DESC:TECHNICAL FIELD
[0001] The present invention relates generally to controlling systems. The present invention, more particularly, relates to a real-time controller for electric drives.

BACKGROUND
[0002] Even though, the modern Military Combat systems are typically equipped with diverse highly sophisticated advanced weaponry, such as guided missiles, and precision guided bombs, gun systems are still widely used as an important component of a weapon configuration. Gun systems are versatile, reliable, lethal and low cost solutions.

[0003] The drive can have two major axes of movement, one along the Azimuth axis and the other along the Elevation axis. The drive can have limited angle of movement in both the axes. The drive has to precisely track the target in dynamic conditions and has to rotate at the desired speed and acceleration. The drive has to precisely stop its movement when it approaches the end limits. The information from the various speed and position sensors has to be read and a control system shall ensure that the drive follows the target accurately. A drive control system shall ensure that the drive possesses good amount of rigidity.

[0004] WO 2004/042315 A2 titled “Real time dynamically controlled Elevation and Azimuth Gun pod mounted on a fixed wing aerial combat vehicle” discloses an apparatus for dynamically controlling the Elevation and Azimuth of an aerial gun unit incorporated within a gun pod unit mounted on a fixed wing aerial combat vehicle. The apparatus comprises of an aerodynamically efficient gun pod unit for storing, delivering, controlling and supporting a controllable movement aerial gun unit, and a controllable movement aerial gun unit, mounted in the aerodynamically efficient gun pod unit, and designed for the delivery of suitable gun projectile units to a ground-based or aerial target.
Hence, there is a need of a real-time controller, which solves the above defined problems.
SUMMARY
[0005] This summary is provided to introduce concepts related to a real-time controller and method thereof. This summary is neither intended to identify essential features of the present invention nor is it intended for use in determining or limiting the scope of the present invention.

[0006] For example, various embodiments herein may include one or more real-time controllers and methods are provided. In one of the embodiments, a method for controlling a drive includes a step of receiving, by a receiving module, input voltage signals from one or more sources. The method includes a step of sensing, by a sensing module, data from the drive. The method includes a step of relaying, by a relay unit, the signals and the sensed data. The method includes a step of analysing, by an analyser, the relay signals and the sensed data, and identifying a target related data of the drive. The method includes a step of controlling, by a control module, the drive in one or more axes based on the identified data. The method includes a step of determining, by a determination module, an error from the identified data based on the controlled drive. The method includes a step of correcting, by a correction module, the error of the identified data. The method includes a step of generating, by a generation module, a command to the drive for following a target based on the corrected error.

[0007] In another embodiment, a real-time controller includes a receiving module, a relay unit, an analyser, a control module, a determination module, a correction module, and a generation module. The receiving module is configured to receive input voltage signals from one or more sources. The sensing module is configured to sense data from the drive. The relay unit is configured to relay the signals and the sensed data. The analyser is configured to analyse the relay signals and sensed data, and identify a target related data of the drive. The control module is configured control the drive in one or more axes based on the identified data. The determination module is configured to determine an error from the identified data based on the controlled drive. The correction module is configured to correct the error of the identified data. The generation module is configured to generate a command to the drive for following a target based on the corrected error.

BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
[0008] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to reference like features and modules.

[0009] Figure 1 illustrates a block diagram depicting a real-time controller, according to an exemplary implementation of the present invention.

[0010] Figure 2A illustrates a block diagram depicting a control station of a real-time controller, according to an exemplary implementation of the present invention.

[0011] Figure 2B illustrates a signal flow diagram depicting a control station of Figure 2A, according to an exemplary implementation of the present invention.

[0012] Figure 3 illustrates a schematic diagram depicting a display card, according to an exemplary implementation of the present invention.

[0013] Figure 4 illustrates a schematic diagram depicting a control card, according to an exemplary implementation of the present invention.

[0014] Figure 5 illustrates a flowchart depicting a method for controlling a drive, according to an exemplary implementation of the present invention.

