Motor control system

Abstract

Systems and apparatus relating to motor control (e.g., for thermal transfer printing) include, according to at least one implementation, a motor control system including: a position controller to receive a demanded position (P.sub.D) input for controlling a motor; a torque controller coupled with the position controller, the torque controller to receive a torque bias (T.sub.B) input for controlling the motor; and a feedback circuit coupled with the torque controller and the position controller; wherein the feedback circuit is configured and arranged to combine an output from the position controller, the output being generated based on the demanded position (P.sub.D) input, with the torque bias (T.sub.B) input to generate a torque demand (T.sub.D) input to the torque controller.

Claims

1. A motor control system comprising: a position controller to receive a demanded position (P.sub.D) input for controlling a motor; a torque controller coupled with the position controller, the torque controller to receive a torque bias (T.sub.B) input for controlling the motor; a switch coupled between the position controller and the torque controller; and a feedback circuit coupled with the torque controller and the position controller; wherein the feedback circuit is configured and arranged to combine an output from the position controller, the output being generated based on the demanded position (P.sub.D) input, with the torque bias (T.sub.B) input to generate a torque demand (T.sub.D) input to the torque controller; and wherein the motor control system is configured to allow the switch to disconnect the output of the position controller from the torque controller during a torque control mode, such that the torque demand (T.sub.D) input is generated from the torque bias (T.sub.B) input, without being affected by the demanded position (P.sub.D) input or an actual position of the motor, during the torque control mode; and allow the switch to connect the position controller with the torque controller and reduce the torque bias (T.sub.B) input to transition from the torque control mode to a position control mode.

2. The motor control system of claim 1, wherein the feedback circuit comprises an electronic filter configured to receive a velocity (V.sub.A) measurement of the motor to adjust the output from the position controller before combination with the torque bias (T.sub.B) input.

3. The motor control system of claim 2, wherein the electronic filter is a first electronic filter, and the position controller comprises an S-curve generator and a second electronic filter, wherein the feedback circuit is configured to provide an actual position (P.sub.A) measurement of the motor to adjust an output of the S-curve generator before provision to the second electronic filter.

4. The motor control system of claim 1, wherein the motor control system is further configured to increase the torque bias (T.sub.B) input from zero or a nominal value during transition from the position control mode to the torque control mode to prevent accumulation of tape feed errors.

5. The motor control system of claim 4, wherein the motor control system is further configured to adjust the torque bias (T.sub.B) input when the motor is operated in the position control mode to compensate for an increase in torque caused by another motor, which is controlled by the motor control system, being switched from the position control mode to the torque control mode.

6. The motor control system of claim 1, wherein the feedback circuit comprises an electronic filter configured to receive a velocity (V.sub.A) measurement of the motor to affect the torque demand (T.sub.D) input generated from the torque bias (T.sub.B) input during the torque control mode.

7. The motor control system of claim 6, wherein the motor is a brushless DC (Direct Current) motor, and the torque controller is configured to receive a measurement of current from the brushless DC motor to control an output provided by the torque controller to the brushless DC motor.

8. A printing apparatus comprising: a printhead; a first spool support on which a supply spool is mountable; a second spool support on which a take up spool is mountable; a first motor coupled with the first spool support; a second motor coupled with the second spool support; and a motor control system coupled with the first motor and with the second motor, the motor control system configured to drive the first and second motors to move a tape between the supply spool and the take up spool, and with respect to the printhead for printing; wherein the motor control system comprises, for at least one of the first and second motors, (i) a position controller coupled with the at least one motor, the position controller to receive a demanded position (P.sub.D) input for controlling the at least one motor, (ii) a torque controller coupled between the at least one motor and the position controller, the torque controller to receive a torque bias (T.sub.B) input for controlling the at least one motor, (iii) a switch coupled between the position controller and the torque controller, and (iv) a feedback circuit coupled with the at least one motor, the torque controller, and the position controller, wherein the feedback circuit is configured and arranged to combine an output from the position controller, the output being generated based on the demanded position (P.sub.D) input, with the torque bias (T.sub.B) input to generate a torque demand (T.sub.D) input to the torque controller, and the motor control system is configured to allow the switch to disconnect the output of the position controller from the torque controller during a torque control mode, such that the torque demand (T.sub.D) input is generated from the torque bias (T.sub.B) input, without being affected by the demanded position (P.sub.D) input or an actual position of the at least one motor, during the torque control mode; and allow the switch to connect the position controller with the torque controller and reduce the torque bias (T.sub.B) input to transition from the torque control mode to a position control mode.

9. The printing apparatus of claim 8, wherein the feedback circuit comprises an electronic filter configured to receive a velocity (V.sub.A) measurement of the at least one motor to adjust the output from the position controller before combination with the torque bias (T.sub.B) input.

