CN109217767B

CN109217767B - Linear transmission system and control device and multi-rotor cooperative control system thereof

Info

Publication number: CN109217767B
Application number: CN201710546571.9A
Authority: CN
Inventors: 池峰
Original assignee: Shanghai Heli Intelligent Technology Co ltd
Current assignee: Guoli Zhizao Shanghai Technology Co ltd
Priority date: 2017-07-06
Filing date: 2017-07-06
Publication date: 2020-08-18
Anticipated expiration: 2037-07-06
Also published as: WO2019007202A1; CN109217767A

Abstract

The application discloses linear transmission system and controlling means and many active cell cooperative control system thereof. The linear transmission system includes a stator, a plurality of movers, and a control device. The stator has a stator coil assembly composed of a plurality of armature winding units. The mover has a permanent magnet array. The plurality of movers can move systematically under the control of the control device. All armature winding units are connected to a common power amplifier and are controlled to be switched on and off by a single logic gating control unit. The linear transmission system is high in servo precision, high in response speed and high in reliability.

Description

Linear transmission system and control device and multi-rotor cooperative control system thereof

Technical Field

The invention relates to a conveying device, in particular to a linear transmission system.

Background

With the development of manufacturing technology towards high yield and high precision, the research of precision motion control technology becomes more and more important, and accordingly, the demand of motion positioning control systems is also more and more large, so that the precision motion positioning control system is widely applied to industries such as automatic production lines, packaging and transportation, assembly automation, screen printing and the like, and higher speed and processing flexibility are provided. The traditional driving system adopts a rotary motor driving structure, and gear heads, shafts, keys, chain wheels, chains, belts and other parts commonly used for transmission of the traditional rotary motor in the transmission system are very complex and heavy. Linear motors employ a moving magnetic field to directly drive moving parts, reducing structural complexity and also reducing costs and speed gains due to reduced inertia, compliance, damping, friction and wear.

The linear motor is a core actuator component of the motion control system, and under the action of electromagnetic thrust, a motor rotor can drive a load to generate high-speed and high-thrust drive, a plurality of linear motors can be combined to construct two-dimensional or multi-dimensional motion, and the linear motors can be used for designing and constructing precise linear transmission equipment and a precise XY workbench.

In a traditional linear transmission system adopting a linear motor, grating or magnetic grating measurement is adopted, an encoder reading head is installed on a rotor and moves along with the rotor, and measured data information of the encoder needs to be connected to a controller through a cable, so that the problems of interference and reliability are caused.

In addition, in the conventional linear transmission system, there is room for further improvement in control response speed. Moreover, when each mover moves and switches on the guide rails with different shapes, the problem that continuous movement is not smooth exists.

Disclosure of Invention

The invention aims to provide a linear transmission system with high response speed and a control device thereof, in particular to a linear transmission system capable of realizing multi-rotor cooperative motion.

To achieve the above object, according to an aspect of the present invention, there is provided a control device of a linear transmission system including a linear motor including a stator and a plurality of movers, the stator having a stator coil assembly including a plurality of armature winding units, and the movers having a permanent magnet array, the control device including:

the position detection unit is used for detecting and outputting the current mover position information of each mover;

the system controller is in communication connection with the coil gating control unit, the system controller receives rotor position information from the position detection unit and transmits the rotor position information to the coil gating control unit, and the coil gating control unit calculates to obtain an armature winding unit which needs to be electrified currently according to the rotor position information; and

a power amplifier, wherein each of the armature winding units is connected to the same power amplifier through a cable, the power amplifier is electrically connected with the coil gating control unit and energizes the corresponding armature winding unit according to information from the coil gating control unit.

In one embodiment, the coil gating control unit and the system controller are physically separate two devices, wherein the coil gating control unit has a plurality of logical gating channels, one for each armature winding unit.

In one embodiment, the open/close state of the logic gating channel of the coil gating control unit calculates the channel number of the armature winding unit covered by the rotor according to rotor position measurement data feedback from the system controller, and performs gating control.

In one embodiment, the position detection unit is connected with the coil gating control unit, and the coil gating control unit processes the rotor position information from the position detection unit and controls the corresponding logic gating channel to be opened and closed, so as to control the corresponding armature winding unit to be powered on and powered off.

In one embodiment, the power amplifier is provided with a plurality of gating channels, each gating channel is connected to one armature winding unit, and the power amplifier controls the corresponding gating channel according to a signal from the coil gating control unit, so that the armature winding unit corresponding to the corresponding gating channel is powered on or powered off.

In one embodiment, the control device is configured to, when the rotor approaches an armature winding unit, energize the armature winding unit closest to the rotor by using the rotor position information collected by the position detection unit in a logic gating manner to generate an electromagnetic field to drive the rotor to move, and when the rotor continuously moves in a certain direction, the system controller switches the coil exciting current to the closest armature winding unit in real time according to the position information collected by the position detection unit.

In one embodiment, the stator coil assembly configures UVW three-phase coils in an alternating UVW phase sequence up and down manner, wherein each armature winding unit has three coil windings, and the three coil windings are respectively a U-phase, a V-phase and a W-phase of the armature winding unit.

In one embodiment, the stator coil assemblies are arranged in a periodically extending manner and are arranged in a straight line, or are arranged in an arc, or are arranged in an arbitrary curved line.

In one embodiment, the U-phase and the W-phase of one armature winding unit are adjacently arranged on the same layer, the V-phase is arranged on the upper layer or the lower layer of the U-phase and the W-phase and aligned with the centers of the U-phase and the W-phase, and the V-phase of the armature winding unit of the other armature winding unit is arranged on the lower layer of the U-phase and the W-phase of the armature winding unit if the V-phase of the one armature winding unit is arranged on the upper layer of the U-phase and the W-phase of the armature winding unit.

In one embodiment, the position detection unit includes a position measurement sensor and an encoder, wherein the position measurement sensor is mounted on the mover, and the encoder is mounted on the stator.

In one embodiment, the position measurement sensor is a grating sensor, and the encoders are arranged on the stator base at equal intervals; or, the position measurement sensor is a magnetic grid sensor, and the encoders are arranged on the stator base according to equal distance.

In one embodiment, the position measuring sensors are gratings, the encoders are arranged on the stator base at equal intervals, wherein the distance between every two adjacent encoders is smaller than the length of the grating on the rotor, so that at a certain moment, the grating on the rotor can enable the two adjacent encoders to acquire the same position information of the rotor and provide the position information to the system controller to perform redundant measurement and servo feedback on the real-time position information of the rotor; or, the position measuring sensors are magnetic grids, the encoders are arranged on the stator base at equal intervals, the distance between every two adjacent encoders is smaller than the length of the magnetic grid on the rotor, so that at a certain moment, the magnetic grid on the rotor can enable the two adjacent encoders to acquire the same position information of the rotor and provide the position information to the system controller to perform redundant measurement and servo feedback on the real-time position information of the rotor, when the rotor moves in a certain direction, the measurement function of the remote encoder is switched to be transferred to the adjacent encoder, and the rotor position information obtained by measurement and calculation of the nearest encoder is used as the position servo feedback signal of the system controller.

In one embodiment, the control device further comprises an input/output processing unit, wherein the input/output processing unit is connected with the system controller in a communication way and is used for transmitting instructions of a user to the system controller and outputting related information.

In one embodiment, the user command includes a position command of the mover, a speed command of the mover, and an acceleration command of the mover.

In one embodiment, the power amplifier has a plurality of sets of three-phase current controllers, and each three-phase current controller is electrically connected with one armature winding unit and is controlled to be opened and closed by one logic gating channel.

In an embodiment, the control device further includes an input/output processing board, the input/output processing board is electrically connected to the position detection unit, the power amplifier, and the system controller, wherein the input/output processing board calculates the mover position information from the position detection unit to obtain global position information of each mover, sends the global position information to the power amplifier and the system controller at the same time, the system controller controls the real-time position of each mover, sends a control signal to the input/output processing board, and then the input/output processing board transmits the control signal to the power amplifier in real time.

According to a second aspect of the present invention, there is also provided a linear transmission system comprising:

a stator base consisting of one or more sub-bases;

a stator coil assembly fixed to the sub-base;

the rotor is provided with a permanent magnet array and a position sensing element, wherein a magnetic field generated by the permanent magnet array and an excitation magnetic field generated by the stator coil assembly can interact to push the rotor to generate translational motion;

a guide rail installed on the stator base, and the mover is disposed on and moves along the guide rail;

a sensor array distributed along the guide rail and arranged to read signals emitted by the position sensing elements provided on the mover;

In one embodiment, the system controller is configured to, when the rotor approaches an armature winding unit, energize the armature winding unit closest to the rotor by using the rotor position information collected by the position detection unit in a logic gating manner to generate an electromagnetic field to drive the rotor to move, and when the rotor continuously moves in a certain direction, the system controller switches the coil exciting current to the closest armature winding unit in real time according to the position information collected by the position detection unit.

