Identification of model parameters for a manufacturing machine, and use thereof for determining optimised trajectories
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Solution Overview
Problem
The commissioning of manufacturing machines with position-controlled drives is a time-consuming and subjective process, often requiring manual adjustments by experienced engineers, which can lead to varying settings and suboptimal performance due to unknown parameters like friction and motor torque limitations.
Innovation Solution
A method that uses a control facility to determine and optimize model parameters through identification runs, including maximum acceleration and jerk, current limits, and torque limits, to generate optimized trajectories for minimum travel time and energy efficiency, based on metrological measurements and boundary conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual iterative adjustment of drive parameters is performed by commissioning engineers, then the machine can be commissioned and operated, but the process is time-consuming and results in subjective variability and suboptimal performance
Solution Approach 1:
The system performs self-identification of drive parameters by automatically executing test trajectories, measuring actual motor behavior, and determining model parameters without human intervention. The control facility autonomously ascertains friction, inertia, and torque characteristics through the identification run, eliminating the need for manual iterative adjustment by commissioning engineers.
Solution Approach 2:
The identification run is performed during the commissioning phase to preliminarily determine accurate drive parameters before normal operation begins. By pre-ascertaining friction coefficients, moment of inertia, and torque limits through automated measurements, the system prepares optimized trajectories in advance, avoiding time-consuming manual adjustments during later operation.
2Ease of operation
If manual iterative adjustment of drive parameters is performed, then the machine can be commissioned, but the settings vary subjectively between different commissioning engineers
Solution Approach 1:
The system performs self-identification of drive parameters by automatically executing test trajectories, measuring actual motor behavior, and determining model parameters without human intervention. The control facility autonomously ascertains friction, inertia, and torque characteristics through the identification run, eliminating the need for manual iterative adjustment by commissioning engineers.
Solution Approach 2:
The system uses feedback from actual motor measurements during the identification run to objectively determine model parameters. By comparing commanded trajectories with actual motor responses and measuring real current consumption and position deviations, the system automatically calculates accurate friction coefficients, inertia values, and torque limits, ensuring consistent results regardless of which engineer performs the commissioning.
3Ease of manufacture
If estimated parameters with large safety factors are used in machine design, then the machine can be built without knowing exact parameters, but the optimum movement performance is not achieved after commissioning
Solution Approach 1:
The identification run is performed during the commissioning phase to preliminarily determine accurate drive parameters before normal operation begins. By pre-ascertaining friction coefficients, moment of inertia, and torque limits through automated measurements, the system prepares optimized trajectories in advance, avoiding time-consuming manual adjustments during later operation.
Solution Approach 2:
The system transforms the drive parameter values from estimated design-stage approximations with safety factors to precisely identified operational values through the identification run. By measuring actual motor behavior during test trajectories, the system determines the true friction coefficients, moment of inertia, and torque characteristics, enabling optimal movement performance in production operation.
4Productivity
If standard trajectories are used without optimized model parameters, then the machine can operate, but energy efficiency and travel time are not optimized
Solution Approach 1:
The system dynamically adapts trajectory parameters based on the identified model characteristics. By using the ascertained friction coefficients, inertia values, and torque limits, the control facility generates optimized trajectories that adjust acceleration profiles, velocity curves, and positioning sequences to minimize energy consumption while achieving tasks in minimum time, rather than using fixed standard trajectories.
Data Source
AI summary
A method parametrizes a model of a manufacturing machine of a manufacturing machine system. The manufacturing machine has at least one axis with a position-controlled drive, by which at least a first machine element can be adjusted relative to a second machine element. A maximum movement range, a maximum movement speed for the axis and a maximum electrical power that can be supplied to the drive of the axis are recorded, as boundary conditions for an identification run, in a control device comprised by the manufacturing machine system.