Motion control system self-calibrating

A motion control system including components such as an accelerometer for detecting zero force positions and for self-calibrating the motion control system. The motion control system may be implemented in an active seat suspension.

BACKGROUND

This specification describes an apparatus and method for self-calibrating a motion control system and for determining zero force positions of a phase of an electromechanical actuator.

SUMMARY

In one aspect a method for self-calibrating a motion control system, includes providing, by a position detector associated with the motion control system position information of an armature; providing a motion directing calibration signal of pre-determined frequency content, to cause a motion control system to provide current to a plurality of phases of a multiphase motor includes the armature; commutating current provided to the plurality of phases so that the net force with the pre-determined frequency content is zero if the actual position of the armature corresponds to the position information; and detecting motion, at the pre-determined frequency, of the armature resulting from the motion directing signal. The predetermined frequency content may include frequencies outside the normal range of operation of the motion control system. The detecting may include filtering an acceleration measurement according to the predetermined frequency content. The method for calibrating a motion control system may further include in the event that that motion resulting from the armature is detected, modifying the position information. The detecting may include measuring the acceleration of the armature. The detecting may include detecting audible vibration resulting from motion of the armature. The method may further include operating the motion control system in a conventional manner, the conventional manner including receiving as input a desired armature position; determining a motion that will cause the position indicated by the position information to match the desired armature position; determining a force required to effect the motion; and applying the required force to the armature.

In another aspect, a self calibrating motion control system includes: a motor includes an armature and a plurality of phases; a position sensor to provide position information of the armature; a calibration signal source to provide a signal directing a motion control system to provide current to the plurality of phases; a commutator to commutate current provided to the plurality of phases so that the net force resulting from the plurality of phases is zero if the actual position of the armature corresponds to the position information; and a motion detector to detect motion of the armature resulting from the motion directing signal. The self calibrating motion control system may include circuitry to modify the position information, and the commutator may further commutate current provided to the plurality of phases so that the net force resulting from the plurality of phases is zero if the actual position of the armature corresponds to the modified position information. The motion detector may include an accelerometer. The motion detector may include a microphone. The calibration device for use in a motion control system may include circuitry to modify the position information and the commutator may commutate current provided to the plurality of phases so that the net force resulting from the plurality of phases is zero if the actual position of the armature corresponds to the modified position information.

In another aspect, a method includes: applying, at a first frequency, a force to an armature of a motor to move the armature through a range of positions; determining, by a position sensor, an indicated position of the armature; exciting, at a frequency higher than the first frequency, a coil of the motor; and measuring the acceleration of the armature; filtering the acceleration of the armature to obtain a filtered acceleration measurement; and when the filtered acceleration measurement is zero, recording the indicated position. The applying may be performed by a linear actuator. The exciting may be performed by a first force source and the applying may be performed by a second force source. The second force source may be gravity. The filtering may include band pass filtering. The method may further include calculating the root mean squared value of the acceleration. The method may be implemented in an active vehicle seat suspension. The force may be applied by an air spring. The force may be applied to a plant mechanically coupled to the armature. The method may further include commutating the motor responsive to the measuring.

In another aspect, a motion control apparatus includes: a motor that includes an armature; a force source, distinct from the motor, for moving the armature through a range of motion; a position detector, for detecting the position of the armature; an accelerometer, for providing a measurement of the acceleration of the armature; a filter, for filtering the measurement; and circuitry for associating a detected position with an acceleration measurement of zero. The motion control apparatus may include a plant mechanically coupling the second force source and the armature. The filter may be a band pass filter. The motion control apparatus may further include circuitry for calculating the root mean squared value of the measurement of the acceleration. The motor may be a multiphase motor. The motion control apparatus may include commutating circuitry for commutating the motor responsive to the acceleration measurement.