In an embodiment, the linear transmission system further includes an input/output processing board, the input/output processing board is electrically connected to the position detection unit, the power amplifier, and the system controller, wherein the input/output processing board calculates the mover position information from the position detection unit to obtain global position information of each mover, and simultaneously sends the global position information to the power amplifier and the system controller, the system controller controls the real-time position of each mover and sends a control signal to the input/output processing board, and then the input/output processing board transmits the control signal to the power amplifier in real time.

In one embodiment, the stator base includes a linear stator base and an arc stator base, wherein the linear stator base mounts a rectangular stator coil assembly to form a linear stator module, and the arc stator base mounts an arc stator coil assembly to form an arc stator module.

In an embodiment, each of the movers has a first sensing element and a second sensing element mounted thereon, wherein the first sensing element and the second sensing element are arranged such that a first signal emitted by the first sensing element is read by a sensor array on the linear stator module when the mover moves on the linear stator module and a second signal emitted by the second sensing element is read by a sensor array on the arcuate stator module when the mover moves on the arcuate stator base.

In an embodiment the mounting positions of the first and second sensor elements on the mover are arranged such that at any time during movement of the mover, two adjacent sensors on the stator are able to pick up a first signal from the first sensor element or a second signal from the second sensor element.

In an embodiment, a distance between two adjacent sensors is smaller than an effective signal transfer distance of the first and second sensor elements of the mover.

In one embodiment, the first sensing element and the second sensing element are magnetic grids, the sensor array is magnetic grid read heads, and the distance between every two adjacent magnetic grid read heads is smaller than the length of the first sensing element and the second sensing element of the mover; or, the first sensing element and the second sensing element are gratings, the sensor array is a grating read head, and the distance between every two adjacent grating read heads is smaller than the length of the first sensing element and the second sensing element of the mover.

In one embodiment, the first sensing element is linear in shape and the second sensing element is arcuate in shape.

In one embodiment, each of the movers is configured to move independently relative to the stator.

In one embodiment, the mover includes two upper and lower permanent magnet arrays, wherein the stator coil assembly is located between the two permanent magnet arrays.

In one embodiment, the controller is electrically connected to both the stator coil assembly and the sensor array via a cable.

In one embodiment, the guide rail is detachably mounted to the stator base.

In one embodiment, the linear transport system further comprises a mounting bracket fixed to the stator base, and the sensor array is mounted on the mounting bracket.

In one embodiment, the mover includes:

a base;

a first auxiliary support plate installed at an upper side of the base;

a second backup support plate spaced apart from the first backup support plate;

a first back iron mounted to the first auxiliary support plate;

a second back iron mounted to the second auxiliary support plate and spaced apart from the first back iron;

the back iron support plate is arranged between the first back iron and the second back iron and forms a U-shaped structure together with the first back iron and the second back iron;

a first array of permanent magnets disposed on a surface of the first back iron; and

a second array of permanent magnets disposed on a surface of the second back iron, wherein the first array of permanent magnets is disposed face-to-face opposite and spaced apart from the second array of permanent magnets.

In one embodiment, the first sensing element and the second sensing element are magnetic grids, and the sensor array is a magnetic grid read head, wherein the first sensing element is mounted on a side of the base opposite to a side where the first back iron is located, and the second sensing element is mounted on a side of the base perpendicular to the side where the first sensing element is mounted; or, the first sensing element and the second sensing element are gratings, the sensor array is a grating reading head, wherein the first sensing element is installed on the side of the base opposite to the side where the first back iron is located, and the second sensing element is installed on the side of the base perpendicular to the side where the first sensing element is installed.

In one embodiment, an arc-shaped block is arranged on the base, and the second sensing element is mounted on an arc-shaped surface of the arc-shaped block.

In one embodiment, the mover further includes a slider and a roller, the slider is mounted on the lower side of the base, and the roller is mounted on the slider.

In one embodiment, the mover further includes a collision prevention block mounted on the base and located on a side surface in the same direction as and opposite to a moving direction of the mover.

According to a third aspect of the present invention, there is also provided a multi-mover cooperative control system of a linear transmission system including a linear motor including a stator and a plurality of movers, the stator having a stator coil assembly including a plurality of armature winding units, and the movers having a permanent magnet array, the multi-mover cooperative control system including:

a plurality of mover virtual axes, wherein each of the mover virtual axes is associated with a respective one of the movers;

a plurality of soft controllers, wherein each soft controller controls a corresponding one of the mover virtual axes, thereby controlling a corresponding one of the movers; and

a position detection unit for detecting a position of each of the movers;

the power amplifier is connected with each armature winding unit through a cable;

and the input and output processing board calculates and distributes position data from the position detection unit and transmits the position data required by each rotor virtual shaft to the soft controller in real time, and the input and output processing board transmits the position data and control signals of each soft controller to the power amplifier in real time so as to switch on and off the corresponding armature winding unit.

In an embodiment, cooperative control between the rotor virtual axes or independent trajectory motions of the rotor virtual axes are performed in real time in cooperation with the soft controllers.

In an embodiment, the number of the mover virtual axes, the number of the movers, and the number of the soft controllers are the same.

Compared with the prior art, the invention has the following progressive effects:

1) compared with the traditional linear motor product which adopts a coil as the rotor and a permanent magnet array as the stator, the linear transmission system has no cable dragging, improves the thrust application efficiency and the servo precision, reduces the use number of the permanent magnet array due to the application of the short magnetic array, and reduces the cost.

2) The linear transmission system realizes the application of standardized modules, the stators adopt the standard modular technology to realize the free splicing and expansion among a plurality of stators, the application requirements of customers with any length can be met, and a plurality of rotors can be simultaneously operated on the stators.

3) In the linear transmission system, the rotor can be switched on the guide rails with different shapes, and can move continuously without any blockage and blockage.

4) In the linear transmission system, all the stator coil assemblies are connected to the common power amplifier for control, so that the linear transmission system has the advantages of better and compact structure, higher response speed and higher reliability.

5) In the linear transmission system, the independent coil gating control unit is arranged to control the on-off of the coil, so that higher response speed can be realized.

Drawings

Fig. 1 is a schematic structural diagram of a linear transmission system according to an embodiment of the present invention.

Fig. 2 is a schematic structural diagram of a linear motor linear segment according to an embodiment of the present invention.

Fig. 3 is a schematic view of a linear motor according to an embodiment of the present invention, wherein the linear motor has a linear section and an arc section.

Fig. 4 is a schematic structural view of a stator coil according to an embodiment of the present invention.

Fig. 5 is a schematic structural view of a linear motor mover according to an embodiment of the present invention.

Fig. 6 is a magnet array distribution of a linear motor mover according to an embodiment of the present invention.

Fig. 7 is a magnet array distribution of a linear motor mover according to another embodiment of the present invention.

Fig. 8 is a schematic structural diagram of a linear motor module according to an embodiment of the present invention.

Fig. 9 is a schematic structural view of a linear motor module according to another embodiment of the present invention.

Fig. 10 is an example thrust constant effect curve of the linear motor of the present invention.

Fig. 11 is a system block diagram of one embodiment of a control apparatus of the linear transmission system of the present invention.

Fig. 12 is a system diagram of one embodiment of a position measurement system of the linear transmission system of the present invention.

Fig. 13 is a system block diagram of an embodiment of a multi-mover cooperative control system of a linear transmission system according to the present invention.

Fig. 14 is a system block diagram of one embodiment of the integrated control device of the linear transmission system of the present invention.

Fig. 15 is a schematic diagram of a control device of the linear transmission system of the present invention.

Detailed Description

The preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings so that the objects, features and advantages of the invention can be more clearly understood. It should be understood that the embodiments shown in the drawings are not intended to limit the scope of the present invention, but are merely intended to illustrate the spirit of the technical solution of the present invention.

In the following description, for the purposes of illustrating various disclosed embodiments, certain specific details are set forth in order to provide a thorough understanding of the various disclosed embodiments. One skilled in the relevant art will recognize, however, that the embodiments may be practiced without one or more of the specific details. In other instances, well-known devices, structures and techniques associated with linear motors may not be shown or described in detail to avoid unnecessarily obscuring the description of the embodiments.