10. The printing apparatus of claim 9, wherein the electronic filter is a first electronic filter, and the position controller comprises an S-curve generator and a second electronic filter, wherein the feedback circuit is configured and arranged to provide an actual position (P.sub.A) measurement of the at least one motor to adjust an output of the S-curve generator before provision to the second electronic filter.

11. The printing apparatus of claim 8, wherein the motor control system is further configured to increase the torque bias (T.sub.B) input from zero or a nominal value during transition from the position control mode to the torque control mode to prevent accumulation of tape feed errors.

12. The printing apparatus of claim 11, wherein the motor control system comprises a position controller, a torque controller and a feedback circuit for each of the first and second motors, and wherein the motor control system is further configured to adjust the torque bias (T.sub.B) input for the supply spool motor, when operated in the position control mode, to compensate for an increase in torque caused by the take up spool motor being switched from the position control mode to the torque control mode.

13. The printing apparatus of claim 12, wherein the feedback circuit, for each of the first and second motors, comprises an electronic filter configured to receive a velocity (V.sub.A) measurement of the at least one motor to affect the torque demand (T.sub.D) input generated from the torque bias (T.sub.B) input during the torque control mode.

14. The printing apparatus of claim 13, wherein each of the first and second motors is a brushless DC (Direct Current) motor, and the torque controller for each of the first and second motors is configured and arranged to receive a measurement of current from a respective brushless DC motor to control an output provided by the torque controller to the respective brushless DC motor.

15. A method comprising: receiving, at a position controller, a demanded position (P.sub.D) input for controlling a motor; generating an output from the position controller based on the demanded position (P.sub.D) input; receiving a torque bias (T.sub.B) input for controlling the motor; combining the output from the position controller with the torque bias (T.sub.B) input to generate a torque demand (T.sub.D) input to a torque controller; generating, at the torque controller, a torque control output for the motor based on the torque demand (T.sub.D) input disconnecting the output of the position controller from the torque controller during a torque control mode, such that the torque demand (T.sub.D) input is generated from the torque bias (T.sub.B) input, without being affected by the demanded position (P.sub.D) input or an actual position of the motor, during the torque control mode; connecting the position controller with the torque controller; and reducing the torque bias (T.sub.B) input to transition from the torque control mode to a position control mode.

16. The method of claim 15, wherein generating the output from the position controller comprises: using a Linear Time Invariant filter function with an output of an S-curve generator and a received actual position (P.sub.A) measurement of the motor to determine a first output indicating a change in position required to be carried out by the motor; using a Linear Time Invariant filter function with a received velocity (V.sub.A) measurement of the motor to determine a second output; and using the second output in conjunction with the first output to determine a demanded torque to be provided by the motor.

17. The method of claim 16, wherein using a Linear Time Invariant filter function with the output of the S-curve generator and the received actual position (P.sub.A) measurement of the motor comprises performing a PID (Proportional-Integral-Derivative) algorithm using the output of the S-curve generator and the received actual position (P.sub.A) measurement of the motor, and wherein using a Linear Time Invariant filter function with the received velocity (V.sub.A) measurement of the motor comprises performing a PID (Proportional-Integral-Derivative) algorithm using the received velocity (V.sub.A) measurement of the motor.

18. The method of claim 15, comprising: increasing the torque bias (T.sub.B) input from zero or a nominal value during transition from the position control mode to the torque control mode to prevent accumulation of tape feed errors.

19. The method of claim 18, comprising adjusting the torque bias (T.sub.B) input when the motor is operated in the position control mode to compensate for an increase in torque caused by another controlled motor being switched from the position control mode to the torque control mode.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

(2) FIG. 1 is an illustrative view of part of a thermal printing apparatus including a motor control system according to the present invention; and

(3) FIG. 2 is an illustrative view of a feedback circuit of the motor control system.

DETAILED DESCRIPTION

(4) Referring to FIG. 1, there is shown a part of a printing apparatus 10. The printing apparatus 10 includes a tape drive shown generally at 11. The printing apparatus includes a housing 13, in or on which is mounted a first spool support 12 and a second spool support 14, which form part of the tape drive 11. A spool of tape 15, 17, for example inked printer ribbon, is mountable on each of the supports 12, 14. The spool supports 12, 14 are spaced laterally from one another. The printing apparatus 10 also includes a printhead 19 for transferring ink from the tape to a substrate 21 which is entrained around a roller 23 adjacent the printhead 19. Depending upon the configuration of the printer, the substrate 21 may be positioned adjacent the printhead 19 on a platen, rather than a roller.