[0015] Figures 6A illustrates graphical representation depicting Elevation drive braking waveforms, according to an exemplary implementation of the present invention.

[0016] Figures 6B illustrates graphical representation depicting Azimuth drive braking waveforms, according to an exemplary implementation of the present invention.

[0017] Figures 7A illustrates graphical representation depicting sinusoidal error distribution in an Elevation drive, according to an exemplary implementation of the present invention.

[0018] Figures 7B illustrates graphical representation depicting sinusoidal error distribution in an Azimuth drive, according to an exemplary implementation of the present invention.

[0019] It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative systems embodying the principles of the present invention. Similarly, it will be appreciated that any flowcharts, flow diagrams, and the like represent various processes which may be substantially represented in computer readable medium and so executed by a computer or processor, whether or not such computer or processor is explicitly shown.
DETAILED DESCRIPTION
[0020] In the following description, for the purpose of explanation, specific details are set forth in order to provide an understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without these details. One skilled in the art will recognize that embodiments of the present invention, some of which are described below, may be incorporated into a number of systems.
[0021] The various embodiments of the present invention provide a real-time controller and method thereof. Furthermore, connections between components and/or modules within the figures are not intended to be limited to direct connections. Rather, these components and modules may be modified, re-formatted or otherwise changed by intermediary components and modules.

[0022] References in the present invention to “one embodiment” or “an embodiment” mean that a particular feature, structure, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.

[0023] In one of the embodiments, a method for controlling a drive includes a step of receiving, by a receiving module, input voltage signals from one or more sources. The method includes a step of sensing, by a sensing module, data from the drive. The method includes a step of relaying, by a relay unit, the signals and the sensed data. The method includes a step of analysing, by an analyser, the relay signals and the sensed data, and identifying a target related data of the drive. The method includes a step of controlling, by a control module, the drive in one or more axes based on the identified data. The method includes a step of determining, by a determination module, an error from the identified data based on the controlled drive. The method includes a step of correcting, by a correction module, the error of the identified data. The method includes a step of generating, by a generation module, a command to the drive for following a target based on the corrected error.

[0024] In another implementation, the sensing data is related to speed and position of the drive, and the sensed data includes an Elevation and an Azimuth axes.

[0025] In another implementation, the method includes a step of creating, by a creation module, one or more schemes, for detecting a phase difference between the receiving module and a transmitting module for the drive.

[0026] In another implementation, the method includes a step of switching, by the creation module, ON the drive with zero phase difference, and detecting the correctness of the End limit switches fitted in the drive on the Elevation & Azimuth axes.

[0027] In another implementation, the method includes a step of producing, by a hunting module, a zero hunting operation for reducing the Servo power requirement to ‘zero’, in an End limit zone.

[0028] In another implementation, the method includes a step of performing, by the relay unit, change in a mode of operation of the drive based on the signals and the sensed data, the mode of operation includes a remote mode and a local mode.

[0029] In another embodiment, a real-time controller includes a receiving module, a relay unit, an analyser, a control module, a determination module, a correction module, and a generation module. The receiving module is configured to receive input voltage signals from one or more sources. The sensing module is configured to sense data from the drive. The relay unit is configured to relay the signals and the sensed data. The analyser is configured to analyse the relay signals and sensed data, and identify a target related data of the drive. The control module is configured control the drive in one or more axes based on the identified data. The determination module is configured to determine an error from the identified data based on the controlled drive. The correction module is configured to correct the error of the identified data. The generation module is configured to generate a command to the drive for following a target based on the corrected error.

[0030] In another implementation, the controller is a Tuneable Proportional-Integral-Derivative (PID) controller, which is configured to allow a user to tune to a desired PID controller values to reduce speed and position errors.

[0031] In another implementation, the controller includes a power supply module. The power supply module is configured to supply power at different voltage levels to the relay unit, and the control module.

[0032] In an embodiment, the real-time controller and solid state devices with minimum time lagging components allow a “Zero Readiness time”.