Throughout the specification and claims, the word "comprise" and variations thereof, such as "comprises" and "comprising," are to be understood as an open, inclusive meaning, i.e., as being interpreted to mean "including, but not limited to," unless the context requires otherwise.

Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

As used in this specification and the appended claims, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise. It should be noted that the term "or" is generally employed in its sense including "and/or" unless the context clearly dictates otherwise.

In the following description, for the purposes of clearly illustrating the structure and operation of the present invention, directional terms will be used, but terms such as "front", "rear", "left", "right", "outer", "inner", "outer", "inward", "upper", "lower", etc. should be construed as words of convenience and should not be construed as limiting terms.

Further, the term "D1 direction" used in the following description mainly refers to a direction parallel to the horizontal direction; the term "D2 direction" refers primarily to a direction parallel to the horizontal direction and perpendicular to the D1 direction; the term "first direction" or "first axis" refers primarily to a direction or axis parallel to the horizontal direction; the term "second direction" or "second axis" refers primarily to a direction or axis parallel to the horizontal direction and perpendicular to the first direction; the term "third direction" or "third axis" refers primarily to a direction or coordinate perpendicular to the horizontal direction.

Fig. 1 is a schematic structural diagram of a linear transmission system. As shown in fig. 1, the linear transmission system includes a plurality of movers 108, two sections of linear motor stator modules 104 and two sections of constant radius arc motor stator modules 106, a magnetic grid or grating 110, a magnetic grid or grating encoder array 109, a guide rail unit 103, a fixed support 102, and a stator base 101. The mover 108 is mounted on a stator module of the linear motor, and is moved in translation along the guide direction by the roller guide 103. Each mover 108 is independently movable relative to all other movers. The mover 108 includes a permanent magnet array and is mounted on the inner surface of the mover yoke. The linear and arcuate motor stator modules formed by

stator modules

104, 106 are attached to the stationary frame 102. The fixing bracket 102 is mounted on the stator base 101. The roller guide 103 is fixed on the stator base 101 by fastening screws. A magnetic grating or grating encoder array 109 is mounted on the fixed support 102. The signals of the encoder array 109 are used for position measurement of the mover. The

stator modules

104 and 106 are energized with exciting currents, so that the designated coils are activated and energized and excited, and excitation magnetic fields generated by the coils interact with permanent magnetic fields generated by the permanent magnetic arrays of the rotor unit 108 to form thrust, so that the rotor unit 108 moves in a translation manner along the guide rail. In an embodiment, the

stator modules

104, 106 and the movers 108 independently control the movement of each mover 108 along the roller guide 103 as a combined function of the motion control system.

The mover movement positioning control device further includes a controller (not shown) electrically connected to the encoder array to acquire position information of the mover. The controller is also electrically connected with the stator so as to enable corresponding coils of the stator to be activated and energized and excited according to the acquired position information of the rotor and the given target position of the rotor, and therefore excitation magnetic fields generated by the corresponding coils interact in permanent magnetic fields generated by the permanent magnet array to form thrust so that the rotor generates translational motion.

Fig. 2 shows a schematic structural diagram of a linear motor linear segment according to an embodiment of the present invention. As shown in fig. 2, the linear motor straight line segment includes two

movers

211, 212 and a stator 200. The stator 200 is formed by a printed circuit board fixed to the stator base 101, wherein 213 are positioning and mounting holes for screwing and fixing the stator 200. On the printed circuit board 200, the stator coil assembly is formed by alternately stacking rectangular coil windings.

The stator coil assembly includes a plurality of armature winding units. In one embodiment,

coil windings

209a, 209b, 209c are U, V, W three-phase coils of one armature winding unit, and

coil windings

210a, 210b, 210c are U, V, W three-phase coils of another armature winding unit. The coils of the

coil windings

209b, 210a and 210c are adjacently arranged on the same layer, and the

coils

209a, 209c and 210b are adjacently arranged on the same layer, namely, the coils corresponding to the V phase are arranged on the upper layer or the lower layer of the U phase and the W phase and are aligned with the centers of the U phase and the W phase. When the U-phase coil and the W-phase coil are adjacently arranged on the upper layer, the V-phase coil is arranged on the lower layer of the U-phase coil and the W-phase coil and is aligned with the geometric centers of the U-phase coil and the W-phase coil. U, V, W three-phase coils constitute basic armature winding units, which are repeatedly arranged along the transverse cycle, 1 group, 2 groups, 3 groups, … … basic units, and so on, and the number of groups of armature winding units is constructed according to the stroke requirement of the linear motor. Each coil winding is provided with a wiring terminal, and adjacent wiring terminals are connected in a UVW three-phase connection mode or a triangular or star connection mode. Each of the

coil windings

209a, 209b, 209c, 210a, 210b, 210c is manufactured by a multilayer coil lamination process, and the connection interfaces of the coils between the layers are vertically interconnected, so that each layer of the coils are connected in series to form one winding.

The armature winding unit can be subjected to periodic extension and can be integrally manufactured. The coil windings may be manufactured in modules of standard length, assembled and spliced stator modules for long-stroke applications. In addition, the armature winding unit can be applied by splicing up and down, and can provide larger thrust. In particular, the armature winding unit may be adapted to be manufactured by a printed circuit board process. Moreover, the air gap of each coil of the armature winding unit is very small and uniform, so that the thrust ripple of the linear motor is very small, the influence of cogging force is small, and the linear motor is particularly suitable for high-precision control application scenes. Fig. 10 shows an example of a thrust constant effect curve of the linear motor of the present invention. The data in the figure shows that the fluctuation of the thrust constant in the technology is less than 5%, which is far lower than the thrust fluctuation of the conventional iron core linear motor, or even better than the conventional iron core-free linear motor.

As shown in fig. 2, the

permanent magnet arrays

211 and 212 of the rotor units are permanent magnet arrays of two rotors, each array is composed of a group of NS arrays or Halbach arrays arranged periodically, and the width of the permanent magnet array unit is W_mThe distance from the center of the N pole to the center of the adjacent S pole is recorded as tau, and the length of the permanent magnet array is recorded as W_mThe width of the array. The width of 2 tau from the N pole to the center of the N pole is taken as a basic unit, the basic units are distributed along the first axis X direction and are repeatedly arranged, 1 basic unit and 2 groups of basic units … … are arranged, and the like, and the number of groups of the rotor magnet array is constructed according to the thrust requirement of the linear motor. The main scaling relationship between the magnet array and the coil windings is as follows:

W_m＝n_m·τ

wherein, W_mFor the width of the rotor permanent magnet array, p is the width of each coil on the center line of a pitch circle, α is the corresponding angle range of each coil based on the width of the pitch circle, R is the radius of the pitch circle, tau is the polar distance of the magnet and is defined as the distance from the center of an S pole to the center of an N pole, and N is_cIs the number of coil windings, n_mThe number of pole pairs of the magnet.

When a plurality of movers run above the stator coils, corresponding coil windings of the permanent magnet coverage area of each mover are electrified and excited to generate horizontal thrust. The linear transmission control system judges the stator coil area covered by the next operation to be moved in advance through the actual position information of each mover measured by the position sensing element, and the coils are electrified in advance in the area to be operated by the mover.

Fig. 3 shows a schematic structural diagram of a linear motor with straight and curved (180 °) segments joined together according to an embodiment of the present invention. As shown in fig. 3, the linear motor stator 300 includes a stator base 301, arc-shaped

stator coil assemblies

302, 303, and straight segment

stator coil assemblies

307 and 308. The straight-line

stator coil assemblies

307 and 308 are connected with arc-shaped (180 °) arc-shaped

stator coil assemblies

302 and 303 with constant radius, and the two are connected to realize seamless interface connection.

The stator 300 is formed from a printed circuit board secured to a stator base 301, wherein the arcuate segments of the

stator coil assemblies

302, 303 are in the shape of a fan ring having a constant center radius R. In which

stator coil assemblies

302 and 303 are fixed to a stator base 301 with screws. The

stator coil assemblies

302, 303 are formed by alternately stacking and arranging the coil windings having fan-shaped rings, the center of each coil is arranged according to a pitch circle line 309 having a constant radius, the width of each coil at the pitch circle center line is p, the width is based on the angle of the pitch circle is alpha, and the conversion relation between the pitch circle center line, the magnet pole pitch tau, and the radius R of the pitch circle line 309 is as follows:

p＝R·α

where p is the width of each coil at the pitch circle center line, α is the angle range corresponding to each coil based on the pitch circle width, R is the pitch circle radius, τ is the magnet pole pitch, defined as the distance from the S pole center to the N pole center, N_cIs the number of coil windings, n_mThe number of pole pairs of the magnet.

