Online Motion System Simulation With Dominant Dynamics Models
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Solution Overview
Problem
Complex dynamics in motor-driven systems make it challenging to accurately model and simulate industrial machine or process performance, requiring significant time and skill, and often necessitate offline processing and delayed commissioning due to the need for mechanical installation and validation.
Innovation Solution
A simplified online simulation method using a dominant order model with reflected inertia and time-varying damping, allowing for execution in industrial controllers or motor drives, enabling commissioning of control programs before mechanical installation is complete.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a detailed accurate model of complex motion system dynamics is used, then model accuracy is improved, but computational complexity and processing time increase significantly
Solution Approach 1:
The patent segments the complex motion system model into multiple simplified sub-models, each representing dominant dynamic characteristics. This segmentation allows the system to maintain accuracy for critical dynamics while reducing overall computational complexity by processing simpler sub-models instead of one comprehensive complex model.
Solution Approach 2:
The patent extracts and isolates the dominant dynamic characteristics from the complex system, separating them from less significant dynamics. By taking out only the essential dynamic behaviors needed for control purposes, the system achieves sufficient model accuracy while dramatically reducing computational requirements.
2Measurement precision
If offline processing is used for model analysis, then computational accuracy is improved, but commissioning time and system setup time increase
Solution Approach 1:
The patent performs preliminary identification of dominant dynamic characteristics during system setup, creating simplified models in advance. This preliminary action enables online simulation and commissioning to proceed efficiently without requiring extensive offline processing, thereby reducing commissioning time while maintaining sufficient accuracy.
Solution Approach 2:
The patent implements dynamic model adaptation that allows the simulation model to adjust online based on actual system behavior. This dynamic approach enables accurate commissioning and validation to occur in real-time during online operation rather than requiring static offline analysis, significantly reducing commissioning time.
3Reliability
If complete mechanical installation is required before validation, then system integration accuracy is improved, but productivity and time to market decrease
Solution Approach 1:
The patent creates a virtual copy or simulation model of the mechanical system that can be validated independently of the physical installation. This copying approach allows control software and system behavior to be tested and validated before complete mechanical installation, enabling parallel development and significantly accelerating commissioning speed while maintaining integration accuracy.
Data Source
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.