Electricity: motive power systems – Positional servo systems – Program- or pattern-controlled systems
Reexamination Certificate
1999-08-27
2001-10-02
Nappi, Robert E. (Department: 2837)
Electricity: motive power systems
Positional servo systems
Program- or pattern-controlled systems
C318S562000
Reexamination Certificate
active
06297612
ABSTRACT:
TECHNICAL FIELD
The present invention relates generally to motion control systems. More particularly, it relates to a motion control system configuration which greatly simplifies assembly, installation, maintenance, and operation of the system.
BACKGROUND
Motion control systems can be designed as open loop or closed loop systems. An open loop system usually includes a controller and a motor connected to a drive with no feedback devices. A closed loop system is typically a controller and a motor connected to a drive with feedback devices also connected between the motor and the controller, forming the closed loop.
In a typical multi-axis closed loop system, such as a servo motor-based configuration, a motion controller is wired to a power supply. The motion controller is then wired or connected to a breakout box. Each axis in the system requires a drive amplifier, which also must be wired to a power supply. The control lines from the motion controller to the drive are connected through the breakout box. Connected to each drive is one servo motor. Commands and power between the drive and the motor are connected through a series of command lines. Encoders on the servo motor provide position feedback to the motion controller and are connected through a series of lines to the break-out box.
Each axis in a motion control system typically includes a series of limit switches or home switches. These are also connected to the breakout box. A single axis in a typical multiaxis system can have, for example, 32 individual connections. An eight-axis system might have over 260 individual connections. A system with this many connections is very complicated, time consuming to install, and requires extensive knowledge and experience on the part of the technician installing the system. Systems such as this are prone to miswiring and other costly mistakes during installation. After the system is installed, future maintenance and repairs are also complicated and prone to mistakes.
What is needed, therefore, is a system and method for simplifying the assembly, installation, maintenance, and operation of multiaxis motion control systems.
SUMMARY
With regard to the foregoing and other objects, the invention provides an expandable coupler system for electrically coupling signals between a motion controller and at least one motor drive of a motion control system. The coupler system includes a special conduit having a plurality of electrically conductive lines for conducting signals between the motion controller and at least one motor drive. The conduit includes a controller connector for connecting the motion controller to the conduit, a drive connector for connecting the motor drive to the conduit, and an expansion connector for connecting a further motion control device, such as a second motion controller or motor drive, to the conduit to expand the system. In this manner, the motion control system may be expanded to provide a multiaxis motion control system having a plurality of motor drives for driving a plurality of motors.
Various forms of the conduit may be employed in accordance with the invention. For example, the conduit may include a substantially rigid substrate with a plurality of electrically conductive lines formed in one or more layers of the substrate. Alternatively, the conduit may include a flexible electrical cable having a plurality of electrically conductive lines.
The present invention also provides an expandable motion control system for controlling operation of one or more motors. The expandable motion control system includes a substantially rigid substrate having a plurality of electrically conductive lines formed in one or more layers of the substrate. A motion controller provides motion control signals on electrically conductive lines of the substrate by way of a first connector, and a power connector provides electrical power signals on electrically conductive lines of the substrate. A first motor drive receives motion control signals and electrical power signals from the substrate and drives a motor, such as a servo motor, through its range of positions in response to the motion control signals. A second connector is configured for being connected to a further motion control device to expand the motion control system and thereby provide, for example, a multiaxis motion control system having multiple motor drives and multiple motors.
The substrate may be a single piece substrate, or it may include a plurality of interconnected, substantially rigid couplers with electrically conductive lines formed in one or more layers of each coupler. For example, the motion controller may include its own motion control coupler configured for connecting the motion controller with one or more similar couplers for the motor drives. A flexible electrical cable, such as a ribbon cable, may also be employed to interconnect two of the couplers.
In one embodiment, each of the motor drive couplers varies somewhat, as dictated by the particular axis to which the motor drive is assigned. In another embodiment, all of the motor drive couplers are substantially identical and include a selector for selecting certain ones of the electrically conductive lines for use by the motor drive. The selector may include a plurality of dip switches which can be manually set by the user. A more automated form of a selector includes a programmable electronic processor which is programmed to select desired ones of the electrically conductive lines.
The present invention also provides a multiaxis motion control system, which includes a multiaxis motion controller for providing motion control signals and a power supply for providing electrical power signals. An electrical conduit having a plurality of electrically conductive lines is employed to conduct the motion control signals and the electrical power signals. A plurality of motor drives are connected to the conduit to receive motion control signals and electrical power signals and to drive the motors through their ranges of positions with electrical power in response to the motion control signals. A plurality of monitors produce motion control signals substantially continuously corresponding to the positions of the motors. The monitor signals are conducted by the conduit to the motion controller for use in producing motion control signals. The motion controller, power supply, motors, monitors, and motor drives are electrically inserted along the conduit such that the order of position of each motor drive along the conduit does not affect operability of the system. If desired, a user interface, such as a computer or ON/OFF switch, may be employed for controlling operation of the system.
The system may include servo motors or stepper motors. The system may also include various types of I/O devices, such as a proximity sensor for sensing the position of a structural member being controlled by a motor. The proximity sensor provides a sensor signal which corresponds to the sensed position of the structural member. The motion controller receives the sensor signal and controls operation of the system based in part on the sensor signal.
The present invention also provides a method for controlling operation of one or more motors, where each motor is movable through a range of positions and is attached to a structural member whose movements are controlled by the motor. The method includes the step of providing an electrical conduit having a plurality of electrically conductive lines. Motion control command signals are produced with a multiaxis motion controller and provided on electrically conductive lines of the conduit. Electrical power signals are also supplied on electrically conductive lines of the conduit. A plurality of motor drives are connected to the conduit to drive the motors through their ranges of positions with electrical power in response to motion control signals. Monitor signals are provided which substantially continuously correspond to the positions of the motors. Monitor signals are conducted via the conduit and used by the motion controller to produce
Bower Benjamin D.
Davis Gregory A.
Shloush Moshe
Duda Rina I.
Luedeka Neely & Graham P.C.
Nappi Robert E.
Robotic Control Group, L.L.C.
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