Synchronous Controller Gradient Adjustment for Machine Shock Prevention
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Solution Overview
Problem
Conventional synchronous controllers cause sudden speed changes in slave axes during changes in synchronous multiplying factors, leading to machine shocks, and existing solutions do not effectively manage the gentleness of these changes.
Innovation Solution
A synchronous controller that calculates and adjusts the gradient of the synchronous multiplying factor to allow for gradual changes, ensuring stable control by designating motion amounts and gradients, and restricting acceleration within safe limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the synchronous multiplying factor is changed from a first value to a second value, then the speed ratio between master and slave axes is adjusted, but the slave axis speed changes suddenly causing machine shock
Solution Approach 1:
The system performs preliminary calculation of the gradient for changing the synchronous multiplying factor before actually executing the change. By pre-calculating the rate of change based on the difference between first and second values, the system prepares a controlled transition path that prevents sudden speed changes and resulting machine shock.
Solution Approach 2:
The synchronous multiplying factor is changed dynamically over time rather than instantaneously. The system controls the slave axis to follow a gradient-based transition from the first value to the second value, making the speed ratio adjustment progressive and smooth, thereby eliminating abrupt speed changes that cause machine shock.
2Adaptability or versatility
If the synchronous multiplying factor is changed to adjust the speed ratio, then the control flexibility is improved, but the gentleness of changing cannot be set
Solution Approach 1:
The system automatically calculates and applies the appropriate gradient for changing the synchronous multiplying factor based on the specified first and second values. The gradient calculation is performed self-service by the control system itself, eliminating the need for manual gentleness setting while maintaining operational ease and control flexibility.
Data Source
AI summary
A synchronous controller capable of gently changing a synchronous multiplying factor and setting the gentleness of changing of the synchronous multiplying factor without shocking a machine. A block for gently changing the synchronous multiplying factor is added between blocks before and after the changing of the synchronous multiplying factor. Synchronous multiplying factors a and b before and after changing of the synchronous multiplying factor designated in the added block, a motion amount p of master axis, a motion amount of a slave axis, and a residual motion amount v of the master axis after the completion of changing the synchronous multiplying factor (or a preliminary motion amount u of the master axis from the start of motion of the block concerned to a position for the start of changing of the synchronous multiplying factor) are read out. A gradient of changing the synchronous multiplying factor and the preliminary motion amount u (or the residual motion amount v) are obtained based on these data. The slave axis is controlled based on the motion amounts u and v and the gradient of changing the synchronous multiplying factor. The synchronous multiplying factor is changed so gently that the machine cannot be shocked. The synchronous multiplying factor gradient can be settled depending on the designated data p, q and v (or u).