In another aspect, an active vehicle seat suspension system, includes: a vehicle seat; an actuator for controlling the motion of the vehicle seat which includes an armature; a position detector to provide position information of the armature; and a self-calibration system for the active vehicle seat suspension. The self-calibration system includes a force source independent of the actuator to move the vehicle seat; a current source to provide current to the actuator at a predetermined frequency; a commutator to commutate the current so that the if the position information is accurate, the actuator applies a predetermined amount of force, and an accelerometer for measuring the acceleration of the armature; and a filter, for filtering the acceleration of the armature. The predetermined amount of force may be zero.

Other features, objects, and advantages will become apparent from the following detailed description, when read in connection with the following drawing, in which:

DETAILED DESCRIPTION

Though the elements of several views of the drawing may be shown and described as discrete elements in a block diagram and may be referred to as “circuitry”, unless otherwise indicated, the elements may be implemented as one of, or a combination of, analog circuitry, digital circuitry, or one or more microprocessors executing software instructions. The software instructions may include digital signal processing (DSP) instructions. Operations may be performed by analog circuitry or by a microprocessor executing software that performs the mathematical or logical equivalent to the analog operation. Unless otherwise indicated, signal lines may be implemented as discrete analog or digital signal lines, as a single discrete digital signal line with appropriate signal processing to process separate streams of audio signals, or as elements of a wireless communication system. Some of the processes may be described in block diagrams. The processes that are performed in each block may be performed by one element or by a plurality of elements, and individual steps of the process may be separated in time. The elements that perform the processes of a block may be physically separated. An element may perform the processes of more than one block.

FIG. 1shows a motion control system10A. The motion control system10A includes an electromechanical transducing device such as a motor12that imparts motion to a plant14. Typically, the motion is imparted by applying force to the plant through an armature16. Alternatively the plant can be rigidly connected to the stator of the motor12, and the armature rigidly connected to a stationary structure. A position sensor18is mechanically coupled to the plant14or to an element rigidly connected to the plant, for example in the implementation ofFIG. 1, the armature14. The position sensor18detects the position of the plant14, and provides position information to control block20A, in some examples through conditioning electronics22. The control block20A is coupled to the motor12and the amplifier26to control the distribution of current supplied by the amplifier and the direction and force applied by the motor12. The three lines between amplifier26and motor12will be explained below, as will the accelerometer36.

In conventional operation, the control block receives as input a desired position, and, from the position sensor18an actual position of the plant14or the armature16. The control block20A determines a motion that will cause the actual position to match the desired position and determines the force required to effect the motion. The control block transmits control signals to the amplifier26, the motor12, or both, to cause the motor to apply the desired force. Typically, the conventional operation of the motion control system10A ofFIG. 1is performed over a range of frequencies, which will be referred to below as the “normal range of operation”. For example, if the motion control system is used as an active vehicle seat, a typical normal range of operation is 0.1 Hz to 50 Hz. Components of the motion control system may be capable of operating at frequencies outside the normal range of operation of the motion control system so that the linear motor may be able to move the armature at frequencies outside the normal range of operation of the motion control system. For example, if the motion control system is used as an active vehicle seat and the normal range of operation is 0.1 Hz to 50 Hz, the linear motor may be able to respond to excitation signals of up to 1 kHz.

It is important that the position information provided by the position sensor18to the control block20A be as accurate as possible. Offsets, drifts, or other inaccuracies, can occur due to flaws in system components, including the position sensor itself. Additional inaccuracies could result from other events or conditions, for example, mechanical misalignments or changes in magnetization of the armature due to mechanical or thermal shock. Accordingly, some method of calibrating the position sensing, processing, and transmission elements is desirable, particularly if the motion control system is designed so that one or more of the components is replaceable independently of the other components or if the motion control system is designed so that components are to be replaced in an environment (for example a vehicle maintenance facility) that may not have expensive calibration equipment.