The stator coil assembly includes a plurality of armature winding units, wherein the

coil windings

304a, 304b, 304c are U, V, W three-phase coils of one set of armature winding units, respectively, and the

coil windings

305a, 305b, 305c are U, V, W three-phase coils of another set of armature winding units, respectively. The

coils

304a, 304b and 304c are adjacently arranged in the same layer, and the

coils

305a, 305b and 305c are adjacently arranged in the same layer, namely, the coils corresponding to the V phase are arranged on the upper layer or the lower layer of the U phase and the W phase and are aligned with the centers of the U phase and the W phase. The U-phase coil and the W-phase coil are adjacently arranged on the same layer, and the V-phase coil is arranged on the upper layer or the lower layer of the U-phase coil and the W-phase coil and is aligned with the geometric centers of the U-phase coil and the W-phase coil. When the U-phase coil and the W-phase coil are adjacently arranged on the upper layer, the V-phase coil is arranged on the lower layer of the U-phase coil and the W-phase coil and is aligned with the geometric centers of the U-phase coil and the W-phase coil. The U, V, W three-phase coils form basic armature winding units, the stator coil assemblies are repeatedly arranged along the transverse cycle, 1 group, 2 groups, 3 groups, … … basic units, and the like, and the number of groups of the coil units is constructed according to the stroke requirement of the linear motor. Each of the

coil windings

304a, 304b, 304c, 305a, 305b, 305c is manufactured by laminating a plurality of layers of coils, and is connected according to a UVW three-phase connection mode, a triangle connection mode or a star connection mode.

The stator coil assembly of the linear motor with a constant radius arc type (180 degrees) can be periodically extended and can be integrally manufactured. The winding coils can be assembled according to two groups of modules with standard 90-degree arc lengths, or can be assembled by a plurality of winding coils, and the stator modules can be assembled and spliced aiming at long-stroke application. In addition, the stator coil assembly can be applied in a splicing mode of being stacked up and down, and larger thrust can be provided. In particular, the stator coil assembly may be adapted to be manufactured by a printed circuit board process. Moreover, the air gap of each coil of the stator coil assembly is very small and uniform, so that the thrust ripple of the linear motor is very small, the influence of the cogging force is small, and the linear motor is particularly suitable for high-precision control application scenarios. The fluctuation of the thrust constant of the linear motor provided by the invention is far lower than that of the conventional iron core linear motor, or even superior to that of the conventional iron core-free linear motor.

Fig. 4 is a schematic diagram showing a stator coil according to an embodiment of the present invention. As shown in fig. 4, the stator coil is composed of a plurality of layers of coils, including 501, 502, 503, 504, …, 508, ….

Coil windings

511, 512 and 513 in the layers where 501 and 502 are located are U, V, W three-phase coils of the armature winding unit respectively. The U-phase coil and the W-phase coil are adjacently arranged on the same layer, and the V-phase coil is arranged on the upper layer or the lower layer of the U-phase coil and the W-phase coil and is aligned with the centers of the U-phase coil and the W-phase coil. When the U-phase coil and the W-phase coil are adjacently arranged on the upper layer, the V-phase coil is arranged on the lower layer of the U-phase coil and the W-phase coil and is aligned with the centers of the U-phase coil and the W-phase coil. U, V, W three-phase coil constitutes basic armature winding units, which are arranged repeatedly along the first axis direction X, 1 group, 2 groups, 3 groups, … … basic units, and so on, and the number of groups of armature winding units is constructed according to the stroke requirement of the linear motor. Similarly, the coil windings in the

layers

503 and 504 are constructed by the same method, and the armature winding units are arranged repeatedly in the first axis direction X in a periodic manner, 1 group, 2 groups, 3 groups, … …, basic units, and so on, and the number of groups of the armature winding units is constructed according to the stroke requirement of the linear motor. By analogy, the processes of 505, 506, 507, 508 and … repeated above are combined layer by layer in an overlapping way, and can be constructed by any number of layers.

The armature winding unit can be subjected to periodic extension and can be integrally manufactured. The winding coils can be manufactured in modules of standard length, assembled and spliced stator modules for long-stroke applications. In addition, the armature winding unit can be applied in a splicing mode of being stacked up and down, and larger thrust can be provided. In particular, the coil assembly may be adapted for manufacture by a printed circuit board process.

Fig. 5 is a schematic structural view of a linear motor mover according to an embodiment of the present invention. As shown in fig. 5, the linear motor mover includes a base 100, a first permanent magnet array 130a, a second permanent magnet array 130b, a first back iron 131a, a second back iron 131b, a first auxiliary support plate 132a, a second auxiliary support plate 132b, a back iron support plate 129, a guide rail guide roller 121, a slide 122, and an anti-collision block 111. The first subsidiary support plate 132a is installed at an upper side of the base 100. The second subsidiary support plate 132b is placed spaced apart from the first subsidiary support plate 132 a. The first back iron 131a is mounted on the first subsidiary support plate 132 a. The second back iron 131b is mounted to the second subsidiary support plate 132b and spaced apart from the first back iron 131 a. The back iron support plate 129 is disposed between the first back iron 131a and the second back iron 131b and forms a U-shaped structure together with the first back iron and the second back iron. The first permanent magnet array 130a of the linear motor is adhered to the first back iron 131 a. The second permanent magnet array 130b of the linear motor is bonded to the first back iron 131 b. The first permanent magnet array 130a and the second permanent magnet array 130b form a bilateral permanent magnet U-shaped mover in a face-to-face manner. A slider 122 is mounted to the underside of the base 100. A set of guide rollers 121 is mounted on the underside of the carriage 122.

Crash blocks 111 are installed at both ends of the base 100. The anti-collision block 111 is made of soft materials such as polyurethane, when a plurality of rotors run on the same closed motion track and accidental collision occurs, the anti-collision block firstly deforms to absorb impact energy, impact force is relieved, and safety of materials on the rotors or the rotors is protected.

The mover is provided with sensing elements such as a straight section grating 125 and/or a curved section grating 126. The linear magnetic grating or grating 125 is mounted on the guide surface of the base 100 and can be measured by an encoder array (i.e., a magnetic grating or grating read head) mounted on the linear section. The distance between two adjacent encoders is less than the effective signal transmission distance of the magnetic grid or the optical grid of the mover. In this embodiment, the distance between two adjacent encoders is smaller than the length of the magnetic grating or the grating. The arc-shaped section magnetic grid or optical grating 126 is installed on the lateral side of the base 100, has a curved arc shape consistent with the guide rail, and can be detected and measured by an encoder array installed on the arc-shaped section. The magnetic grids or the optical gratings of the straight line section and the arc section do not interfere with the encoder in movement.

Here, the straight-segment grating or grating 125 and the arc-segment grating or grating 126 may be replaced by other sensing elements such as hall sensing elements. The sensing elements include a first sensing element and a second sensing element, wherein the first sensing element and the second sensing element are arranged such that a first signal emitted by the first sensing element is read by an encoder array on the linear stator module when the mover moves over the linear stator module, and a second signal emitted by the second sensing element is read by an encoder array on the arcuate stator module when the mover moves over the arcuate stator module.

The first and second sensor elements are mounted on the mover and their mounting positions on the mover are arranged such that at any time during movement of the mover, a first signal from the first sensor element or a second signal from the second sensor element can be picked up by two adjacent encoders on the stator.

When the rotor is in operation, the permanent magnet array of the rotor generates driving force under the current excitation of the stator coil, and the whole rotor is pushed to move along the guide rail through the guide rail guide roller 121. The guide roller 121 may move along a linear guide or an arc guide. The sensor element may detect a moving position of the mover.

Fig. 6 is a magnet array distribution of a linear motor mover according to an embodiment of the present invention. As shown in fig. 6, the first permanent magnet array 131a and the second permanent magnet array 131b are 2 sets of permanent magnet arrays facing each other, and include a first permanent magnet, a second permanent magnet, and a third permanent magnet, wherein the first and second permanent magnets are main magnets, and the third permanent magnet is an auxiliary magnet. The first

permanent magnets

413a, 413b, 417a, 417b, 421a, 421b have magnetization directions directed from the S pole to the N pole, i.e., in the positive direction of the Z axis along the third coordinate axis. The magnetization direction of the second

permanent magnets

415a, 415b, 419a, 419b, 423a, 423b is directed from the S pole to the N pole, i.e., in the negative Z-axis direction along the third coordinate axis.

The third

permanent magnets

412a, 412b, 414a, 414b, 416a, 416b, 418a, 418b, 420a, 420b, 422a, 422b, 424a, 424b are auxiliary magnets, and the magnetization direction thereof is along the first coordinate axis X direction.

