Abstract: A system and method of transitioning between motion trajectories in an independent cart system includes controlling motion of a mover along a track segment with a segment controller responsive to a first motion trajectory. At least one operating state for the first motion trajectory is received at an external controller as the segment controller is controlling motion of the mover responsive to the first motion trajectory. A second motion trajectory for the mover is generated with the external controller, where the second motion trajectory includes the at least one operating state as an initial condition for the second motion trajectory. While the segment controller is controlling motion of the mover along the track segment responsive to the first motion trajectory, the second motion trajectory is transmitted from the external controller to the segment controller, and the segment controller switches from the first motion trajectory to the second motion trajectory.

Abstract: 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.

Abstract: 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.

Abstract: A system and method for motor control includes at least one dynamic offset value provided to a motor drive. Each dynamic offset value is determined by an external processing device and transmitted to the motor drive. The external processing device includes a rigid-body model of the motor and of the load controlled by the motor to generate each dynamic offset value. The dynamic offset value may be a position, velocity, or torque offset signal or a combination thereof. Each dynamic offset value and the desired motion profile are provided at a first update rate. The system control loops execute at a second update rate faster than the first update rate. Each dynamic offset value and the reference command are interpolated to generate values for each period of the second update rate. The interpolated values are provided to the system control loops to achieve desired performance of the motor.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: An industrial system and a method including using a processor, estimating a reliability of a component of an industrial system using a prognostic model program, using the processor, updating weighting vector parameters of the prognostic model program based on collected data and a previous reliability estimate using machine learning, and using the processor, selectively generating a warning based on comparison of the reliability with a threshold and/or deviation of weighting vector parameters.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: Various embodiments of the present technology generally relate to condition monitoring in industrial environments. More specifically, some embodiments relate to an embedded analytic engine for motor drives that monitors induction motor conditions for potential failures including rotor faults and stator faults. In an embodiment, a condition monitoring module is configured to obtain runtime signal data from a controller within a drive, derive runtime metrics from the runtime signal data based on an induction motor fault condition, provide the runtime metrics as input to a machine learning model constructed to identify a status of the induction motor based on the runtime metrics and output the status, and monitor the induction motor fault condition based on the status of the induction motor output by the machine learning model.

Abstract: Various embodiments of the present technology generally relate to condition monitoring in industrial environments. More specifically, some embodiments relate to an embedded analytic engine for motor drives. A drive-embedded analytic engine discussed herein enables industrial enterprises, employers, and other users to monitor an industrial operation comprising at least a motor and a mechanical load in order to detect failures before they occur. An embedded analytic engine may perform condition monitoring from within a frequency drive based on a configuration specific to a monitored fault condition. In order to detect fault conditions, the embedded analytic engine may obtain baseline signal data from an industrial operation using rotating machinery, obtain recent runtime signal data from the industrial operation, and use the signal data to produce data light metrics that may be used to detect fault conditions from within the drive.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.