Proper calibration of the motion control system and accurate position information is particularly important if the power consumption of, or the heat produced by, the motion control system is important. Most motors transduce electrical energy to motion by the interaction of the magnetic field associated with electrical current in a coil with the magnetic field of a permanent magnet structure. Some relative positions between the coil and the permanent magnet structure result in no electrical energy being transduced to motion (hereinafter referred to as “zero force positions”). For example,FIG. 2shows force output and relative displacement between a coil and a magnet structure of a motor. At points28, when current is applied to the coil, no electrical energy is transduced to mechanical force. It is disadvantageous to direct current to the coil when the coil and magnet structure are at a zero force position, because the current causes no force and is dissipated as heat, reducing the efficiency of the motor. One method of avoiding or limiting the number of zero force positions is to use a multi-phase motor. A multi-phase motor typically includes more than one coil, with the coils placed linearly (in a linear motor) or radially (in a rotary motor) so that if one of the coils is at a zero force position, at least one other coil is not at a zero force position. The current is switched (commutated) among the windings so that more current is applied to coils that are not at a zero force position. For example,FIG. 3shows the force output of three coils (curves30,32, and34) when supplied with a constant current irrespective of displacement. At point48, the coil represented by curve30is at a zero force position, but the coils represented by curves32and34are not at zero force positions, so at point48, more current could be applied to one or both of the coils represented by curve32and34than is applied to the coil represented by curve30. If position information is inaccurate, the wrong amount of current can be applied to the various coils, causing the motor to operate inefficiently.

A motor with three independently energizable coils is referred to as a three phase motor. In a linear motor, the three coils are typically positioned equidistant from each other and so that the coils alternate along the length of the linear motor. In a rotary motor, the three coils are typically displaced angularly so that the three coils differ in phase. The current is commutated between the three coils, as indicated schematically inFIG. 1by the three lines between amplifier26and motor12. In practice, for a three phase motor, it is necessary to control the current to only two of the three phases. Since the sum of the currents to the three phases is zero, controlling the current to two phases controls the current to the third phase.

A motion control system including the elements of the system ofFIG. 1and including some additional elements is shown inFIG. 4. The additional elements provide information for calibrating the position sensing, processing, and transmission elements or for causing the system to operate more efficiently or both. The motion control system10B ofFIG. 4includes the elements ofFIG. 1and in addition includes a second force source38. The accelerometer36is physically coupled to the armature16as shown or to the plant14to measure the acceleration of the armature or plant and is also operationally coupled to the control block20A to provide information to the control block. The second force source38is physically coupled to the plant14to apply force to the plant to cause the plant to move. The second force source38, the plant14, the motor12, and the armature16are arranged so that motion of the plant caused by the second force source38causes corresponding motion of the armature16. Ideally, the system is configured and dimensioned so that motion of the plant caused by the second force source38causes the armature16to move through its entire range of motion.

A process for operating the system ofFIG. 4to detect zero force positions is shown inFIGS. 5A and 5B. As shown inFIG. 5A, at block40, the plant14is moved by the second force source to cause corresponding motion of the armature16, preferably through the armature's entire range of travel. The force is applied at a relatively low frequency (which could be essentially zero) and the force could be sufficient to move the armature at a constant velocity. Concurrently with block40, at block42a coil of motor12is excited by an excitation signal with known frequency content, as will be explained below. Concurrently with blocks40and42, at block44, the zero acceleration positions are detected by the accelerometer. The zero acceleration positions correspond to zero force positions. The zero force positions can then be used to calibrate the system or to increase motor efficiency, or both. Ideally, the armature is moved through its entire range of motion so that all zero force positions of the armature are detected.