[0033] In an embodiment, a control station is designed in such a way to provide “Zero Hunting” during braking operations.

[0034] In an embodiment, the real-time controller significantly reduces the residual speed of the motor to ‘zero’, during braking, thereby reducing the servo power requirement during braking.

[0035] In an embodiment, the real-time controller allows the user to tune to the desired “PID” Controller values.

[0036] In an embodiment, the real-time controller discloses ways to reduce the installation time of the drives.

[0037] In an embodiment, the real-time controller provides the user about the information of the ‘Phase Difference’ between the drives and transmitting section, thereby eliminating the Phase Mismatch.

[0038] In an embodiment, the real-time controller provides the user about the healthiness of the electric drive, including the healthiness of the end limits, before Powering ON the 3-phase, thereby reducing the failures of the subunits during integration.

[0039] In an embodiment, the real-time controller aims at an improvised real time dynamic control of Elevation and azimuth drives. The real-time controller is implemented in an apparatus called the ‘Control Station’ which can dynamically control the drives in Elevation and Azimuth axes. It takes an input voltage of 220V,400Hz and 36V,400Hz from the source. It also gets the information of an incoming command speed and the position of the target. The control station is capable of controlling the drive in both local mode as well as remote mode. In the remote mode, the drive can be controlled by RADAR or other sighting systems.

[0040] In an embodiment, the real-time controller allows the user to understand the ‘Phase difference’ between the drive and the transmitting systems, thereby eliminating the Phase Mismatch.

[0041] Figure 1 illustrates a block diagram depicting a real-time controller, according to an exemplary implementation of the present invention.

[0042] A real-time controller (100) (hereinafter referred to as “controller”) includes a receiving module (102), a sensing module (104), a relay unit (106), an analyser (108), a control module (!10), a determination module (112), a correction module (114), and a generation module (116).

[0043] The receiving module (102) is configured to receive input voltage signals from one or more sources. In an embodiment, the receiving module (102) is configured to receive input voltage of 220 Volts (V), 400 Hertz (Hz), and 36 Volts (V), 400 Hertz (Hz) from a source.

[0044] The sensing module (104) is configured to sense data from the drive. In an embodiment, the sensing module (104) includes a plurality of sensors. The sensed data is related to speed and position of the drive, and includes an Elevation and Azimuth axes.

[0045] The relay unit (106) is configured to cooperate with the receiving module (102) and the sensing module (104) to receive the voltage signals and sensed data from the drive, respectively. The relay unit (106) is further configured to relay the signals and the sensed data. In an embodiment, the relay unit (106) is configured to perform change in a mode of operation of the drive based on the signals and the sensed data. The mode of operation includes a local mode and a remote mode.

[0046] The analyser (108) is configured to cooperate with the relay unit (106) to receive the relay signals and sensed data. The analyser (108) is configured to analyse the relay signals and the sensed data, and identify a target related data of the drive.

[0047] The control module (110) is configured to cooperate with the analyser (108) to receive the identified data. The control module (110) is further configured to control the drive in one or more axes based on the identified data.

[0048] The determination module (112) is configured to cooperate with the analyser (108) and the control module (110) to receive the identified data and controlled related data. The determination module (112) is further configured to determine an error from the identified data based on the controlled drive.

[0049] The correction module (114) is configured to cooperate with the determination module (112) to receive the determined error. The correction module (114) is further configured to correct the error of the identified data.

[0050] The generation module (116) is configured to cooperate with the correction module (114) to receive the corrected error of the identified data. The generation module (116) is further configured to generate a command to the drive for following a target based on the corrected error.

[0051] In an embodiment, the controller (100) includes a power supply module (118), a creation module (120), and a hunting module (122).

[0052] The power supply module (118) is configured to supply power at different voltage levels to the relay unit (106) and the control module (110).

