Note: Descriptions are shown in the official language in which they were submitted.
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3 BACKGROUND OF THE INVENTION
(i) F1ELD OF THE INVENTION
The present in~ention relates to a controller for
winding an unvulcanized rubber sheet, and more particularly
to a controller for winding an unvalcanized rubber sheet
applicable to a machine for molding tires and transmitting
` belts such as V belts~ flat belts and serrated toothed belts.
(ii) DESCRIPTION OF THE PRIOR ART
Heretofore, when an unvulcanized rubber sheet or an
unvulcanized rubber sheet containing cloth, cords or short
fibers ~hereinafter referred to as an unvulcanized rubber
sheet in general) is wound on a drum having a cylindrical
outer periphery, an operator draws out the unvulcani~ed
rubber sheet through a plyservicer to adhere an end of the
rubber sheet to the surface of the drum, rotates the drum by
a predetermined quantity to wind the rubber sheet and then
cuts the rubber sheet. Accordingly, there are drawbacks that
much labor is required and the productivity and the quality
thereof are greatly dependent on a skill of the ~perator.
20In order to remove the drawback~ and improve the
operation, there have been proposed many manners such as a
manner for winding an unvulcanized rubber sheet previou51Y
cut in a predètermined length on a drum and a manner
disclosed in Japanese Patent Application Laid-open No.
2538144J83. However, in any manners, since the drum having a
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same peripheral length is used for a given period of time, it
is necessary to change the setting condition such as the
length of winding the rubber sheet on the drum when the
peripheral length of the drum is varied. Accordingly, when
the periphral length of the drum is frequently changed as in
the molding of the transmitting belt which is a product
having various types but manufactured in a small quantity,
the actual rate of operation of facilities and operators is ~markab~ `
reduced and the rate of occurrence of defective products due
to the mistake of setting condition is increased.
SUMMARY OF THE IN~ENTION
The present invention is to be proposed in view of
-the above drawbacks in the prior art. An object of the
present invention is to resolve the above drawbacks in the
prior art and provide a controller for winding an
unvulcanized rubber sheet capable of always attaining the
correct winding operation of the rubber sheet automatically
against the variation of the setting condition with the high
working rate and preventing the occurrence of mistake of the
operator.
Accordinglyç the gist of the present invention
resides in a controller for winding an unvulcanized rubber
sheet comprising a cylindrical drum rotated by a motor for
winding the unvulcanized rubber sheet thereon, a conveyer for
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feeding the unvulcanized rubber on the drum, a data
processor for calculating a ratio of peripheral velocities of
the drum and the feeding conveyer and a feeding quantity of
the unvulcanized rubber sheet on the basis of a previously
inputted data and a sequence control unit responsive to an
output of the data processor for controlling a sequence
operation of a movable portion.
~ riefly explaining the controller for winding the
unvulcanized rubber sheet, one or both of the drum and the
feeding conveyer are driven by a DC servomotor or a pulse
motor to be capable of changing the speed of rotakion thereof
continuously 90 that the peripheral velocities of the drum
and the conveyer are electrically synchronized with each
other. The variation of setting condition of the mechanical
movable portion is made by the data processor on the basis of
the previously inputted sequence order of the molding
operation and the necessary data. With the controller so
constructed, the mold~ng operation in which the setting
condition is varied for each operating cycle can be attained
with the high working rate and the occurrence of mistake such
as wrong setting of the condition by the operator can be
prevented. Further, the outer peripheral length of the drum
(or the peripheral length corresponding to the length of a
material attached on the drum) is measured in advance before
the rubber sheet is wound on the drum, and the winding length
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is automatically calculated on the basis of the measured
data to set the calculated length. Thus, the peripheral
length of the drum or the thickness of the material
previously attached on the drum is automatically corrected so
that the more exact winding operation can be attained.
Since *he above construction is provided in the
present invention, the following effects are achieved.