FIG. 5Bshows the output of the accelerometer36during the process ofFIG. 5A, with the coil being excited having the force output and displacement characteristics illustrated inFIG. 2. For simplicity, the curve ofFIG. 5Bis only shown from zero through 25% displacement. The portions of the curve between 25% displacement and 50% displacement, between 50% displacement and 75% displacement, and between 75% displacement and 100% displacement, are, respectively, substantially identical to the curve ofFIG. 5B. Curve60represents the accelerometer output. When the armature (which in this example includes the magnet structure) is at 0% displacement, exciting the coil at step42ofFIG. 5Aresults in high maximum force on the armature and therefore high maximum accelerometer output. As the armature is moved by the second force source, exciting the coil results in less maximum force on the armature and therefore less maximum acceleration, as indicated by the accelerometer output envelope62. The maximum accelerometer output decreases until at point28(a zero force position), the maximum accelerometer output is substantially zero, and the position is recorded as a zero acceleration position at step44ofFIG. 5A. In an actual implementation, the maximum acceleration may not be exactly zero; some very small amount of parasitic acceleration may be detected, resulting from, for example, the structure having some mechanical resonance. One method of approximating when the accelerometer output is zero includes determining the derivative of the acceleration. When the acceleration is small and derivative of the acceleration changes sign, the acceleration is substantially zero.

In one implementation in which the plant14is a vehicle seat, the excitation signal may be a 500 Hz sine wave. The frequency content of the excitation signal does not need to be a single frequency, but may be a sweep or filtered noise. If the frequency content of the excitation signal is outside the normal range of operation of the motion control system, the motion control system can discriminate between motion that is responsive to the excitation signal and motion that is responsive to normal operation of the motion control system. The frequency of the excitation signal should be within the operational capabilities of the system; for example, the motion control system should be capable of moving the armature at the frequency of the excitation signal, and if the motion control system includes digital signal processing, the frequency should satisfy the Nyquist sampling criterion. If the excitation frequency is within the audible range of frequencies, vibration in response to the excitation signal will be audible. Additional criteria for the excitation signal frequency are set forth below in paragraph.

If the second force source is a component of the motion control system (for example, if the motion control system is an active vehicle seat suspension and the second force source a controllable air spring, or if the motion control system controls vertical position and the second force source is gravity), the system ofFIG. 4can be self-calibrating, or the determination of zero force positions and the calibration of system components such as the position sensor can be performed without expensive motion control calibration equipment.

FIG. 6shows a portion of the motion control system ofFIG. 1or4, with additional elements band pass filter37and RMS calculator39to calculate the RMS value of the filtered acceleration measurement. The RMS calculator39and band pass filter37are typically implemented as digital signal processing devices and are shown inFIG. 6as separate blocks. In an actual implementation, the digital signal processing device incorporating the RMS calculator39and band pass filter37may be stand alone processors, may be combined into a single processor, or may be integrated with a processor associated with the accelerometer36, the conditioning electronics22or the control block20A.

FIG. 7shows a process for operating a motion control system having the elements ofFIG. 4as modified byFIG. 6to discriminate between the effect of the force applied by the secondary force source and the effect of the excitation of the coil. Referring toFIGS. 1,4, and7, at block40, the plant14is moved by the second force source to cause corresponding motion of the armature16. Ideally, the motion is at a constant velocity, or alternatively, the force is applied by the second force source at a low frequency, for example, 0.5 Hz. Concurrently with block40, at block42a coil is excited with a signal of known frequency content, for example a sine wave with a frequency of 500 Hz. Concurrently with blocks40and42, at block41, the acceleration of the armature is measured; at block43, the accelerometer output is filtered with a passband encompassing the known frequency content. At block45, the RMS value of the filtered accelerometer output is calculated. And at block44, the zero acceleration points are detected. The zero acceleration positions correspond with zero force positions. The zero force positions can then be used to calibrate the system or to increase motor efficiency, or both. Ideally, the armature is moved through its entire range of motion so that all zero force positions of the armature are detected.

In one implementation, the motion control system ofFIGS. 1 and 4is an active vehicle seat suspension system similar to the active vehicle seat suspension described in US Patent Application Publication US2006/0095180 (hereinafter '180) published May 4, 2006. The motor12and armature16may be a three phase linear actuator. The plant14may be the seat 16 of '180. The position sensor18may be the vertical position sensor 24 of '180. The second force source38may be an air spring or air cylinder with an associated reservoir as shown in FIG. 14 of '180 and described in the corresponding portions of the specification, for example at paragraphs. In other active seat suspension systems, the second force source could be gravity.