[0053] The creation module (120) is configured to create one or more schemes for detecting a phase difference between the receiving module (102) and a transmitting module (not shown in a figure) for the drive. The creation module (120) is further configured to switch ON the drive with zero phase difference, and detect the correctness of the End limit switched fitted in the drive on the Elevation and Azimuth axes. In an embodiment, the creation module (120) is configured create schemes to Switch ON the drives, with zero phase difference, which greatly reduces the integration time of one or more drives.

[0054] The hunting module (122) is configured to produce a zero hunting operation for reducing the Servo power requirement to ‘zero’, in an End limit zone.

[0055] In an embodiment, the controller (100) is a Tuneable Proportional-Integral-Derivative (PID) controller, which is configured to allow a user to tune to a desired PID controller values to reduce speed and position errors. In one embodiment, the Tuneable PID controller is connected to an end user, so that the speed and position errors can be kept to vey minimum, in a dynamic condition also.

[0056] Figure 2A illustrates a block diagram depicting a control station (200) of a real-time controller, according to an exemplary implementation of the present invention. In Figure 2A, a control station (200) includes a power supply section (202), a relay section (210), a control section (222, 228), and a display section (232).
[0057] The power supply section (202) is configured to supply power to other modules/ sections of the control station (200). In an embodiment, the power supply section is located at a Rack 1 of the control station (200). The power supply section includes a power supply card traverse axis (204), transformers (206), and a power supply card elevation axis (208). The relay section (210) is configured to relay the input voltage signals received from one or more sources, and sensed data. The relay section (210) is located at a Rack 2 of the control station (200). The relay section (210) includes a relay card traverse axis (212), a local mode synchronization traverse axis (214), a relay pack (216), a relay card elevation axis (218), and a local mode synchronization elevation axis (220). The control section (222, 228) is configured to control an electric drive in one or more axes. The control section (222, 228) is configured to check whether the drives are rotating or not. If the drives are not rotating, it provides an error. It also provides a command to go to a proper state. The control section (222, 228) is located at two racks, i.e. at a Rack 3 and a Rack 4. The control section (222) on the Rack 3 includes a control card traverse axis (224) and a mismatch error card (226). The control section (228) on the Rack 4 includes a control card elevation axis (230). The display section (232) is located at a Rack 5 of the control station (200). The display section (232) includes a display card (234).

[0058] Figure 2B illustrates a signal flow diagram depicting a control station (200) of Figure 2A, according to an exemplary implementation of the present invention.

[0059] The control station (200) is connected with input connectors (201) to receive power and input voltage signals from one or more sources. The received power is transmitted to the transformers (206) of the power supply section (202), and the relay card traverse axis (212) and the relay card elevation axis (218). The transformers (206) are configured to increase or decrease the received input voltage signals, and to couple with the power supply card traverse axis (204) and the power supply card elevation axis (208) to supply power to other modules. After coupling of the power supply card traverse axis (204) with the transformers (206), the power supply card traverse axis (204) is configured to supply power to the local mode synchronization traverse axis (214) and the local mode synchronization elevation axis (220) of the relay station (210), the control card traverse axis (224), and the mismatch error card (226), and the control card elevation axis (230) of the control station (228), and the display card (234) of the display section (232). In an embodiment, Figure 3 illustrates a schematic diagram depicting a display card (300), according to an exemplary implementation of the present invention. In another embodiment, Figure 4 illustrates a schematic diagram depicting a control card (400), according to an exemplary implementation of the present invention.

[0060] In an embodiment, the controller (100) of Figure 1 is an improvised real-time dynamic controller, which includes time lagging components to generate command voltages configured to allow the user to instantly operate one or more electric drives, without any necessity of the readiness time. The features are incorporated in the control card (400). The view of the display card (300) is shown in Figure 3. In one embodiment, an improvised method of “Zero Hunting” of the drives during braking operations is incorporated in the control card (400). This reduces the residual speed of a motor, and thereby significantly reducing the Servo power requirement during braking. The view of the control card (400) is shown in Figure 4.