(5) Each of the spool supports 12, 14 is independently drivable by a respective motor 16, 18. Each of the motors 16, 18 is a brushless DC motor. Each of the spool supports 12, 14 is rotatable clockwise and anti-clockwise by means of its respective motor 16, 18. Each motor 16, 18 is electrically connected to a controller 24 via a sensor 20, 22. This sensor is typically a rotary encoder although it will be appreciated that other technologies are perfectly acceptable. The controller 24 is operable to control the mode of operation of each of the motors 16, 18 and the amount of drive provided by each of the motors 16, 18. Each sensor 20, 22 enables the controller 24 to determine the angular position and rotational speed of a rotor of each respective motor 16, 18. Information relating to the current drawn by each motor 16, 18 is provided to the controller 24. The motors 16, 18, the sensors 20, 22 and the controller 24 all form part of a motor control system 25.

(6) The controller 24 receives inputs relating to a demanded position of each motor 16, 18 to advance the tape to a required position, the actual position of the motor 16, 18, the measured velocity of each motor 16, 18, the current drawn by the motor 16, 18, and a torque bias T.sub.B required by the motor at a given point in time. The purpose of the torque bias will be explained in more detail below. The position of the controller 24 relative to the remainder of the printing apparatus 10 is irrelevant for the purposes of the present invention.

(7) In use, a supply spool 17, upon which unused tape is wound, is mounted on the spool support 14, and a take up spool 15, upon which used tape is wound, is mounted on the spool support 12. The tape generally advances in a tape path between the supply spool 17 towards the take up spool 15. The tape is guided in the tape path between the spools 15, 17 adjacent the printhead 19 by guide members 26.

(8) The tape drive 11 should be calibrated before printing operations commence. Such calibration is generally required when the printing apparatus 10 is switched on, and when the spools of tape 15, 17 are replaced. The calibration process includes determining an initial estimate of the diameters of each of the spools of tape 15, 17 mounted on the spool supports 12, 14. An example of a suitable method of obtaining such an estimate is described in detail in the applicant's patent GB2310405. As tape passes from one spool to the other, for example from the supply spool 15 to the take up spool 17, it passes over a roller of known diameter. The roller is preferably one of the guide members 26. Tape is drawn from the supply spool 17, with the motor 16 which drives the take-up spool support 12 operating in position control mode. The motor 18 which drives the supply spool support 14 operates in torque control mode to deliver a predetermined torque.

(9) Following the calibration process, the motor control system 25 maintains and updates values for the diameters of the spools 15, 17 by monitoring the amount of tape transferred from the supply spool to the take-up spool. The controller 24 takes into account the thickness of the tape to compute an expected change in the diameters of the spools 15, 17 over a period of time. This technique relies on the tension in the tape being kept substantially constant during printing operations and advancement of the tape between the spools 15, 17.

(10) When the tape is at rest, the motor control system 25 maintains the desired tape tension by operating one motor, for example the supply spool motor 18, in a first control mode, in which position is a dominant control parameter. This first control mode will be referred to herein as position control mode. The other motor, for example the take up spool motor 16, is operated in a second control mode, in which the dominant control parameter is torque. The second control mode will be referred to herein as torque control mode.

(11) Therefore the tape drive 13 operates in a similar fashion to one in which one of the motors 16, 18 is a stepper motor and the other motor 16, 18 is a DC motor. One motor 18 ensures that the absolute position of the tape relative to the printhead is accurately controlled, whilst the other motor 16 maintains the tension in the tape at the desired predetermined value.

(12) A demanded position P.sub.D of the motor 18 is received by an S-curve generator 28, an output of which is used, along with an actual position P.sub.A of the motor 18 in an algorithm, preferably a PID (Proportional-Integral-Derivative) algorithm, applied by an electronic filter 29 to determine the change in position required to be carried out by the motor 18. An actual velocity V.sub.A of the motor is input to a second electronic filter 31, which performs an algorithm, again preferably a PID algorithm, and an output of the second electronic filter 31 is used in conjunction with an output of the first electronic filter 29, relating to the change in position of the motor 18, to determine a demanded torque T.sub.D to be provided by the motor 18. A demanded torque T.sub.D and the amount of current A drawn by the motor 18 are fed back to a torque controller 30 to provide a control output to the motor 18. Although the algorithms implemented by the filters 29, 31 are described as being PID algorithms, it will be appreciated that any Linear Time Invariant filter function may be used.

(13) The motor 16 being operated in torque control mode does not use inputs relating to demanded position P.sub.D or actual position P.sub.A of the motor 16. The inputs relating to actual velocity V.sub.A may also be disregarded. The torque controller 30 receives a torque demand T.sub.D based only on the torque bias T.sub.B, and optionally upon the actual velocity V.sub.A of the motor 16. The current A of the motor 16 may also be fed back to the torque controller 30 to generate a control output for the motor 16, such as the BLDC (Brushless Direct Current) motor shown in FIG. 2.