The motion control system ofFIGS. 1 and 4can be used in a variety of applications. Some applications are described in '180 at paragraphs. For example, the plant can include a seat, a passenger, any fixtures associated with the seat, the seat's support structure, or power electronics. The plant can be an engine mount, a platform on a boat, as seat, bed, or cab used in any moving vehicle such as a car truck, boat or other watercraft, train, bus, recreational vehicle, ambulance, tractor, truck-trailer, farm machinery, construction machinery, weapons platform, airplane, helicopter or other aircraft, a personal transportation device, such a wheelchair, or baby carriage. Other examples could include a machine tool isolation table, interferometer benches, photolithography tables, and the like. The plant could be a bed for sleeping, or a suitable device to transport cargo that is fragile or explosive.

Referring again toFIG. 3, at each armature position (designated inFIG. 3as a percentage of total motor displacement; for a rotary motor each armature position could be designated in degrees or radians), the force outputs of the three phases differ in amplitude, and may also differ in direction (with force outputs >0 representing force exerted in one direction and force outputs <0 representing force in the opposite direction). For each position, there is a commutation pattern (that is a pattern of currents) to the three phases that results in maximum combined force output for the three phases.FIG. 8shows a control block20B similar to the control block20A of the motion control system ofFIG. 1or4, with an additional element, namely a maximum force determiner50.

As described above in the discussion ofFIG. 1, in conventional operation (referring toFIGS. 1, and8), the control block receives as input a desired position, and, from the position sensor18an actual position of the plant14or the armature16. The control block20B determines a motion that will cause the actual position to match the desired position and determines the force required to effect the motion. The control block transmits control signals to the amplifier26, the motor12, or both, to cause the motor to apply the desired force.

In a motion control system with the maximum force determiner50ofFIG. 8, the control system determines a commutation pattern resulting in maximum force for the position indicated by the position sensor, and transmits a commutation control signal to the amplifier, the motor, or both, to apply the desired force according the maximum force commutation pattern.

In an actual implementation, the maximum force determiner50may comprise calculating circuitry, but more conveniently is a look up table (LUT). In many systems, the maximum force determiner can be implemented as a minimum current determiner that determines a commutation pattern that results in the minimum current to achieve a desired force.

Referring again toFIG. 3, at each armature position (designated inFIG. 3as a percentage of total motor displacement; for a rotary motor each armature position could be designated in degrees or radians), the force outputs of the three phases differ in amplitude, and may also differ in direction (with force outputs >0 representing force exerted in one direction and force outputs <0 representing force in the other direction). For each armature position, there is a commutation pattern (that is a pattern of currents) to the three phases that results in zero combined force output for the three phases.FIG. 9shows a control block20C similar to the control block20A ofFIG. 1or4with additional elements calibration signal source52and zero force determiner54.

In operation (referring toFIGS. 1,4, and9), the control block20C receives from calibration signal source52a calibration signal including instructions to cause the motor to exert a force. The force is applied at a frequency or range of frequencies as discussed above. The zero force determiner determines a commutation pattern that would result in the motion control system exerting zero force if the position sensed by the position sensor18is accurate. The accelerometer36detects acceleration resulting from force applied in response to the calibration signal. If the frequency of the calibration signal is in the audible range of frequencies, motion may be detectable by a microphone or may be audible to a user of the motion control system. If the position as determined by the position sensor is accurate, there is no net force at the predetermined frequency pattern, and therefore no acceleration, and therefore no motion, resulting from the calibration control signal. However, if the position as determined by the position sensor is not accurate, some force will be exerted by the motion control system, resulting in motion that is detected by the accelerometer. The process can be repeated, with an offset or adjustment to the position as determined by the position sensor until no motion is detected, thereby calibrating the position sensor with the other elements of the motion control system.

