Actuator motion controller with regeneration compensation

Abstract

Actuators are components of machines, which move and/or control a mechanism or system. During operation, actuators can experience regeneration events, with the actuator actually generating excess energy (e.g., regenerative energy) which must be stored or dissipated to avoid damaging the power supply. An actuator motor controller is configured to implement field oriented voltage control and flux weakening voltage control without current sensors. Dissipating regenerative energy includes providing a motor controller to command a motor drive to modify an input voltage, or to dissipate regenerative energy in a dump circuit. This command can cause motor windings to dissipate regenerative energy. Systems having a plurality of actuators distribute regenerative energy from one actuator to another. A central controller provides centralized regeneration dissipation control for the plurality of actuators. A power distribution unit includes a dump resistor to dissipate regenerative energy in addition to or instead of in the actuators.

1 . A system for controlling regenerative energy, the system comprising:
 a power source;   a plurality of actuators, each actuator comprising:
 a motor controller; 
 a motor drive configured to receive power from the power source and to receive a command from the motor controller; 
 at least one motor winding configured to receive a voltage from the motor drive; and 
 one or more sensors configured to detect a parameter associated with the actuator and communicate at least one signal containing information about the detected parameter to the motor controller; 
 wherein the motor controller is configured to process the at least one signal from the one or more sensors and provide control of the actuator; 
   a power bus connecting the plurality of actuators to the power source; and   a bus dump circuit configured to dissipate regenerative energy from one or more of the plurality of actuators.   
     
     
         2 . The system of  claim 1 , wherein the plurality of actuators are configured to dissipate energy based on a temperature of any of the plurality of actuators. 
     
     
         3 . The system of  claim 1 , wherein the plurality of actuators are configured to dissipate energy based on a temperature of any of the plurality of actuators and/or of the bus dump circuit. 
     
     
         4 . The system of  claim 1 , comprising a power distribution unit (PDU) with a PDU dump resistor. 
     
     
         5 . The system of  claim 4 , wherein the plurality of actuators are configured to dissipate energy based on a temperature of any of the plurality of actuators or of the PDU. 
     
     
         6 . The system of  claim 1 , wherein each of the plurality of actuators is configured to apply an RDC command to the command from the motor controller, wherein the RDC command is configured to be adjusted using a temperature of a resistor in the bus dump circuit. 
     
     
         7 . The system of  claim 6 , wherein the RDC command is random, DC, or a sine wave. 
     
     
         8 . The system of  claim 6 , wherein each of the plurality of actuators is configured to measure or estimate a temperature of the bus dump circuit and the RDC command is adjusted using the temperature of the bus dump circuit. 
     
     
         9 . The system of  claim 6 , wherein a relationship between the RDC command and the temperature of the respective bus dump circuit in each actuator is proportional. 
     
     
         10 . The system of  claim 1 , wherein regenerative energy can be dissipated in the motor windings of the plurality of actuators and/or in at least one resistor of the bus dump circuit. 
     
     
         11 . A method of controlling regenerative energy, the method comprising:
 providing a plurality of actuators, each actuator comprising:
 a motor controller; 
 a motor drive configured to receive power from a power source and to receive a command from the motor controller; 
 at least one motor winding configured to receive a voltage from the motor drive; and 
 one or more sensors configured to detect a parameter associated with the actuator and communicate at least one signal containing information about the detected parameter to the motor controller; 
 wherein the motor controller is configured to process the at least one signal from the one or more sensors and provide control of the actuator; 
   detecting a regenerative condition;   connecting the plurality of actuators to a power source using a power bus;   dissipating the regenerative energy in the motor windings of the plurality of actuators and/or in a bus dump circuit.   
     
     
         12 . The method of  claim 11 , wherein the plurality of actuators dissipate energy based on a temperature of any of the plurality of actuators. 
     
     
         13 . The method of  claim 11 , wherein the plurality of actuators are configured to dissipate energy based on a temperature of any of the plurality of actuators and/or of the bus dump circuit. 
     
     
         14 . The method of  claim 11 , comprising providing a power distribution unit (PDU) with a PDU dump resistor. 
     
     
         15 . The method of  claim 14 , wherein the plurality of actuators dissipate energy based on a temperature of any of the plurality of actuators or of the PDU. 
     
     
         16 . The method of  claim 11 , comprising, for each of the plurality of actuators:
 applying an RDC command to the command from the motor controller; and   adjusting the RDC command using a temperature of a resistor in the bus dump circuit.   
     
     
         17 . The method of  claim 16 , wherein the RDC command is random, DC, or a sine wave. 
     
     
         18 . The method of  claim 16 , comprising:
 measuring or estimating a temperature of the bus dump circuit; and   adjusting the RDC command using the temperature of the bus dump circuit.   
     
     
         19 . The method of  claim 16 , wherein a relationship between the RDC command and the temperature of the respective bus dump circuit in each actuator is proportional. 
     
     
         20 . The method of  claim 11 , wherein regenerative energy can be dissipated in the motor windings of the plurality of actuators and/or in at least one resistor of the bus dump circuit.