According to the present invention, even if the
setting conditions containing the outer peripheral length o~
the drum, for example, are varied for each operating cycle,
the high working rate can be maintained by the automatic
control and the correct winding operation can be always
attained. Therefore, the occurrence of the operating error by
the operator can be effectively prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a cross sectlonal side view of a portion
showing the configuration of an embodiment of the present
invention;
Fig. 2 shows a drive mechanism for winding the
unvulcanized rubber sheet as viewed from the front side in
Fig. 1;
Figs. 3(A), (B~ and (C) show the winding procedure
of the unvulcanized rubber sheet according to an embodiment
of the present invention; and
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Fig. 4 is a block diagram showir-g a necessary part of
a controller according to an embodiment of the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the present invention will now be
described in detail with reference to the accompanying
drawings.
Referring to Figs. 1 to 4, numeral 1 denotes a drum
having an actual outer periphery for the molding operation,
2 a head stock for rotatably supporting the drum 1 and
including a drive unit for rotating the drum 1, 3 a fixed
frame for a servicer, and 4 and 5 unvulcanized rubber sheets,
respectively. Generally, a plurality of types of rubber
sheets (two types of rubber sheets are shown) are provided
and one or a plurality of types of the rubber sheets of them
; are wound on the drum 1 depending on a specification of a
product. numerals 6 and 7 denote feeding units of the rubber
sheets 4 and 5, respecti~ely. In the figure, only two sets of
feeding units are provided but can be increased or decreased
if desired.
The head stock 2 comprises a head stock houslng 10,
a main shaft 8 which is rotatably supported to the head
stock housing 10 through a bearing 9 and has one end on which
the drum 1 is mounted detachably by means of known means and
-- 6 --
.... , ., .. ~ . . _ , . . .. . ... . .. . ... . .. . .. . . .
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the other end on which a pulley 11 is fixedly mounted, a pulse
motor 15 directly coupled to a reduction gear 14l a pulley
13 fixedly mounted.on an output shaft of the reduction gear
14, a toothed belt 12 which is received on the pulley 11 and
a proximity switch 16 of a high accuracy type which is
fixedly mounted in the head stock housing 10 for detecting a
projection 11a mounted on a peripheral side of the pulley 11.
A roller 18 for measuring the outer peripheral
length of the material wound on the drum 1 is rotatably
mounted on one end of a lever 19. A known pulse generator
~hereinafter referred to as PG) 22 is coup.led with a shaft oF
the roller 18 and the PG is to generate pulses co-responding
to the rotational quantity of the roller 18, The other end
of the lever 19 is fixedly mounted one end of a shaft 20
which is rotatably~ mounted on a bracket 21 fixed on the head
stock housing 10. An air cylinder 17 not shown is coupled
with the other end of the shaft 20 and the lever 19 is swung
through the shaft 20 by the operation of the air cylinder 17.
Numeral 23 denotes a rr~ovable frarne for the feeding
~0 unit 6~ which is mounted on the fixed frame 3 slidably in the
.direction perpendicular to the axial core of the drum 1 by a
known guide means not shown. A feed screw 25 meshing with an
internal thread 24 fixedly mounted on the movable frame 23
has both ends which are rotatably mounted in bearings 26
fixed on the fixed frame 3 and is coupled with a geared motor
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.... .. .. ......... .. . .. . ... . .
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28 with a brake fixedly mounted on the frame 3 through a
coupling 27. The movable frame 23 is moved in the direction
perpendicular to the axiai core of the drum 1 by operating
the motor 28 and the movement quantity thereof is detected by
the PG 29 mounted to the motor 28. Although not shown, -there
is also provided with a limit switch for preventins the
over-stroke of the movable frame 23.
Numeral 30 denotes a belt conveyer for feeding the
rubber sheet, 31 a drive roll thereof, 32 a chute fixedly
mounted on the movable frame 23 and 33 a known cutter mounted
on the rnovable frame 23 for cuttin~ the rubber sheet with a
predetermined angle in the moving direction of the rubber
sheet. The cutter 33 includes a round knife, a knife heater
or the like depending on the construction of the rubber sheet
and includes a drive means or the like although not shown.