[0061] In another embodiment, the position error loop and speed error loop are also incorporated in the control card (400). The speed information of both the desired speed and the actual speed are obtained and the speed error is calculated. Similarly, the position error is also obtained by demodulating the output of the synchronization, as provided in the local mode synchronization traverse axis (214) and the local mode synchronization elevation axis (220) of the relay section (210). The control card (400) allows the user to tune the PID controller values to reduce the position error values.

[0062] In an embodiment, the controller (100) of Figure 1 provides the user about the information of the phase difference between the drive and the transmitting devices. This is accomplished by comparing the reference phase and the incoming signal phase. This scheme gives the user, an advantage to know the INPHASE/ OUT OF PHASE condition of the drive, thereby eliminating the phase mismatch problem of the drive. In an embodiment, the mismatch error card (226) of the control section (228), as shown in Figures 2A and 2B, is configured to eliminate the phase mismatch problem of the drive. Similarly, the healthiness of the ‘End limits’ and the Healthiness of the drives can be thoroughly checked, before powering ON the drives, which reduces the installation time, and the failures of the subunits of the electric drive. All these features are provided by the control card (400). In another embodiment, the control card (400) calculates the net error due to position & speed variations. The braking schemes are incorporated in the controller card along with the PID controllers.

[0063] Figure 5 illustrates a flowchart (500) depicting a method for controlling a drive, according to an exemplary implementation of the present invention.

[0064] The flowchart (500) starts at a step (502), receiving, by a receiving module (102), input voltage signals from one or more sources. In an embodiment, a receiving module (102) is configured to receive input voltage signals from one or more sources. At a step (504), sensing, by a sensing module (104), data from the drive. In an embodiment, the sensing module (104) is configured to sense data from the drive. At a step (506), relaying, by a relay unit (106), the signals and the sensed data. In an embodiment, a relay unit (106) is configured to relay the signals and the sensed data. At a step (508), analysing, by an analyser (108), the relay signals and the sensed data, and identifying a target related data of the drive. In an embodiment, an analyser (108) is configured to analyse the relay signals and the sensed data, and is further configured to identify a target related data of the drive. At a step (510), controlling, by a control module (110), the drive in one or more axes based on the identified data. In an embodiment, a control module (110) is configured to control the drive in one or more axes based on the identified data. At a step (512), determining, by a determination module (112), an error from the identified data based on the controlled drive. In an embodiment, a determination module (112) is configured to determine an error from the identified data based on the controlled drive. At a step (514), correcting, by a correction module (114), the error of the identified data. In an embodiment, a correction module (114) is configured to correct the error of the identified data. At a step (516), generating, by a generation module (116), a command to the drive for following a target.

[0065] Figures 6A illustrates graphical representation (600A) depicting Elevation drive braking waveforms, according to an exemplary implementation of the present invention.

[0066] Figure 6A represents elevation drive braking waveforms for Elevation axis. In this, no hunting is observed in the speed waveform. The residual speed is reduced to zero after braking. With the help of the braking waveforms, significant improvement in braking angle is achieved, with a braking angle of less than 3.50. The same performance in the other direction of rotation provide the significant improvement.

[0067] Figures 6B illustrates graphical representation (600B) depicting Azimuth drive braking waveforms, according to an exemplary implementation of the present invention.

[0068] Figure 6B represents Azimuth drive braking waveforms for Azimuth axis. In this, no hunting is observed in the speed waveform. The residual speed is reduced to zero after braking. With the help of the braking waveforms, significant improvement in braking angle is achieved, with a braking angle of less than 5.50. The same performance in the other direction of rotation provide the significant improvement.

[0069] Figures 7A illustrates graphical representation depicting sinusoidal error distribution in an Elevation drive, according to an exemplary implementation of the present invention.

[0070] Figure 7A represents sinusoidal error distribution in an Elevation drive at Elevation axis. In this, feedforward, feedback, and position error waveforms are shown. It ensures three mil error response of less than 30%, and four mil error response of less than 15%. Further, a plot is taken at an elevation drive at 300/ S.

