Synchronous Control Unit for Dual Shaft Synchronization
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Solution Overview
Problem
Existing synchronous control units for machine tools fail to maintain synchronization between shafts when trouble occurs in the control unit or communication path issues arise, leading to reduced synchronization accuracy and inability to supply movement commands.
Innovation Solution
A synchronous control unit with a first and second motor, amplifiers, communication monitoring sections, and a switching mechanism that switches between synchronous systems to maintain synchronization by decelerating motors using position feedback and deceleration commands when communication troubles are detected, allowing simultaneous deceleration and safe stopping of both motors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the NC command synchronous system is used, then movement commands can be supplied to both shafts through the control unit, but synchronization is lost when communication trouble occurs in the control unit or communication paths
Solution Approach 1:
The patent introduces a third communication path as an intermediary between the first and second amplifiers, allowing them to communicate directly without passing through the control unit. This mediator path enables the amplifiers to exchange position feedback values and maintain synchronization even when the control unit experiences communication troubles.
Solution Approach 2:
The patent establishes redundant communication paths and switching mechanisms in advance, so that when communication trouble occurs in the primary control unit paths, the system can immediately switch to the alternative third communication path without losing synchronization. This preparatory cushioning ensures continuous operation.
2Reliability
If the master-slave synchronous system is used, then synchronization can be maintained through position feedback, but the slave shaft cannot follow the master shaft when cutting disturbance frequency is high
Solution Approach 1:
The patent implements bidirectional position feedback between amplifiers through the third communication path. Each amplifier receives position feedback from the other shaft and uses it to adjust its output, enabling both shafts to follow each other's motion even under high-frequency cutting disturbances, overcoming the unidirectional feedback limitation of traditional master-slave systems.
3Reliability
If communication monitoring sections detect trouble, then the system can switch to safe mode, but the motors cannot be simultaneously decelerated without position coordination
Solution Approach 1:
During safe stopping, the amplifiers continue to exchange position feedback values through the third communication path, allowing them to coordinate their deceleration movements. This feedback mechanism ensures that both motors decelerate while maintaining their positional relationship, preventing synchronization loss even during emergency stopping.
Data Source
AI summary
In the first synchronous system of the synchronous control unit (1), movement commands of the first motor (23) and the second motor (13) made by the movement command making section (9), which are synchronized with each other, are respectively supplied to the first amplifier (22) and the second amplifier (12) through the first communication path (11) and the second communication path (21). In the second synchronous system switched from the first synchronous system, the first motor (23) is decelerated by a deceleration command made by the deceleration making section (29) and the second motor (13) is decelerated synchronously with the first motor by a movement command made by the position feedback value controlled by the first motor (23) supplied to the second amplifier (12) through the third communication path (31).