Numeral 34 denotes a photo-electric switch mounted
on the movable frame 23 for detecting a cut end qb of the
rubber shee-t 4.
Numeral 35 denotes a movable frame mounted on the
frame 23 and moved slidably in the direction perpendicular to
-the axial core of the drum 1 by operation of the air
cylinder 37 not shown. A sponge roller 36 for pressing the
rubber sheet 4 on the drum 1 is rotatably mounted on the
movable frame 35.
The drive roll 31 is rotatably supported by
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bearings 40 mounted in the movable frame 23. A toothed belt
42 is provided between a pulley 41 mounted on one shaft of
the drive roll 31 and a pulley 43 mounted on an output shaft
of a pulse motor 44 fixedly mounted on the movable frame 23.
Thus, by operating the pulse motor 44, the drive roll 31 is
rotated to feed the rubber sheet 4.
The feeding unit 7 has the same construction as the
feeding unit 6 except that the length of the belt conveyer
is different and therefore the description thereof will be
omitted. Numeral 38 denotes a sponge roller identical with
the roller 36 and which can be moved to a position 3~a by
operation of the air cylinder 39 not shown. Numeral 45
denotes a pulse motor for driving the belt conveyer, 46 a
geared motor~with a brake~ for moving a movable frame for the
feeding unit 7 and 47 a PG for detecting the movement
quantity of the mavable frame.
: Numeral 48 denotes a data processor which comprises
a central processing uni-t ~hereinafter referred to as CPU)
for performing the data processing in accordance with a
previously inputted program, a full keyboard for inputting
data indicatin~ the sequence of the molding operation, a
: Braun tube display unit (hereinafter referred to as CRT) for
indentifying the inputted data, a CRT interface for
transmitting and receiving signals between the keyboard and
the CRT and the CPU, a digital switch for inputting a
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material number of the rubber sheet supplied to the rubber
sheet feeding unit not shown, a memory circuit containing a
read-only-memory (ROM) and a randam-access-memory (RAM) for
storing the indication data and the like, and an input/output
interface for transmitting and receiving signals between the CPu
and the sequence circuit unitand the like. Further, it is
con~enient to add an external memory reading unit for reading
the indication data from an external memory in which the
indication data i5 stored pre~iouslY and a printer for
recording the re5ultant data of the molding operation. The
keyboard, the CRT and the digital switch may be conveniently
mounted in an operating control described later.
Numeral 49 denotes a sequence circuit unit for
controlling the operation of each units and which utilizes a
programmable controller ~ generally named a sequencer) in
this embodiment. Numeral 50 denotes an operating control
includin~ an automatic~manual selector switch, a
push-botton switch for start and stop, an indicating lamp and
the like. Numerai 51 denotes a counter for counting the
pulses generated from the PG 22 during one rotation of the
drum 1, that is, until the proximity switch 16 is operated
next after the switch 16 is operated once. Numera1 53 denotes
a pulse generator used -to set the speed o~ rotation of the
drum 1 at the time other than the winding time of the rubber sheet
and ~ncluding a deYice~for setting the nu~ber~o~ generated pulse
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per second. Numeral 52 denotes a digital switch for
setting the rotation quanti-ty of the drum 1 at the time other
than the winding time.
Numeral 5~ denotes a pulse generator which is
utilized when the rubber sheet is wound on the drum and
generates pulses at a predetermined P/S until the number of
generated pulses reaches a value designated by the data
processor 48.
Numerals 55 and 56 denote frequency dividers for
di~iding the pulse signals generated from the pulse generator
54 in accordance with a frequencY dividing data signal
produced from the data processor 48 so as to automatically
set a ratio of peripheral velocities of the drum 1 and the
feeding conveyer 30 and the feeding quantity of the rubber
sheet. Numeral 57 denotes a digital switch for setting the
feeding quantity of the rubber sheet by the feeding conveyer
at the time other than when the rubber sheet is wound, and
numeral 58 denotes a pulse generator for use with the digital
switch 57 and including a P~S setting de~ice.