Typically, the zero force commutation pattern is the maximum force commutation pattern, displaced by 90 electrical degrees. The zero force determiner54may comprise calculation circuitry, but may also be an LUT. The calculating or look-up process may be done by a standalone processor or may be done by a processor associated with other functions of the control block20C or the conditioning electronics22. The calibration signal source is most conveniently a signal source that causes the motion control system to exert force according to a known frequency pattern. The frequency pattern may be a single frequency, preferably outside the normal range of operation of the motion control system, preferably with no system resonances at nearby frequencies. Additionally, particularly if the calibration system is operated during normal operation of the motion control system, the frequency should be outside the range of operation of the motion control system so that the calibration signal does not result in motion of the armature that is similar in amplitude or frequency of motion that the motion control system is designed to counteract. Also, the frequency of the calibration signal should not be a frequency that annoys or discomforts a passenger (such as a frequency that causes motion sickness). In one embodiment, the calibration signal is a 500 Hz sine wave. Additional desirable features of the frequency content of the calibration signal are stated above in paragraph [0014].

FIG. 10shows a control block20D similar to the control block20A ofFIG. 1or4with the maximum force determiner50ofFIG. 8and with the calibration control signal source52and the zero force determiner54ofFIG. 9. A motion control system with the control block20D can calibrate the motion control system whenever the power source24can provide power, even during normal operation of the motion control system. If the motion control system is calibrated during normal operation of the system, motion corresponding with the frequency pattern of the calibration control signal indicates that the position indicated by the position sensor is not accurate. A motion control system according toFIG. 10can include the RMS calculator37or the band pass filter39(or depending on the frequency range of the calibration signal, a high or low pass filter) ofFIG. 6to determine if there is any motion resulting from the calibration control signal. Calibration can be performed at predetermined intervals or upon the occurrence of predetermined events, such as when the system is turned on.

FIG. 11Ashows a process for self-calibrating a motion control system. At block102, a motion directing signal having pre-determined frequency content is provided. At block104, position information is received from the position sensor18ofFIG. 1or4and, based on the position information, a zero force commutation pattern is received from zero force determiner54ofFIG. 9or10. At block106, current is applied to the phases of the motor according to the zero force commutation pattern. At block108, the acceleration is received from the accelerometer ofFIG. 1or4, and it is determined at block110if there is motion with the frequency content of the motion directing signal. If there is motion, the positional information is modified and blocks104,106,108and110may be repeated with the modified position information until there is no motion with the frequency content of the motion direction signal.FIG. 11Aalso illustrates that the self-calibration can be performed while the motion control system is performing conventional operation. Conventional operation is indicated by blocks with dashed lines. As described above in paragraph, at block112, position information (from the position sensor18ofFIG. 1or4) and a desired position are received and the motion appropriate to cause the actual position to match the desired position in determined. At block114, the force required to effect the appropriate motion is determined. At block116, the force is applied by directing current, preferably according to the maximum force commutation pattern corresponding with the position information received from the position sensor ofFIG. 1or4. The maximum force commutation pattern may be received from maximum force determiner50ofFIG. 8or10.

FIG. 11Bshows that the detecting motion with the frequency content of the motion directing signal can include band passing (or high or low passing, depending on the frequency content) the acceleration signal and determining the RMS value of the filtered acceleration signal.

A self-calibrating motion control system operated according toFIG. 11Ais particularly advantageous for motion control systems in which it is desirable for any of the elements of the motion control system, for example, the control block20C or20D, the position sensor18, the amplifier26, the motor12and armature16, or the conditioning electronics22to be replaced independently of the other elements. The functionality of control blocks20C or20D permits the motion control system to self calibrate when a component is replaced. With conventional motion control systems, if any one component is replaced, the entire motion controls system must be recalibrated, typically at a factory, by a skilled technician, using expensive and specialized fixtures and measuring equipment.

Numerous uses of and departures from the specific apparatus and techniques disclosed herein may be made without departing from the inventive concepts. Consequently, the invention is to be construed as embracing each and every novel feature and novel combination of features disclosed herein and limited only by the spirit and scope of the appended claims.