The third

permanent magnets

412a, 414a have magnetization directions directed in the first coordinate axis in the direction of the first

permanent magnet

413a, 412a in the positive direction of the X-axis, and 414a in the negative direction of the X-axis.

The third

permanent magnet

414a, 416a has a magnetization direction pointing away from the second permanent magnet 415a along the first coordinate axis, and the magnetization direction of 416a points in the positive direction of the X-axis.

The third

permanent magnets

416a, 418a have magnetization directions directed in the direction of the first permanent magnet 417a along the first coordinate axis, and the magnetization direction of the third permanent magnet 418a is directed in the negative direction of the X axis.

The third

permanent magnets

418a, 420a have magnetization directions pointing away from the second permanent magnet 419a along the first coordinate axis, and the magnetization direction of 420a points in the positive direction of the X-axis.

The third

permanent magnets

418a, 420a have magnetization directions pointing away from the first permanent magnet 419a along the first coordinate axis, and the magnetization direction of 420a points in the positive direction of the X-axis.

The third

permanent magnets

420a, 422a have magnetization directions directed in the direction of the second permanent magnet 421a along the first coordinate axis, and the 422a magnetization direction is directed in the negative direction of the X axis.

Third

permanent magnet

422a, 424a has a magnetization direction pointing away from first permanent magnet 423a along the first coordinate axis, and 424a has a magnetization direction pointing in the positive direction of the X-axis.

The third

permanent magnets

412b, 414b have magnetization directions pointing away from the first permanent magnet 413b along the first coordinate axis, the magnetization direction of 412b pointing in the positive direction of the X-axis, and the magnetization direction of 414b pointing in the negative direction of the X-axis.

The third

permanent magnets

414b, 416b have magnetization directions directed in the direction of the second permanent magnet 415b along the first coordinate axis, and 416b have magnetization directions directed in the negative direction of the X-axis.

The third

permanent magnets

416b, 418b have magnetization directions directed away from the first permanent magnet 417b along the first coordinate axis, and the magnetization direction of the third permanent magnet 418b is directed in the positive direction of the X-axis.

The third

permanent magnets

418b, 420b have magnetization directions directed in the direction of the second permanent magnet 419b along the first coordinate axis, and the magnetization direction of 420b is directed in the negative direction of the X axis.

The third

permanent magnets

420b, 422b have magnetization directions directed away from the second permanent magnet 421b along the first coordinate axis, and the 422b magnetization direction is directed in the positive direction of the X-axis.

Third

permanent magnets

422b, 424b have magnetization directions pointing in the direction of first permanent magnet 423b along the first coordinate axis, and 424b have magnetization directions pointing in the negative direction of the X-axis.

The first, second and third permanent magnets are typically combined into a Halbach array unit by using prism-shaped magnet blocks, and they jointly form a permanent magnet array with a symmetrical layout of a rotor. Halbach array element width W_mThe distance from the N pole to the center of the adjacent S pole permanent magnet is recorded as tau, and the length of the permanent magnet array is recorded as W_mThe width of the array. The first, second and third permanent magnets construct a Halbach magnet group with a complete cycle, the Halbach magnet group is distributed along the X direction of the first shaft in a cycle repeated arrangement mode, 1 Halbach basic unit, 2 Halbach basic units … … are arranged, and by analogy, the number of groups of the rotor magnet array is constructed according to the thrust requirement of the linear motor.

The first back iron 403 and the second back iron 402 are made of a material with high magnetic permeability, such as steel, iron, and the like. The magnetic flux of the Halbach basic unit in the direction of the back iron is used for constructing a magnetic line of force loop, so that the magnetic leakage is reduced. The Halbach basic unit has the characteristic of single-side flux density, the flux density distribution of the coil-facing side of the Halbach basic unit is higher than that of a traditional NS array, and the flux density of the back iron-facing side is very weak, so that the thickness of the back iron can be thinner than that of the back iron of the traditional NS array. And the weight of the rotor unit can be reduced by using a low-density high-strength material as an auxiliary support. To reduce local magnetic leakage, the thickness of the back iron is kept at least 1 mm. In order to reduce the influence of the edge leakage flux, the width of the third

permanent magnets

412a, 412b, 424a, 424b along the third axis X is half the width of the

permanent magnets

414a, 414 b. The width of the first and second permanent magnets along the X direction is 0.5-0.9 times of tau. The first auxiliary support plate 401 and the second auxiliary support plate 404 are auxiliary support members made of a low-density high-rigidity material, and are used for enhancing the support rigidity of the back iron.

Fig. 7 is a magnet array distribution of a linear motor mover according to another embodiment of the present invention. As shown in fig. 7, the magnet array unit of the mover is composed of 2 sets of base units of the NS permanent magnet array facing each other and a yoke, and the first

permanent magnets

512a, 512b, 514a, 514b, 516a, 516b in the center of the base units have their magnetization directions directed from the S pole to the N pole, i.e., directed in the positive direction of the Z axis along the third coordinate axis; the magnetization direction of the second

permanent magnet

513a, 513b, 515a, 515b, 517a, 517b in the center of the basic unit is directed from the S pole to the N pole, i.e., in the negative direction of the Z axis along the third coordinate axis.

The first and second permanent magnets are typically combined into an NS base unit using prismatic magnet blocks, which together form a symmetrically arranged permanent magnet array of mover units. The width of the NS permanent magnet array unit is W_mAnd the distance from the N pole to the center of the adjacent S pole permanent magnet is recorded as tau. The first permanent magnet and the second permanent magnet construct NS magnet groups of a complete cycle, the NS magnet groups are distributed along the first axis direction X and are repeatedly arranged periodically, 1 NS basic unit, 2 groups of NS basic units … … are arranged, and the like, and the number of groups of the rotor magnet array is constructed according to the thrust requirement of the linear motor.

The

back irons

601 and 602 are soft magnetic materials, such as cobalt iron alloy, iron nickel alloy, silicon steel, iron aluminum silicon alloy and the like, and the soft magnetic materials refer to IEC60404-1 standard, and form magnetic line loops by the magnetic flux of the NS basic unit in the direction of the back iron. The NS basic unit has bidirectional magnetic density characteristics, according to the requirement of electromagnetic thrust, the higher the magnetic density intensity distribution of the coil facing side is required to be, the better the magnetic density of the back iron facing side is required to be, the smaller the magnetic density is required to be, the better the back iron thickness is, therefore, the back iron thickness is enough to reduce the magnetic leakage, and the thickness is kept to be at least 5 mm. In addition, the width of the first and second permanent magnets along the X direction is 0.5-1 times of τ.

Fig. 8 is a schematic structural diagram of a linear motor module according to an embodiment of the present invention. As shown in fig. 8, the linear motor module includes a mover and a stator module. The mover module may employ a mover structure as shown in fig. 5. The stator module comprises a base body and a stator coil assembly fixed on the base body, wherein the stator coil assembly comprises at least two layers of coil units which are mutually overlapped and arranged. The coil unit may be made of a coreless coil through a printed circuit board process. The stator coil assembly is operatively disposed between the first permanent magnet array and the second permanent magnet array.

The adjacent two layers of coil units contain a plurality of armature winding units each having three

coil windings

401a, 401b, 401 c. The three

coil windings

401a, 401b, 401c are respectively U-phase, V-phase and W-phase of the armature winding unit, wherein the U-phase and W-phase of each armature winding unit are adjacently arranged in the same layer, and the V-phase is arranged on the upper layer or the lower layer of the U-phase and W-phase and aligned with the centers of the U-phase and W-phase. In the adjacent two layers of coil units, if the V phase of one armature winding unit in the two adjacent armature winding units is on the upper layer of the U phase and the W phase of the armature winding unit, the V phase of the armature winding unit of the other armature winding unit is on the lower layer of the U phase and the W phase of the armature winding unit.

U, V, W three-phase coils form basic armature winding units which are repeatedly arranged along the first axis direction X periodically, 1 group, 2 groups, 3 groups, … … groups, the basic units and so on, and the number of groups of the armature winding units is constructed according to the stroke requirement of the linear motor.

Fig. 9 is a schematic structural view of a linear motor module according to another embodiment of the present invention. As shown in fig. 9, the linear motor module includes a magnet mover and a stator coil unit. The mover is composed of 2 sets of basic units of the permanent magnet array facing each other and a magnetic yoke, the first

permanent magnet

430a, 430b in the center of the basic unit has the magnetization direction pointing from the S pole to the N pole, i.e. pointing to the positive direction of the Z axis along the third coordinate axis; the magnetization direction of the second

permanent magnets

431a, 431b at the center of the basic unit is directed from the S pole to the N pole, i.e., in the negative direction of the Z axis along the third coordinate axis.

