Rockwell Automation Technologies Incorporated

Cleveland State University

Robert J Miklosovic

Brian Fast

Mark A Chaffee

Aderiano M Da Silva

Jonathan D Hoffman

Robert H Schmidt

Ahmed Mohamed Sayed Ahmed

Joachim Thomsen

Gerry M Nagel

Robert Guenther

Michael Wayne Cromheecke

David Christopher Mazur

Haihui Lu

Timothy M Rowan

Rob Alan Entzminger

Jonathan Alan Mills

Arun K Guru

Todd A Wiese

Roberto S Marques

Zhendong Zhang

Zhiqiang Gao

Ryan Coon

Marius G Chis

Adam M Shea

Lei Jin

Qing Zheng

Wankun Zhou

Aaron Radke

Michelle E Holt

Jasper Hao Yang

Maulik Kalolia

Mark Chaffee

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

A motor drive receives a position feedback signal from a position sensor operatively connected to a motor. The motor drive receives a command signal defining a desired operation of the motor. A processor in the motor drive generates an acceleration feedforward signal from the command signal and an acceleration reference signal from the command signal and the position feedback signal. The processor also generates an estimated disturbance acceleration from the acceleration reference signal. The acceleration feedforward signal is multiplied by a first gain to obtain a first product, and the estimated disturbance acceleration by a second gain to obtain a second product. The first and second gains are functions of first and second portions of the system inertia. A current reference signal is generated based on the first product and second products, and an output voltage to the motor is generated from the current reference signal.

System and method for inertial compensation in a motor drive

Embodiments of this present disclosure may include systems that perform operations including receiving a request to access data associated with an industrial automation device from a requesting device and identifying the industrial automation device based on the request. The operations may include sending a query for template data to the industrial automation device based on the request and receiving the template data. The operations may include determining a data structure based on the requesting device and generating the data structure based on the template data and a mapping between the data structure and the template data. The operations may additionally include sending the data structure to the requesting device.

Symbolic access of industrial device systems and methods based on an off-premise gateway device

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 shaping the trajectory of a motion command to reduce the effects of a load on performance of a motor dynamically modifies the motion profile in real time to limit the reference signals in the motion profile to feasible commands. A load observer determines an estimated disturbance acceleration. The estimated disturbance acceleration includes the dynamics of the controlled load and is used to modify a maximum and a minimum limit for the acceleration reference. The acceleration limits are, in turn, used to determine velocity limits. The motion profile and modified acceleration and velocity limits are provided to a state filter which determines a new motion profile for use by the motor drive to control operation of a motor and to control the load connected to the motor.

System and method for trajectory shaping for feasible motion commands

A system includes a motor configured to be coupled to a non-rigid load and a control system disposed within, or communicatively coupled to, a drive system configured to control an operation of the motor. The control system includes a processor and a memory accessible by the processor. The memory stores instructions that, when executed by the processor, cause the processor to generate a smooth move input profile to control the operation of the motor based on inputs specifying a desired operation of the motor, apply a notch filter having a notch filter frequency to the smooth move input profile to produce a filtered smooth move input profile, and send a command to the drive system based on the filtered smooth move input profile, wherein the command is configured to adjust the operation of the motor.

Systems and methods for non-rigid load vibration control

A system may include a power converter and a control system communicatively coupled to the power converter. The control system may determine a first DC voltage associated with the DC bus based on one or more DC external capacitance values that correspond to one or more loads coupled to the power converter. The control system may also determine a second DC voltage associated with the DC bus based on a capacitance of a system in which the power converter operates. The control system may also determine a third DC voltage associated with the DC bus based on the first DC voltage and the second DC voltage and adjust an operation of the power converter based on the third DC voltage.

Power converter control system observer

Provided herein are systems, methods, and software for improving drive efficiency in an industrial automation system. In one implementation, a system comprises a mechanical load, an electromechanical device attached to the mechanical load, and a drive coupled to the electromechanical device. A processor is programmed to generate and display an acceleration curve, a duplicate acceleration curve, an energy curve and a duplicate energy curve. A user input is received indicating a change to at least a portion of the duplicate acceleration curve, and a change to the duplicate energy curve is calculated and displayed. A modified command signal based on the user input is calculated, and the drive is configured to control the electromechanical device via the modified command signal to mechanically operate the mechanical load perform a task.

System and method for improving drive efficiency in an industrial automation system

A system and method for online simulation of a controlled machine or process utilizes a simplified model of the system dynamics and may be used with hardware in the loop to evaluate performance of the controlled system or with software in the loop to perform commissioning of the control program prior to completion of the mechanical installation. The simplified model includes dominant order dynamics of the controlled system such as the inertia of the system and a damping factor. Further, the online simulation is scheduled to execute at an update rate slower than the update rate of the control loops within the motor drive. The simplified model and reduced update rate reduce the computational burden on the processor such that the simulation may be performed either on the industrial controller or on the motor drive.

Method and apparatus for online simulation of complex motion systems

A motor drive having controller settings which will result in improved tuning-less performance is disclosed. Gain values for the control loops and/or observer are determined independently of the mechanical loading and the resultant effects of that loading on the motor. The motor drive includes a control loop operable to receive a command signal and to generate a controller reference signal to achieve desired operation of a motor connected to the motor drive. The motor drive also includes a load observer operable to generate a signal that estimates a response required by the motor drive as a result of a load present on the motor. The response estimate signal is provided to the controller to isolate the effects of the load dynamics from operation of the control loops within the controller. A modified controller reference signal is generated as a function of the response estimate signal and the controller reference signal.

System and method for isolation of load dynamics in motor drive tuning

An improved system and method for analyzing motor performance to detect vibration of an electric machine controlled by a motor drive is disclosed. A load observer determines an estimated torque present as a load on the motor as a function of input signals corresponding to a desired torque to be generated by the motor and to a measured angular position of the motor during operation. The motor drive determines a frequency response of the estimated torque to identify at what magnitude and frequency any vibration components are present within the estimated torque signal. The motor drive compares the frequency response of the estimated torque signal to set points. If the measured magnitude of vibration at a particular frequency, as seen in the frequency response, exceeds a threshold set in one of the set points for that frequency, the motor drive generates an output signal indicting an excessive vibration is present.

System and method of integrated vibration monitoring in motor drives

For predicting a load pattern, a method determines a torque error from a torque reference modified by a low pass filter function of the torque reference. The torque reference is one of measured from an induction machine energized by a flux current and a torque current and calculated in an induction machine controller. The method determines a torque increase pulse in response to a torque relative variation calculated from the torque error exceeding an increase threshold. In response to detecting the torque increase pulse, the method determines a change delay time from the torque relative variation and the torque increase pulse. The method further determines a change period from at least two torque increase pulses. The method increases the flux current before a change time that is predicted as a function of the change delay time and the change period.

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Chardon, OH, United States of America

Robert J Miklosovic