Online Motion Simulation Using Simplified Axis Dynamics
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Solution Overview
Problem
Current industrial control systems face challenges in accurately simulating complex motion systems and commissioning control programs due to complex dynamics and the need for offline processing, which delays validation and optimization of motor drive performance.
Innovation Solution
A method and system for online simulation of an axis of motion using a simplified model with a simulation module that generates estimated velocity and position, allowing for commissioning of control programs before mechanical installation, utilizing a processor module, axis controller, and control module to adjust gain factors based on feedback signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a detailed model is used to accurately represent complex motion system dynamics, then model accuracy is improved, but computational intensity increases and offline processing is required
Solution Approach 1:
The patent transforms the complex motion model into a simplified representation by changing the parameters from detailed physical characteristics to dominant dynamic characteristics (natural frequency, damping ratio, reflected inertia). This parameter transformation enables accurate online simulation while reducing computational intensity, as the simplified model can be executed in real-time on the motor drive without requiring offline processing.
2Reliability
If complete mechanical installation is required before validation, then system reliability is improved, but commissioning time increases
Solution Approach 1:
The patent enables preliminary validation and commissioning of control programs through online simulation before complete mechanical installation is available. The simulation module allows the control program to be tested and optimized using estimated position and velocity signals, performing required validation actions in advance. This preliminary action reduces commissioning time while maintaining system reliability through subsequent final validation.
3Measurement precision
If offline processing is used for model analysis, then computational accuracy is improved, but validation time increases
Solution Approach 1:
The patent replaces offline computational processing with an online simulation system that executes directly on the motor drive. The simulation module substitutes the traditional offline analysis approach with a real-time computational system that maintains sufficient accuracy for commissioning and validation tasks. This substitution eliminates the need for separate offline processing steps, enabling continuous online validation and significantly reducing total validation time.
Data Source
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AI summary
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.