Three-in-one AC Servo Drive Integration
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Solution Overview
Problem
Current multi-axes AC servo drive systems require extensive wiring and assembly time due to a centralized design with separate components for each motor, leading to inefficiencies in space usage and cost.
Innovation Solution
A three-in-one AC servo drive integrates control and power modules with a main console, featuring a communication interface, I/O unit, current detector, FPGA, DSP, and power module to manage multiple motors efficiently, reducing redundant components and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a centralized design with separate components for each motor is used, then each motor can be controlled independently, but the wiring and assembly time increase significantly
Solution Approach 1:
The patent combines multiple separate servo drive components into a single integrated three-in-one servo drive unit that can control multiple motors simultaneously. This merging of previously separate components (reducing multiple individual drives to one unified drive) maintains independent motor control capability while significantly reducing wiring complexity and assembly time, directly resolving the technical contradiction between independent control reliability and assembly efficiency
2Reliability
If separate servo drives are used for each motor, then each motor has dedicated control capabilities, but the occupied space and cost increase
Solution Approach 1:
The three-in-one servo drive integrates multiple control modules and power modules into a single compact unit, merging previously separate drives that would occupy multiple discrete spaces. This consolidation maintains dedicated control capabilities for each motor through internal modular architecture while significantly reducing the total occupied space and installation footprint
Solution Approach 2:
The servo drive is designed with multi-functional capability to control multiple different types of motors (linear motors, rotary motors, etc.) through a single unified platform. This universality allows the system to provide dedicated control for each motor type while using shared common components, thereby reducing overall space requirements compared to having separate specialized drives for each motor
3Reliability
If separate servo drives are used for each motor, then each motor has its own control module, but the cost and assembling time increase
Solution Approach 1:
The patent merges multiple separate control modules and power modules into a single integrated three-in-one servo drive, eliminating the need to manufacture and assemble multiple individual drive units. This consolidation reduces manufacturing costs through economies of scale, shared component procurement, and simplified production processes while maintaining the reliability of dedicated control for each motor through internal modular architecture
Solution Approach 2:
The universal three-in-one servo drive platform can control multiple different motor types (linear, rotary, etc.) with a single unified design, eliminating the need to manufacture separate specialized drives for each motor type. This universality significantly reduces development costs, manufacturing complexity, and inventory requirements while maintaining dedicated control capabilities through software-based motor type identification and parameter configuration
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 integrated design minimizes space occupation, reduces costs, and shortens assembly time by eliminating redundant elements and using shared components, resulting in a more compact, cost-effective, and efficient multi-axes control system.
Implementation Method 1
a converter to convert AC power to DC power
Implementation Method 2
a plurality of inverters converting DC power of the power bus to AC power and generating AC voltage and AC current for corresponding servo motor according to PWM signal of the FPGA
Implementation Method 3
a capacitor for stabilizing DC power for the power bus
Implementation Method 4
a plurality of current sensors for sensing current supplied from the inverter to the servo motors
Data Source
AI summary
A three-in-one AC servo drive includes a main console, a control module, a power module and a plurality of servo motors. A single drive can be connected to a plurality of motors. The power module and control module for the motors can be integrated to a single modular unit. Therefore, the redundant portion such as communication interface, display unit and I/O unit can be eliminated. The capacitor of the bus of the IGBT module can also be reduced, whereby the occupied space and cost can be reduced with less assembling time.