The first and second permanent magnets are typically combined into an NS basic unit using prismatic magnet blocks, which together form a mover unitPermanent magnet array of symmetrical overall arrangement. Width of NS element is W_mThe half period length is denoted as τ. The first magnet and the second magnet construct NS magnet groups of a complete period, the NS magnet groups are distributed along the first axis direction X and are arranged repeatedly in a periodic mode, 1 NS basic unit, 2 groups of NS basic units … … are arranged, and the like, and the number of groups of the rotor magnet arrays is constructed according to the thrust requirement of the linear motor.

The NS basic unit has bidirectional magnetic density characteristics, according to the requirement of electromagnetic thrust, the magnetic density intensity distribution of the coil facing side of the NS basic unit needs to be higher and better, and the magnetic density of the back iron facing side needs to be smaller and better, so that the back iron thickness can have enough thickness to reduce magnetic leakage, and the thickness of the back iron can be kept at least 5 mm. In addition, the width of the first and second permanent magnets along the X direction is 0.5-1 times of tau.

Fig. 11 shows an embodiment of a control device of the linear transmission system of the present invention. As shown in fig. 11, the linear transmission system includes a linear motor rotor 601, a support plate 602, a stator base 604, coil windings 606 and a control device, wherein the

coil windings

606A, 606B and 606C are connected according to a UVW three-phase star or delta connection and are periodically arranged on the stator base 604 according to a three-phase alternating current sequence of the linear motor. The control device includes a magnetic grid 603, an encoder 611, an integrated power amplifier 613, an integrated input-output processing board 614, an integrated system controller 610, and an industrial PC. Each three-phase UVW coil winding is connected to a group of three-phase current controllers of a power amplifier (power amplifier board) 613, and each three-phase current controller can be controlled to be turned on and off through one logic gating channel. The power amplifier 613 may support 3N phase coil control, such as 1 group 3 phase, 2 groups 3 phase, …, N groups 3 phase windings, and so on, with the maximum support coil being determined by the number of IGBT or MOSFET chips on the board.

The mover position information measured by the encoder array is accessed to the integrated input/output processing board 614. The input output processing board 614 may support data access and computational processing for any number of sensors in a range such as 32-way, 64-way, 128-way, etc., for example, 64-way sensor sampling data up to a sampling update frequency of at least 20 kHz. The input/output processing board 614 calculates global position information of each mover from the sampled mover position information, and transmits the global position information to the power amplifier 613. Specifically, the input/output processing board 614 calculates the global position information of each mover according to the sampled mover position information, and transmits the global position information to the integrated system controller 610 in real time. The system controller 610 performs real-time position control of each mover, and transmits a control signal to the input/output processing board 614, and then the input/output processing board 614 transmits the control signal to the power amplifier 613 in real time to turn on or off the corresponding coil winding.

In particular, the power amplifier 613 is provided with a plurality of gate channels (or logic gate channels), each gate channel being connected to one armature winding unit. And the gating channel opening and closing state of the power amplifier calculates the channel number of the rotor covering coil according to the measured data feedback of the position sensor of the rotor, and performs gating control.

In particular, the input/output processing board 614 supports sending some other auxiliary signals sampled by it to the industrial PC for information processing. The auxiliary signals include, for example, motor temperature, hall signal, switching signal, and hardware signals such as power amplifier 613 and input/output processing board 614.

In this embodiment, the system controller 610 simultaneously receives a client application command signal from the industrial PC via the communication link, or simultaneously sends a device control status signal to the industrial PC. The communication link comprises, for example, EtherCAT, 485, RS232, optical fiber, CAN bus, wireless communication and other supporting industry standard protocols.

Fig. 12 shows an embodiment of a position measurement system of the linear transmission system of the present invention. As shown in fig. 12, the position measurement system includes a position measurement sensor 582, here a magnetic grating or optical grating. The distance between every two adjacent encoders 583 is smaller than the length of the magnetic grid or grating 582 on the mover, so that at a certain moment, the magnetic grid on the mover enables the two adjacent encoders to acquire the same position information 581 of the mover at the same time, and provide the position information to the system controller to perform redundant measurement on the real-time position information of the mover. If a certain sensor fails to generate faults in the operation process, the other adjacent sensor can take over the real-time position measurement function, and reliable real-time servo feedback can be carried out. When the rotor moves towards a certain direction, the measuring function of the distant encoder is switched to be transferred to the adjacent encoder, and the position data obtained by measurement and calculation of the nearest encoder is used as a position servo feedback signal of the system controller. The measurement position of each mover module relative to the stator module is calculated as follows:

wherein the content of the first and second substances,

global position data, P, in a closed-loop transmission system for the ith mover_sensor(j) For the calibration value of the measurement feedback position of the jth encoder relative to the mover magnetic grid,

and switching the data of the global position of the rotor at the moment of sampling the sensor for simultaneously covering the current position sensor and the previous position sensor at the motion position of the rotor. i represents the number of each mover module, j represents the number of each sensor, and g is global position data.

Particularly, the position measuring system of the linear transmission system can realize synchronous global real-time absolute position measurement of a plurality of rotors, the magnetic grid on each rotor is used as a motion unit, and the encoder is installed on the stator module.

In particular, the position measurement system of the linear transmission system is provided with sensor element failure mode detection logic by a plurality of sensor redundancy measurement modes, and the position of a sensor failure can be indicated by a maintainer in the next shutdown maintenance period of the system.

In an alternative embodiment, Hall effect element sensors may be used for position measurement instead of the magnetic grating or optical grating 583. in this embodiment, Hall sensors are installed at each winding slot position of the stator coil assembly, and position data is obtained by measuring the flux transformation of the rotor permanent magnet array unit.

Fig. 13 illustrates an embodiment of a multi-mover cooperative control system of a linear transmission system according to the present invention. As shown in fig. 13, the multi-mover cooperative control system includes an application software layer 631, a plurality of soft controllers 632, an integrated input/output processing board 633, a plurality of mover virtual shafts 634, a stator coil assembly 635, a coil winding 606, and a power amplifier (power driving board) 636. In an embodiment, each mover acts as an independently controllable motion entity that moves upon energization of the stator coil assembly 635. The rotors can be controlled synchronously or asynchronously. Each mover is defined as an independent mover virtual axis, has an independent motion path plan, and is controlled by each corresponding soft controller 632.

Specifically, the number of mover virtual axes corresponds to the number of movers, and the number of soft controllers 632. The soft controller 632 is a digital controller. The soft controller can exist in a controller based on a DSP, ARM or FPGA chip, or can exist in a plurality of physical controllers, and each physical controller adopts high-speed signal cascade. Typically, the maximum number of soft controllers 632 may be 8, 16, 32, 64, 128, etc. according to their physical controller definitions, and any number of mover virtual axes may be controlled within the range of the maximum number of soft controllers 632 described. Particularly, cooperative control or independent track motion between virtual shafts of each rotor is realized by high-speed real-time cooperative control between soft controllers.

In an embodiment, the functions of the integrated input/output processing board 633 include performing data calculation and distribution of the dynamic position encoder, and transmitting the position measurement signals required for each mover virtual axis to the soft controller 632 in real time. Furthermore, the integrated i/o processing board 633 transmits the position data and the control signal calculated by each soft controller to the power amplifier 636 in real time, so as to energize the stator coil assemblies. In particular, the input/output processing board 633 coordinates and processes signals of the soft controller 632, the mover virtual shaft, the position sensor array, and the input/output driving board 636 in real time at a high speed, so that seamless information data interaction is realized among the modules.

In this embodiment, the controller in which the soft controller 632 resides receives the client application command signal from the application software layer via the communication link, or sends the device control status signal to the application software layer. The communication link comprises, for example, EtherCAT, 485, RS232, optical fiber, CAN bus, wireless communication and other supporting industry standard protocols.

Fig. 14 shows an embodiment of the integrated control device of the linear transmission system of the present invention. As shown in fig. 14, the integrated drive control scheme includes a linear motor 600, a power amplifier 608, a coil gating control unit 603, and a system controller 604. The linear motor 600 includes a permanent magnet mover unit 601 and a stator coil assembly (coil array) 500. In an embodiment, each armature winding unit of stator coil assembly 500 shares a power source. Each stator coil assembly module is connected to a power amplifier 608 by a power cable 605. When the mover 601 moves to a certain position, the coils covered by the mover need to be energized and excited at the same time. The coil gating control unit 603 calculates, according to the position information of each mover of the system controller 604, a coil unit to be energized and excited at that time. Each three-phase UVW coil winding is connected to a gated channel of the power amplifier 608. The gated channel logic unit determines the channels of each three-phase current controller to be controlled to open and close through logic communication 606. The power amplifier 608 may support 3N phase coil control, such as 1 group of 3 phase, 2 groups of 3 phase, …, N groups of 3 phase windings, and so on, with the maximum number of coils supported being determined by the number of IGBT or MOSFET chips on the board.