(14) When the tape is required to be advanced between the spools 15, 17, the controller 24 causes both of the motors 16, 18 to operate in position control mode. The transition of the motor 16, 18 which was previously operated in torque control mode into position control mode is smooth. This transition from torque control mode to position control mode is carried out by gradually reducing the torque bias T.sub.B to a nominal value, which may be zero.

(15) During tape advance, the two motors 16, 18 advance the tape accurately along the tape path past the printhead 19, using the values of the diameters of the spools 15, 17 and a co-ordinated moving target position. The co-ordinated moving target position is arrived at by the control system 25 determining the desired position of the tape at a point in time, and the controller 24 controls the motors 16, 18 to achieve this desired position of the tape.

(16) During tape advance, it is desirable for the amount of tape fed into the tape path from the supply spool 17 to be equal to the amount of tape taken up by the take up spool 15, in order to maintain the tape tension substantially constant. However, this is difficult to achieve in known tape drives because disturbances of the tape which occur during printing operations, and the fact that the spools 15, 17 are not perfectly cylindrical, mean that the control of the motors 16, 18 is based upon inaccurate estimates, and thus the tension is unlikely to be kept as near to constant as desired. In the present invention, the smooth transition of the take up motor from position control mode to torque control mode prevents the accumulation of such errors increasing long term drift in the ribbon tension.

(17) Once the advancement of the tape has been completed, one of the spool motors 16, 18, for example the take up spool motor 16, smoothly transitions from position control mode to torque control mode, by increasing the torque bias T.sub.B relating to the motor 16, whilst the other spool motor, for example the supply spool motor 18, remains in position control mode. Gradually increasing the torque bias T.sub.B from zero during deceleration of the tape causes a smooth transition of the motor from position control mode to torque control mode, before the inputs relating to position P.sub.A, P.sub.D are disregarded. The other motor, in this case the supply spool motor 18, remains in position control mode, however the value of torque bias T.sub.B applied to this motor may be adjusted, so as to compensate for the increase in torque which is likely to be caused as a result of switching the take up spool motor 16 into torque control mode. In practice, it may be possible to retain a constant torque bias T.sub.B irrespective of whether the motors 16, 18 are stationary or in motion, however, the desired torque bias T.sub.B will be such that it causes the tension in the tape to remain substantially constant, by the two motors 16, 18 applying equal and opposite forces on the tape.

(18) The motor control system 25 is capable of testing the accuracy of its control of the advancement of the tape in two ways.

(19) The first method of testing is to determine the ratio of the torques applied to the two motors 16, 18 when the tape drive 11 is stationary. In such a situation, one motor 16, 18 is stationary, whilst the other motor 16, 18 supplies a torque so as to maintain its position, and to maintain the tension in the tape. The ratio of the torques should be the same as the ratio of the diameters of the spools 15, 17 at that time.

(20) The second method of testing is carried out as the tape drive 11 is completing a movement of the tape. As the take up spool motor 16 transitions from position control mode to torque control mode, the controller 24 monitors the angular position change of take up spool motor 16 between its expected target position and its rest position at the correct ribbon tension, using the sensor 20. The angular position change that occurs together with the spool diameter gives a measure of the disturbances and errors in the position control of the motor 16.

(21) The operation of the control system 25 is iterative, in that it takes into account the results of the testing method(s) carried out over a number of tape advancements (printing cycles) to correct the estimate of the diameters of the spools 15, 17 for future printing cycles.

(22) The method of operation of the tape drive 11 described above retains the supply spool motor 18 in position control, as the supply spool 17 is more likely to be cylindrical than the take up spool, the tape on the supply spool 17 not having been unwound, and ink removed from it before being rewound on a different spool. Therefore this mode of operation is more likely to provide accurate positioning of the tape adjacent the printhead 19. However, it will be appreciated that either spool motor 16, 18 could be switched to torque control mode during tape advance.

(23) When power is removed from the motors 16, 18, the control system 25 manages the tension of the tape in the tape path. If the tape is in tension when power is removed from the motors 16, 18, one or both of the spools 15, 17 will be accelerated by the force exerted by the tension in the tape. Even when the tape is no longer in tension, each spool 15, 17 which has been accelerated will continue to rotate owing to the momentum of the spool(s) 15, 17, and tape may spill from the printing apparatus 10. Of course, this is undesirable, and unacceptable. To overcome this problem, the control system 25 operates at least one of the motors 16, 18, so as to enable a controlled release of tension from the tape, before power is removed from the motors 16, 18. Alternatively, a mechanical device may be used to inhibit or prevent the acceleration of the spools 15, 17 upon removal of power from the motors 16, 18.

(24) Whilst the invention has been described in relation to thermal printing apparatus, it will be appreciated that the motor control system may be utilised in relation to other devices or apparatus.

(25) When used in this specification and claims, the terms comprises and comprising and variations thereof mean that the specified features, steps or integers are included. The terms are not to be interpreted to exclude the presence of other features, steps or components.

(26) The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.