Numeral 59 denotes a relay circuit unit for selecting
the pulse signal of the pulse generator 53 or the frequency
divider 55. Numeral 60 denotes a relay circuit unit for selecting
the pulse signal of the pulse generator 58 or the frequency
divider 56 and performing the control operation for
selectively feeding the rubber sheet 4 or 5. Numeral 61
... .. .. ... ... .. . . .. . . . . . . ..
6~0
denotes a pulse motor driver responsive to the output pulse signal
of the relay circuit unit 59 for driving a pulse motor 15
and numerals 62 and 63 denote pulse motor drivers responsive
to the output pulse signal of the relay circuit unit 60 for
driving pulse motors 44 and 45, respectively.
Numerals 64 and 65 denote AC motor control units for
the geared motors 28 and 46 with AC brake~ respectively? and
including a comparison circuit for a stroke setting signal
produced from the data processor and a position detection
pulse signal produced from the PG 29 and 47.
Numeral 66 denotes a pneumatic control device for
air cylinders 17, 37 and 39 and including a solenoid operated
valve and a pressure reducing valve.
Further, the controller comprises a limit switch, ~.
a proximity switch, a photo-electric switch and the like for
detecting the operating condition of the movable frames and
the air cylinders and a driving circuit for the rubber sheet
feeding device although not shwon.
The present invention will now be described by way ~-
of example with reference to the formation of the V belt to ~-i
which the present invention is applied.
Concerning all types of V belts which are planned
to be formed by the present controller, the specification
data including the type number V and the peripheral length L
for each ~ belt, the material number Mn of the used rubber
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sheet, the thickness Mt of the rubber sheet and the number o~
wound iayers M~ corresponding to the grade number ~ and the
number D of the used drum, the material number Mn of rubber
sheet supplied to the ser~icer, the supply location thereof P
~the feeding de~ice number~ and mechanical data described
later are inputted and stored in the data processor 48.
Before starting the formation of the belt, the designation
data including the formation order N, the type number V, the
peripheral length L and the grade number M of the V belt to
be formed in a predetermined time of period are inputted to
the data processor ~8 and the operating control 50 is then
operated to start automatically.
The sequence circuit unit 49 then produces a data
: request signal to supply it to the data processor 48. When
the data processor 48 identifies in response to the data
request signal that the counter memory in the memory circuit
is N, the CPU selects the type number V, the peripheral
length L and the grade number M of the V belt of the
formation order N on the basis of the designation data in the
memory circuit to select the specification data
corresponding to the selected designation data and performs a
next operation~
~ The forward stroke data signal for the feeding unit
6 andJor 7 is given by
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3L2~6~L9
Xl= ~t- hl~(L t C)i --d 2
where a " b " c, and d, are mechanical data which are
.calculated by the following equations and inputted previously
~the data for the feeding units 6 and 7 are required to be
calculated and inputted independently).
al = k,(~, - 5~), b~ = 2~ cl = 2
dl= 2l~h
kl ; the nurnber of pulse trains generated by the PG's 2~ and
47 when the feeding units 6 and 7 are moved a unit
distance.
S~ ; the horizontal distance between the center of the drum 1
when the feeding units 6 and 7 are in a wait position
and the center of the sponge rolls 36 and 38 bein~ in
the wait position.
sl ; the pxope.r pressing stroke of the sponge rol1s 36 and 38.
r ; the radius of the sponge rolls 36 and 38.
h ; the difference in height between the center of the drum ..
1 and the center of the sponge rolls 36 and 38.
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The results.to be calculated by the following
equation are previously set to the digital switch 57 as for
the feeding units 6 and 7, respectively.
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The feeding length of the rubber sheet 4 and~or 5
is given by
X2- k2(Lo~ Sz)
k~ ; the number of outpu* pulses supplied to the pulse motors
44 and 45 required to cause the feeding units 6 and 7 to
feed the rubber sheets 4 and 5 a unit distance.