In addition, the coil gating control unit 603 receives current control information from the system controller 604 via the communication link 607, and then transmits the information to the power amplifier 608 in real time. The communication link 607 typically employs an optical fiber, 485, etc. communication link interface.

Specifically, the open/close state of the logical gating channel of the coil gating control unit 603 calculates the number of the channel covering the coil of the mover according to the position measurement data feedback of the mover of the system controller 604, and performs gating control. Here, the logic gating channel refers to a switch that determines a channel by a digital signal level "0" or "1" in the coil gating control unit, that is, "0" makes the coil in an off state, and "1" makes the coil in a gating state.

Fig. 15 shows a schematic diagram of a control system of the linear transmission system of the present invention. As shown in fig. 15, the control system includes a position command generator 520, a position controller 521, a speed controller 523, a differentiation unit 522, a summer 519, a commutation control unit 524, a control sensor processing unit 510, a summer 518, a current controller 525, a coil on-off processing unit 526, a summer 517, an amplifier 528, a current sensor 527, a position sensor array 210, a mover unit 501, and a stator coil assembly 500. The position command generator 520 determines the planned position of the movement required by the mover and may also program different modes of application, such as position, velocity, acceleration trajectory curves calculated over time. Furthermore, position command generator 520 can also respond to external events such as register pulse signals, station-to-bit signals, synchronous motion signals of external servo axes. The summer 519 compares the position reading of the position sensor closest to the mover obtained by the control sensor processing unit 510 with the position given by the position command generator 520, and the difference is sent to the position controller 521, and information in units of velocity is obtained through tuning and amplification processing of the position controller 521, and then sent to the summer 518. The position information collected by the control sensor processing unit 510 is processed by the differentiating unit 522 into velocity information, which is sent to the summer 518. The summer 518 sums the two velocity information, processes and amplifies the summed information to obtain information based on current units, and transmits the information and the position information collected by the control sensor processing unit 510 to the commutation control unit 524 for commutation processing. In the vector control of the permanent magnet linear synchronous motor, three-phase current of the permanent magnet linear synchronous motor is synthesized into an output current vector which is positioned on a q axis of a magnetic field, and a d axis exciting current vector is made to be 0, so that the synchronous motor can be used for controlling the output current vector according to the requirement of the output current vectorThe control is carried out in a mode of a direct current motor, and the output force is axial force along the first direction X. Permanent magnet linear synchronous motor generally adopts i_dIn the control mode of 0, the current in the three-phase winding is given according to the alternating current with the phase difference of 120 degrees, and the commutation algorithm realizes the current commutation process from dq0 to the three-phase coil UVW, and the following formula is shown:

the inverse transformation formula for the commutation calculation is as follows:

for the control of the permanent magnet synchronous linear motor, the d axis and the 0 axis are both controlled to be zero, and the current commutation calculation process of a given coil is realized by converting the output force of the controller into the current of the iq axis.

Summer 517 sums and compares the given current of three-phase coil UVW processed by commutation control unit 524 with the coil current sampled by current sensor 527, and then passes the current deviation to current controller 525 for current shaping and tuning.

The conventional current controller adopts PI control, the tuned signal is sent to a power amplifier 528 for current amplification, and the amplifier 528 may adopt power devices such as MOSFET or IGBT.

In the control system of the motion control apparatus, each coil is connected to a power amplifier 528, which is a digitally logic controlled power amplifier with a closed loop of current. When the mover 501 is moved to a designated coil at a calculated position, the control sensor processing unit 510 uses the acquired position information of the position sensor array 210 to determine the closest coil to switch to the power amplifier gating connection, and the control sensor processing unit 510 passes the logic information of the coil gating to the logic circuit of the coil on-off processing unit 526 to establish an electromagnetic field on the armature windings to advance or maintain the position of the static mover. Each coil is not provided with an independent power driver, all the coils share one power amplifier with a multi-path current loop closed loop, only the coil winding closest to the target position is electrified through gating information to enable operation, and at the position where the rotor does not stop moving, the coils of the stator coil assembly are electrified and continuously switched logically to establish an electromagnetic field so as to enable the rotor to generate corresponding movement. The mode of logic switching enables all coils to share one power amplifier, the manufacturing cost of the system is more economical, and the efficiency of configuring one power amplifier by one mover as the same as that of the traditional linear motor is obtained.

While the preferred embodiments of the present invention have been described in detail above, it should be understood that aspects of the embodiments can be modified, if necessary, to employ aspects, features and concepts of the various patents, applications and publications to provide yet further embodiments.

These and other changes can be made to the embodiments in light of the above detailed description. In general, in the claims, the terms used should not be construed to be limited to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled.

Claims

1. A control device of a linear transmission system including a linear motor including a stator and a plurality of movers, the stator having a stator coil assembly including a plurality of armature winding units, and the movers having a permanent magnet array, the control device comprising:

2. The control apparatus of claim 1, wherein the coil gating control unit and the system controller are physically separate two devices, wherein the coil gating control unit has a plurality of logical gating channels, one for each armature winding unit.

3. The control device as claimed in claim 2, wherein the open and close states of the logic gating channel of the coil gating control unit calculate the channel number of the armature winding unit covered by the mover based on the mover position measurement data feedback from the system controller, and perform gating control.

4. The control device as claimed in claim 1, wherein the position detection unit is connected to the coil gating control unit, and the coil gating control unit processes the mover position information from the position detection unit and controls the corresponding logic gating channel to open and close, thereby controlling the corresponding armature winding unit to be powered on and off.

5. The control device according to claim 1, wherein the power amplifier is provided with a plurality of on-off gating channels, each of which is connected to one of the armature winding units, and wherein the power amplifier controls the corresponding on-off gating channel according to a signal from the coil gating control unit, so that the armature winding unit corresponding to the corresponding on-off gating channel is powered on or off.

6. The control device as claimed in claim 1, wherein the control device is configured such that when the mover approaches an armature winding unit, the armature winding unit closest to the mover is energized by the position information collected by the position detection unit in a logic gating manner to generate an electromagnetic field to drive the mover to move, and when the mover moves in a certain direction without stopping, the system controller switches the coil exciting current to the closest armature winding unit in real time according to the position information collected by the position detection unit.

7. The control apparatus of claim 1, wherein the stator coil assembly configures UVW three-phase coils in an alternating UVW phase sequence up and down, wherein each of the armature winding units has three coil windings, and the three coil windings are respectively a U-phase, a V-phase and a W-phase of the armature winding unit.

8. The control apparatus according to claim 1, wherein the stator coil assemblies are arranged in a periodically extending manner, and are arranged in a straight line, or are arranged in a curved line.

9. The control device according to claim 1, wherein the U-phase and the W-phase of one armature winding unit are adjacently arranged in the same layer, the V-phase is arranged in the upper layer or the lower layer of the U-phase and the W-phase in alignment with the centers of the U-phase and the W-phase, and the V-phase of the armature winding unit of the other armature winding unit is arranged in the lower layer of the U-phase and the W-phase of the armature winding unit if the V-phase of one armature winding unit is arranged in the upper layer of the U-phase and the W-phase of the armature winding unit.

10. The control device according to claim 1, wherein the position detecting unit includes a position measuring sensor and an encoder, wherein the position measuring sensor is mounted on the mover, and the encoder is mounted on the stator.

11. The control device of claim 10, wherein the position measurement sensors are grating sensors, the encoders being mounted on the stator base in an equidistant arrangement; or, the position measurement sensor is a magnetic grid sensor, and the encoders are arranged on the stator base according to equal distance.

