Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: In one embodiment, a tangible, non-transitory computer readable medium stores instructions that, when executed by a processor, cause the processor to receive one or more inputs relating to mechanical design and desired motion of an industrial machine and iteratively generate an enhanced motion profile until it converges to a motion profile within boundaries based on the one or more inputs, and that minimize energy cost. The enhanced motion profile reduces energy consumption when applied to a motor drive to control a motor connected to the industrial machine. The instructions, when executed by the processor, may also cause the processor to apply the enhanced motion profile to the motor drive to control the motor connected to the industrial machine.

Abstract: 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.

Abstract: 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.