Lo ; the length of the end 4b of the rubber sheet fed from
the cutting position of the rubber sheet 4 by the cutter
33 beFore starti ng the winding op~ration ~this length
is previously inputted to the data processor 48 as a
mechanical data).
S2 ; the distance between the cutting position of the rubber
lS sheet 4 by the cutter 33 and the detection position by
the photo-electric switch 34.
The data processor 43 supplys the above calculated
result Xl to the AC motor control units 64 and 65 and supplys
the si~nal of the position number P ~for example 6) supplied
with the rubber sheet having the used material number Mn to
the sequence circuit unit 49. The sequence circuit unit 49
thus sends the start signal to the AC motor control unit (for
example, the AC motor control un~t ~)and starts the
measurement of the peripheral length.
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6~
b~hen the start command is supplied to the AC ~otor cont-
rol unit 64, the feed screw 25 is rotated through the
geared motor 28 with brake to move the feeding unit 6 forward
~to approach the drum 1). When the number of the pulses
generated by the PG 29 reache~ the above value Xl, the
forward movem`ent of the feeding unit 6 is stopped and the
stro~e completion signal is supplied to the sequence circuit
unit 49. Thus, the sequence circuit unit 49 causes the relay clrcuit
unit 6n to select the pulse generator 58 and the pulse
motor diriver 62 and supplys the pulse generation command to
the pulse generator 58 so that the feeding conveyer 30 is
operated through the pulse motor 44 to ~eed the rubber sheet
4. When the number of pulses ~enerated from the generator 58
after the end 4b of the rubber sheet 4 has been detected by
the photo-elctric switch 34 reaches the value X2 preset to
the digital switch 57 ~Fig. 3(A)), the feeding conveyer 30 is
stopped and the pulse generator 58 supplys the feeding
completlon signal to the sequence circuit unit 49.
On the other hand, the peripheral length is
measured durlng the above operation. The sequence circuit
unit 49 first operates the air cylinder 17 through the
pneumatic control device 66 to bring the peripheral length
measureing roller 18 into contact with the surface of the
drum 1 (or the surface of the rubber sheet wound on the dru~).
The relay circuit unit 5~ is caused to select the pulse
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... . . .
generator 53 to start the generation of pulses and the drum 1
is rotated through the pulse motor driver 61 and the pulse
motor 15. When the proximity switch 16 operates, the counter
51 starts to count the pulses of the PG 22 and when the
proximity switch 16 operates next, the counter 51 stops to
count the pulses of the PG 22 and the resultant count signal
X3 is supplied to the data processor 48 with the count -~
completion signal being 5uppl ied to the sequence circuit unit
4~. The sequence circuit unit 49 stops the rotation of the
drum 1 and returns the air cylinder 17 to its original ;:
po5 i tion to termin~te the measurement of the peripheral
length.
The data processor 48 performs the following
calculation on the basis of the measured peripheral length
data signal X3.
'
Measured peripheral length Ln =~3X3
Frequency dividing ratio of drum KD =a~ 1~D
Frequency dividing ratio of conveyer KC = as/(Lgi x ~D)
i = 1 t 2, winding order .
LDI = 1~ ~ ~ X ~t~) X ~
LD2 - L~ ~ 2 7~ 1t ~ ) ~ Ir (M~ 1t 2 ) X ~ 2
Wound rotational quantity X~ =a~ LL )
i = 1, 2~ : winding order
LE~' L~ 4, X ~tl) t ~l
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.. . ~ ~, . ..... ~ .. ... ........ . ... ... . . . .