12. The control device of claim 10, wherein the position measuring sensors are optical gratings, and the encoders are mounted on the stator base in an equidistant arrangement, wherein the distance between every two adjacent encoders is smaller than the length of the optical grating on the mover, so that at a certain time, the optical grating on the mover can enable the two adjacent encoders to acquire the same position information of the mover, and provide the position information to the system controller for performing redundant measurement and servo feedback on the real-time position information of the mover, when the mover moves in a certain direction, the measurement function of the distant encoder is switched to the adjacent encoder, and the position information of the mover calculated by the measurement of the nearest encoder is used as the position servo feedback signal of the system controller; alternatively, the first and second electrodes may be,

the position measuring sensor is a magnetic grid, the encoders are arranged on the stator base at equal intervals, the distance between every two adjacent encoders is smaller than the length of the magnetic grid on the rotor, so that at a certain moment, the magnetic grid on the rotor can enable the two adjacent encoders to acquire the same position information of the rotor, the position information is provided for the system controller to carry out redundancy measurement and servo feedback on the real-time position information of the rotor, when the rotor moves in a certain direction, the measurement function of the remote encoder is switched to be transferred to the adjacent encoder, and the rotor position information obtained by measurement and calculation of the nearest encoder is used as the position servo feedback signal of the system controller.

13. The control device of claim 1, wherein the power amplifier has a plurality of three-phase current controllers, each three-phase current controller is electrically connected to one armature winding unit and is controlled to be opened and closed by a logic gating channel.

14. The control device according to claim 1, further comprising an input/output processing board electrically connected to the position detection unit, the power amplifier, and the system controller, wherein the input/output processing board calculates mover position information from the position detection unit to obtain global position information of each mover, sends the global position information to the power amplifier and the system controller simultaneously, and the system controller controls a real-time position of each mover and sends a control signal to the input/output processing board, and then the input/output processing board transmits the control signal to the power amplifier in real time.

15. A linear transmission system, characterized in that the linear transmission system comprises:

a stator base consisting of one or more sub-bases;

a stator coil assembly fixed to the sub-base;

16. The linear transmission system of claim 15, wherein the coil gating control unit and the system controller are physically independent two devices, wherein the coil gating control unit has a plurality of logical gating channels, one for each armature winding unit.

17. The linear transmission system as claimed in claim 16, wherein the open and closed states of the logic gating channel of the coil gating control unit calculate a channel number of an armature winding unit covered by a mover based on mover position measurement data feedback from the system controller and perform gating control.

18. The linear transmission system as claimed in claim 15, wherein the position detection unit is connected to the coil gating control unit, and the coil gating control unit processes the mover position information from the position detection unit and controls the corresponding logic gating channel to open and close, thereby controlling the corresponding armature winding unit to be powered on and off.

19. The linear transmission system of claim 15, wherein the power amplifier is provided with a plurality of on-off gating channels, each of which is connected to one of the armature winding units, wherein the power amplifier controls the corresponding on-off gating channel according to a signal from the coil gating control unit, thereby energizing or de-energizing the armature winding unit corresponding to the corresponding on-off gating channel.

20. The linear transmission system of claim 15, wherein the system controller is configured to energize an armature winding unit closest to the mover with position information collected by the position detection unit in a logic gating manner to generate an electromagnetic field to drive the mover to move when the mover approaches the armature winding unit, and to switch the coil exciting current to the closest armature winding unit in real time according to the position information collected by the position detection unit when the mover moves in a certain direction without stopping.

21. The linear transmission system of claim 15, wherein the stator coil assembly configures UVW three-phase coils in a UVW phase sequence alternating up and down, wherein each of the armature winding units has three coil windings, and the three coil windings are respectively a U-phase, a V-phase and a W-phase of the armature winding unit.

22. The linear transport system of claim 15, wherein the stator coil assemblies are arranged in a periodically extending manner, and are arranged in a straight line, or in an arbitrary curved line.

23. The linear transmission system according to claim 15, wherein the U-phase and the W-phase of one armature winding unit are adjacently disposed at the same level, the V-phase is disposed at an upper level or a lower level of the U-phase and the W-phase in alignment with centers of the U-phase and the W-phase, and the V-phase of the armature winding unit of the other armature winding unit is disposed at a lower level of the U-phase and the W-phase of the armature winding unit if the V-phase of one armature winding unit is at the upper level of the U-phase and the W-phase of the armature winding unit.

24. The linear transmission system of claim 15, wherein the position detection unit includes a position measuring sensor and an encoder, wherein the position measuring sensor is mounted on the mover and the encoder is mounted on the stator.

25. The linear transport system of claim 24, wherein the position measurement sensors are grating sensors, the encoders being mounted on the stator base in an equidistant arrangement; or, the position measurement sensor is a magnetic grid sensor, and the encoders are arranged on the stator base according to equal distance.

26. The linear transport system of claim 24, wherein the position measuring sensors are optical gratings, and the encoders are mounted on the stator base in an equidistant arrangement, wherein the distance between every two adjacent encoders is smaller than the length of the optical grating on the mover, so that at a certain time, the optical grating on the mover enables the two adjacent encoders to acquire the same position information of the mover, and provide the position information to the system controller for performing redundant measurement and servo feedback on the real-time position information of the mover, when the mover moves in a certain direction, the measurement function of the distant encoder is switched to the adjacent encoder, and the position information of the mover calculated by the measurement of the nearest encoder is used as the position servo feedback signal of the system controller; or, the position measuring sensors are magnetic grids, the encoders are arranged on the stator base at equal intervals, the distance between every two adjacent encoders is smaller than the length of the magnetic grid on the rotor, so that at a certain moment, the magnetic grid on the rotor can enable the two adjacent encoders to acquire the same position information of the rotor and provide the position information to the system controller to perform redundant measurement and servo feedback on the real-time position information of the rotor, when the rotor moves in a certain direction, the measurement function of the remote encoder is switched to be transferred to the adjacent encoder, and the rotor position information obtained by measurement and calculation of the nearest encoder is used as the position servo feedback signal of the system controller.

27. The linear transmission system as claimed in claim 15, further comprising an input and output processing board electrically connected to the position detection unit, the power amplifier, and the system controller, wherein the input and output processing board calculates mover position information from the position detection unit to obtain global position information of each mover, transmits the global position information to the power amplifier and the system controller simultaneously, and the system controller controls a real-time position of each mover and transmits a control signal to the input and output processing board, which then transmits the control signal to the power amplifier in real time.

28. The linear transport system of claim 15, wherein the stator base includes a linear stator base and an arcuate stator base, wherein the linear stator base mounts a rectangular stator coil assembly to form a linear stator module and the arcuate stator base mounts an arcuate stator coil assembly to form an arcuate stator module.

29. The linear transport system of claim 15, wherein the guide rail is removably mounted to the stator base.

30. The linear transport system of claim 15 further comprising a mounting bracket secured to the stator base, the sensor array being mounted to the mounting bracket.

31. The linear transmission system of claim 28, wherein the mover includes:

a base;

a first auxiliary support plate installed at an upper side of the base;

a second backup support plate spaced apart from the first backup support plate;

a first back iron mounted to the first auxiliary support plate;

32. The linear transport system of claim 31, wherein each of the movers has a first sensing element and a second sensing element mounted thereon, wherein the first sensing element and the second sensing element are arranged such that a first signal emitted by the first sensing element is read by a sensor array on the linear stator module as the mover moves on the linear stator module and a second signal emitted by the second sensing element is read by a sensor array on the arcuate stator module as the mover moves on the arcuate stator base.

33. The linear transport system of claim 32, wherein the first sensing element and the second sensing element are magnetic grids and the sensor array is a magnetic grid read head, wherein the first sensing element is mounted on a side of the base opposite to a side on which the first back iron is mounted, and the second sensing element is mounted on a side of the base perpendicular to a side on which the first sensing element is mounted; or, the first sensing element and the second sensing element are gratings, the sensor array is a grating reading head, wherein the first sensing element is installed on the side of the base opposite to the side where the first back iron is located, and the second sensing element is installed on the side of the base perpendicular to the side where the first sensing element is installed.

34. The linear transport system of claim 32, wherein the base has an arcuate block, and the second sensing element is mounted on an arcuate surface of the arcuate block.

35. The linear transport system of claim 31, wherein the mover further includes a slider and a roller, the slider being mounted to an underside of the base, and the roller being mounted to the slider.

36. The linear transmission system of claim 31, wherein the mover further includes a collision prevention block mounted on the base and located on the same side as and opposite to the moving direction of the mover.

37. A multi-mover cooperative control system of a linear transmission system including a linear motor including a stator and a plurality of movers, the stator having a stator coil assembly including a plurality of armature winding units, and the movers having a permanent magnet array, the multi-mover cooperative control system comprising:

a position detection unit for detecting a position of each of the movers;

38. The multi-mover cooperative control system as claimed in claim 37, wherein the cooperative control between the mover virtual axes or the respective independent trajectory motions are cooperatively controlled in real time between the soft controllers.

39. The multi-mover cooperative control system as claimed in claim 37, wherein the number of the mover virtual axes, the number of the movers, and the number of the soft controllers are the same.