state. When magnetic saturation is detected (through current threshold or torque constant decrease rate), the system switches from a predefined torque constant to a corrected torque constant that accounts for saturation effects, thereby maintaining accurate output calculation across different operating conditions
Solution Approach 2:
The system implements feedback by monitoring the torque constant's rate of change. When the torque constant decreases beyond a predetermined threshold, the system detects magnetic saturation and automatically corrects the torque constant value, creating a closed-loop control that maintains accuracy despite changing magnetic conditions
2Power
If the power supply equipment capacity is increased to handle power peaks, then the power supply can meet peak demand, but the cost and installation space increase
Solution Approach 1:
The system performs preliminary calculation of the servo motor's actual output power using corrected torque constants before power supply sizing. By accurately determining the real power requirements (accounting for magnetic saturation losses), the system enables right-sizing of power supply equipment to match actual needs rather than theoretical maximums, avoiding over-provisioning
Solution Approach 2:
The patent replaces physical power supply capacity expansion with a computational solution. Instead of increasing hardware capacity to handle peak demands, the system uses corrected torque constant calculations and control algorithms to optimize power utilization, allowing smaller power supply equipment to meet actual operational requirements
3Power
If the motor is operated under lower operation condition to reduce power consumption, then the power peak is reduced, but the operating efficiency decreases
Solution Approach 1:
The system dynamically adjusts the torque constant based on real-time magnetic saturation conditions rather than using a fixed conservative value. This allows the motor to operate at optimal efficiency points when possible while still accurately managing power peaks through corrected calculations, rather than being forced into consistently lower operation conditions
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for precise output calculation of servo motors even during magnetic saturation, improving power management and reducing the need for costly and inefficient power supply equipment upgrades.
Implementation Method 1
when the density of the magnetic flux exceeds the maximum value, the winding enters a magnetic saturation state
Data Source
AI summary
A servo motor control apparatus for controlling a servo motor includes a storage unit configured to store a torque constant predefined for the servo motor, a torque constant correction unit configured to correct the torque constant stored in the storage unit when magnetic saturation occurs in a winding of the servo motor, and an output calculation unit configured to calculate an output of the servo motor on the basis of the torque constant stored in the storage unit or the torque constant after correction calculated by the torque constant correction unit, a value associated with a current of the servo motor, and a value associated with a speed of the servo motor.