~2a,L~L9~
LE2 = L~ ~ 2~ (~ tl)t2~ 2x ~t2) t ~2
where ~; and ~; represent correction coefficients on the
basis of the characteristics and the lap area of the rubber
sheet, and Z~ represents the speed of rotation (RPM) of the
drum when the rubber shee-t i 5 wound. These data are
previously inputted as the specification data. Further, the
data a3, a4, as and a6 are the mechanical data calculated by
the following equations and previously inputted. It may be
convenient to utilize the following equation of a instead of
utilizing the equation.
a3=l~d/k3~ a~ = ~o ~l /k4,
D k~
d ; diameter of the roller 18 for measuring the peripheral
length
k3 , number of pulses generated by the PG 22 for one rotaion
of the roller 18
H : PXS of the pulse generator 54
k4 ; number of pulses supplied to the pulse motor 15 required :i`
for one rotation of the drum 1
After the above calculation is completed, the
signal KD' KC and X~ are supplied to the frequency divider
55, 56 and the pulse genetator 54, respectively, and the
~2~
calculation completion signal is supplied to the sequence
circuit unit 49. In accordance with the feeding completion
signal and the calculation completion signal for -the rubber
sheet 4, the sequence circuit unit 49 causes the relay circuit
unit . 59 to select the frequency divider 55 and the relay circuit
unit 60 to select the frequency divider 56 and the pulse
motor drive At the same time, the air cylinder 37 is
operated through the pneumatic control circuit 66 to move the
sponge roller 36 so that the end 4b of the rubber sheet 4 is
pressed and adhered to the surface of the drum 1 (Fig.
3(a)). Thereafter, the pulse generation command i9 supplied
to the pulse generator 54 and the pulse motors 15 and 44 are
driven in synchronism with each other through the frequency
dividers ~5 and 56, the relay circuit units 59 and 60t and the -
pulse motor drivers 61 and 62 to wind the rubber sheet 4 on ~;~
the drum 4. When the number of pulses generated by the pulse
generator 54 reaches X4(Fig. 3(C)), the pulse motors 15 and
44 are stopped and the winding completion signal is produced
to the sequence circuit unit 49. Thus, the sequence circuit
2.0 unit 49 controls the cutter 33 through a circuit not shown to -
cut the rubber sheet 4. Then ? the pulse generator 54 is
operated for a predetermined time to drive only the pulse
motor 15 through the frequency divider 55, the relay ci-rcuit unit
59 and the pulse motor driver 61. After the remainig portion
of the rubber sheet 4 is wound, the feeding unit 6 is
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returned to the wait condition and the winding process is
terminated.
In accordance with the specification of the V be1t,
further layers of the rubber sheet 5 may be wound by the
same operation.
When all the winding process is terminated, the
sequence circuit unit 49 produces the end signal to the data
processor 48 and causes the data processor 48 to per~orm the
next process, that is, the exchange of the drum and the like.
In the data processor 48, the counter memory in the memory
circuit is incremented by 1 to be (N~1).
Although -the abo~e description has been made to the
V belt by way of example, the formation of the flat belt or
the like can be made in the same manner if the ~ormation
includes the process of winding the unvulcanized rubber sheet
on the drum.
In the above embodiment~ although only the pulse
motor 15 is provided for rotating the drum 1, other
equipments are provided in many cases and stitching and
cutting operations are performed while rotating the drum 1.
In such a case, it is advantageous in a cycle time that
another motor is pro~ided which is switched with the pulse
motor 15 through a clutch to rotate the drum 1. In the case
where the additional motor is switched through the clutch to
rotate the drum 1 and the rotation of the drum 1 for
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measuring the peripheral length is made by the additional
motor, the pulse generator 53 and the relay circuit unit 59 are
removed in the circuit of Fig. 4 and the frequency divider 55
may be directly coupled with the pulse motor driver 61.
. Further, although the pulse motors are used to
drive both the drum 1 and the conveyer for the feeding units
6 and 7~ one of them may be a DC servomotor~ a DC motor with
PG, an AC motor with PG or a pulse motor and the other may be
a DC servomotor. In such a case, while the circuit of Fi~. 4
is partly changed to be suitable for such a motor drive
circuit, the variation is simple to those skilled in the art
and the description will be omitted.
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