[0071] Figures 7B illustrates graphical representation depicting sinusoidal error distribution in an Azimuth drive, according to an exemplary implementation of the present invention.

[0072] Figure 7B represents sinusoidal error distribution in an Azimuth drive at Azimuth axis. In this, feedforward, feedback, and position error waveforms are shown. It ensures three mil error response of less than 45%, and four mil error response of less than 15%. Further, a plot is taken at an elevation drive at 400/ S.

[0073] It should be noted that the description merely illustrates the principles of the present invention. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described herein, embody the principles of the present invention. Furthermore, all examples recited herein are principally intended expressly to be only for explanatory purposes to help the reader in understanding the principles of the invention and the concepts contributed by the inventor(s) to furthering the art and are to be construed as being without limitation to such specifically recited examples and conditions. Moreover, all statements herein reciting principles, aspects, and embodiments of the invention, as well as specific examples thereof, are intended to encompass equivalents thereof.

,CLAIMS:
1. A method for controlling a drive, comprising:
receiving, by a receiving module (102), input voltage signals from one or more sources;
sensing, by a sensing module (104), data from said drive;
relaying, by a relay unit (106), said signals and said sensed data;
analysing, by an analyser (108), said relay signals and said sensed data, and identifying a target related data of said drive;
controlling, by a control module (110), said drive in one or more axes based on said identified data;
determining, by a determination module (112), an error from said identified data based on said controlled drive;
correcting, by a correction module (114), said error of said identified data; and
generating, by a generation module (116), a command to said drive for following a target based on said corrected error.

2. The method as claimed in claim 1, wherein said sensed data is related to speed and position of said drive, and said sensed data includes an Elevation and an Azimuth axes.

3. The method as claimed in claim 1, wherein said method includes creating, by a creation module (120), one or more schemes, for detecting a phase difference between said receiving module (102) and a transmitting module for said drive.

4. The method as claimed in claim 3, wherein said method includes switching, by said creation module (120), ON said drive with zero phase difference, and detecting the correctness of the End limit switches fitted in said drive on said Elevation & Azimuth axes.

5. The method as claimed in claim 4, wherein said method includes producing, by a hunting module (122), a zero hunting operation for reducing the Servo power requirement to ‘zero’, in an End limit zone.

6. The method as claimed in claim 1, wherein said method includes performing, by said relay unit (106), change in a mode of operation of said drive based on said signals and said sensed data, said mode of operation includes a remote mode and a local mode.

7. A real-time controller (100) for a drive, comprising:
a receiving module (102) configured to receive input voltage signals from one or more sources;
a sensing module (104) configured to sense data from said drive;
a relay unit (106) configured to cooperate with said receiving module (102) and said sensing module (104), said relay unit (106) configured to relay said signals and said sensed data;
an analyser (108) configured to cooperate with said relay unit (106), said analyser (108) configured to analyse said relay signals and sensed data, and identify a target related data of said drive;
a control module (110) configured to cooperate with said analyser (108), said control module (110) configured to control said drive in one or more axes based on said identified data;
a determination module (112) configured to cooperate with said analyser (108) and said control module (110), said determination module (112) configured to determine an error from said identified data based on said controlled drive;
a correction module (114) configured to cooperate with said determination module (112), said correction module (114) configured to correct said error of said identified data; and
a generation module (116) configured to cooperate said correction module (114), said generation module (116) configured to generate a command to said drive for following a target based on said corrected error.
8. The controller (100) as claimed in claim 7, wherein said controller is a Tuneable Proportional-Integral-Derivative) PID controller, configured to allow a user to tune to a desired PID controller values to reduce position error.

9. The controller (100) as claimed in claim 7, wherein said controller (100) includes a power supply module (118), said power supply module (118) configured to supply power at different voltage levels to said relay unit (106), and said control module (110).