Control System for Sheet Alignment via Reaction Force Estimation
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Solution Overview
Problem
Existing control systems for correcting oblique motions of sheets by pressing them against a conveyance roller often apply excessive or insufficient force, leading to bending or inadequate alignment, and face challenges in accommodating varying sheet thickness and material, potentially causing damage.
Innovation Solution
A control system comprising a mechanical device, driving device, and measuring device, with a controller executing position control, reaction force estimation, and compliance control processes, which estimates and corrects the operation amount to prevent intensive impact without requiring additional hardware like force sensors, using a virtual spring, damper, and inertia model.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the sheets are sent out more to ensure adequate correction of oblique motions, then the alignment accuracy is improved, but excessive force may be applied causing bending or damage to the sheets
Solution Approach 1:
The system dynamically adjusts the send-out amount based on real-time reaction force feedback. The controller continuously monitors the reaction force during sheet transport and modifies the motor operation amount accordingly, transitioning from a static fixed send-out amount to a dynamic adaptive control that responds to actual sheet conditions
Solution Approach 2:
The system implements feedback control by measuring the reaction force acting on the sheet during transport and using this information to correct the operation amount. The controller compares the measured reaction force with a target value and adjusts the motor output to minimize the difference, ensuring optimal correction without excessive force
2Object-affected harmful factors
If the sheets are sent out less to avoid excessive force, then sheet damage is reduced, but the oblique motions are not adequately corrected
Solution Approach 1:
The feedback mechanism allows the system to detect when the send-out amount is insufficient by monitoring reaction force characteristics. When oblique motion correction is inadequate, the reaction force pattern indicates this, and the controller increases the operation amount to achieve proper alignment
Solution Approach 2:
The system adapts the send-out amount dynamically based on real-time conditions. Rather than using a conservative fixed amount, the controller adjusts the motor operation in real-time to provide exactly the right force needed for correction, which may be more than initially planned but less than maximum capacity
3Device complexity
If a fixed rotation amount is used for the roller to simplify control, then device complexity is reduced, but the system cannot accommodate varying sheet thickness and material conditions
Solution Approach 1:
The system uses feedback from reaction force measurement to adapt to different sheet conditions. The controller measures the reaction force during transport and automatically adjusts the operation amount based on the actual sheet properties, eliminating the need for manual setup or complex sensing while maintaining versatility
Solution Approach 2:
The system performs self-adjustment based on reaction force feedback without requiring external intervention for each sheet type. The controller automatically determines the appropriate operation amount by monitoring the interaction between the roller and sheet, making the system self-adapting to various sheet thicknesses and materials
4Speed
If intensive force is applied to ensure correction, then alignment speed is improved, but impact damage may occur to the sheets
Solution Approach 1:
The system applies force in a controlled, periodic manner through continuous feedback adjustment. Rather than a single intensive impulse, the controller makes incremental adjustments to the operation amount based on ongoing reaction force measurement, achieving correction through sustained controlled action rather than sudden impact
Solution Approach 2:
The compliance control acts as a cushioning mechanism by softening the interaction between the roller and sheet. The reaction force feedback creates a compliant control system that prevents hard impacts by continuously adjusting the force application to match the sheet's actual resistance
Data Source
AI summary
A control system for pressing an abutting object against an abutted object includes: a mechanical device including a motor and causing a force from the motor to act on the abutting object to displace the abutting object toward the abutted object, a driving device driving the motor according to an inputted operation amount, a measuring device measuring a physical amount related to displacement of the abutting object, and a controller. The controller executes: a position control process to calculate the operation amount to be inputted to the driving device, a reaction force estimation process to estimate a reaction force acting on the abutting object, and a compliance control process to correct the operation amount which is calculated in the position control process and to be inputted to the driving device by a compliance control based on an estimate value of the reaction force estimated in the reaction force estimation process.