Rockwell Automation Technologies Incorporated

Aderiano M Da Silva

Robert J Miklosovic

Robert H Schmidt

Brian Fast

Jonathan D Hoffman

Michael Wayne Cromheecke

Peter B Schmidt

Mark R Cooper

Joachim Thomsen

Xikai Sun

Peter M Smit

Oliver C Haya

Arun K Guru

Gerry M Nagel

Jon P Vanderpas

Michelle E Holt

Jasper Hao Yang

Maulik Kalolia

Vincent Bourrelly

Michael Cromheecke

Kevin C Craig

A method includes using at least one processor to detect that a tool coupled to an end effector of a robot having multiple joints is contacting a surface. The robot includes multiple joint motors configured to control multiple motions of the multiple joints. One or more control systems are configured to control each of the joint motors in a joint position mode. The method also includes identifying, via the at least one processor, a first joint of the multiple joints in response to detecting that the tool is contacting the surface. The method also includes sending, via the at least one processor, a command to at least one of the one or more control systems associated with a first joint motor of the multiple joint motors that corresponds to the first joint. The command is configured to cause the at least one of the one or more control systems to operate in a torque mode. The method also includes sending, via the at least one processor, a joint torque value to the at least one of the one or more control systems. The at least one of the one or more control systems is configured to cause the first joint to apply the joint torque value via the first joint motor.

Applied force control for robots

For estimating motor torque and velocity, a method estimates a velocity profile for a motor based on line-to-line voltages and phase currents for the motor. The velocity profile is estimated without a position input and a velocity input. The method further estimates a torque profile for the motor based on the line-to-line voltages, the phase currents, and a time interval of the velocity profile of motor velocities greater than a velocity threshold, and wherein the motor is operating over the time interval.

Estimating motor drive torque and velocity

A system and method for real-time detection of anomalies in a motor drive includes a controller receiving one or more signals corresponding to real-time operation of a controlled system. The controller samples the real-time signal during operation of the controlled system and maintains a moving window of the sampled data. A signature of the sampled data within the moving window is then generated. Each signature corresponds to operation of the controlled system within the period of time defined by the moving window. An identifier and a number of occurrences of each signature may be stored with the signature. An initial table of expected signatures may be generated, for example, by executing a training, or learning, period within the control system. The controller compares each real-time signature against the table of expected signatures to detect the occurrence of an anomaly.

Method and system for real-time anomaly detection in a motor drive

A linear and curvilinear encoder is provided in which absolute mechanical position and high resolution position determination can be obtained using a cart having a mover with 'hybrid' teeth, configured in a curvilinear profile or shape, moving along a curvilinear track with a stator having teeth. The absolute mechanical position and high resolution position determination can be detected on the track by applying an excitation signal to a coil surrounding particular teeth of the stator to produce an electromagnetic (EM) field which can be influenced by the profile or shape of the teeth of the mover. A resulting pick-up signal can then be detected in a pick-up coil surrounding particular teeth of the stator with different harmonics in the pick-up signal corresponding to harmonics of the profile or shape of the teeth.

Hybrid encoder system for position determination

In one embodiment, a tangible, non-transitory computer readable medium stores instructions that, when executed by a processor, are configured to cause the processor to receive a first set of inputs including a motion profile of a machine, a mechanical design of the machine, or both, generate a number of axis solutions for one or more actuators, drives, and load transmission components based on a model using the first set of inputs, generate a production rate versus amount of energy consumed per part curve for each of the number of axis solutions, and display the production rate versus amount of energy consumed per part curves for each of the number of axis solutions. One of the curves includes a point on the curve indicative of a lowest amount of energy consumed for a desired production rate range.

Systems and methods to enhance machine designs and production rate schedules for minimized energy cost

An improved system for tuning a motor controller is disclosed. The controller gains are initially set based on the measured frequency response for the controlled system. A desired level of performance is defined by setting a desired phase margin and a desired gain margin to be observed in the frequency response. An improved method of determining the frequency response provides for a reduced computational intensity. The initial tuning routine uses the frequency response to set not only controller gains, but also settings for filters in the control module. Having obtained the desired level of performance from the initial tuning, the motor drive executes an adaptive tuning routine while controlling the motor. The adaptive tuning routine tracks changes in the operating performance and adjusts the filter settings or the controller gains to return operation to within the desired level of performance while the motor continues to operate.

Method for tuning a motor drive using frequency response

A motor drive is provided with integrated frequency response analysis tools for generating drive performance metrics that are independent of motion profile and tuning. The metrics are broadly applicable to a wide range of applications, tunings, and load types, and can be used to fairly compare performance across different drives models and assist in drive selection. The frequency analysis tools include a transformation algorithm that reduces or eliminates spectral leakages, a signal generation component that scales the test input signal as a function of frequency avoid saturation based on defined limits of the controlled system, and a phase unwrapping algorithm that correctly unwraps the phase of open-loop and closed-loop response curves. The frequency response analysis tools yield an open-loop response, a closed-loop response, a tracking error response, and a disturbance rejection response, which are used to derive performance metrics for the drive.

Drive performance measurement

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Oak Creek, WI, United States of America

Aderiano M Da Silva