Motion system health management using existing servo drive variables

1. A method of managing health of a motion system with a servo drive, the method comprising:

driving a motor of the motion system using the servo drive to perform a sequence of motions to build a three-dimensional torque model;

as the motor is being driven, for each motion, collecting a current I that is used to drive the motor, a position P of the motor and a velocity V of the motor together at the same time to produce multiple sets of current I, position P and velocity V values;

for each set of current I, position P and velocity V values, computing a corresponding torque value using an equation T=Kt*I, where T is a torque value, Kt is a torque constant and I is a driving current;

building the three-dimensional torque model for the motion system using the position P, velocity V and corresponding torque values, the three-dimensional torque model being a three-dimensional model in space defined by position, velocity and torque;

after the three-dimensional torque model has been built, collecting motion variables that are used by the servo drive to drive the motor of the motion system in response to motion commands, the motion variables including an actual current I to drive the motor, an actual position P of the motor and an actual velocity of the motor;

calculating a health indication value for the motion system exclusively using the collected motion variables, wherein calculating the health indication value comprises:

computing an actual torque value using the actual current I; and

taking a difference between the actual torque value and a torque value from the three-dimensional torque model to derive a torque deviation value that is used as the health indication values, wherein the torque value from the three-dimensional torque model is selected using the actual position P and the actual velocity V; and

in response to the health indication value, generating a notification for maintenance of the motion system.

2. The method of claim 1 , further comprising calculating another health indication value, wherein the health another indication value is a friction coefficient value that is computed using only the collected motion variables used by the servo drive.

3. The method of claim 2 , wherein the friction coefficient value is a viscous friction coefficient value or a Coulomb friction coefficient value.

4. The method of claim 3 , wherein at least one of the viscous friction coefficient value and the Coulomb friction coefficient value is derived using the equation:

T=J*A+B*w+C *( dw ),

where T is the torque, J is the inertia, A is the acceleration, B is the viscous friction coefficient value, w is the velocity value, C is the Coulomb friction coefficient value, and dw is the direction of velocity.

5. The method of claim 1 , further comprising calculating another health indication value, wherein the another health indication value is a total impact value that is computed using magnitudes of changes in acceleration based on the collected motion variables.

6. The method of claim 5 , further comprising calculating the total impact value by computing a sum of the magnitudes of changes in acceleration at a plurality of instances and multiplying the sum with inertia of the motion system.

7. A motion system comprising:

a motor, and

a servo drive configured to drive the motor, the servo drive including, memory; and

at least one processor configured to:

drive the motor of the motion system to perform a sequence of motions to build a three-dimensional torque model;

as the motor is being driven, for each motion, collect a current I that is used to drive the motor, a position P of the motor and a velocity V of the motor together at the same time to produce multiple sets of current I, position P and velocity V values;

for each set of current I, position P and velocity V values, compute a corresponding torque value using an equation T=Kt*I, where T is a torque value, Kt is a torque constant and I is a driving current;

build the three-dimensional torque model for the motion system using the position P, velocity V and corresponding torque values, the three-dimensional torque model being a three-dimensional model in space defined by position, velocity and torque;

after the three-dimensional torque model has been built, collect motion variables that are used by the servo drive to drive the motor of the motion system in response to motion commands, the motion variables including an actual current I to drive the motor, an actual position P of the motor and an actual velocity of the motor;

calculate a health indication value for the motion system exclusively using the collected motion variables, wherein calculating the health indication value comprises:

computing an actual torque value using the actual current I; and

taking a difference between the actual torque value and a torque value from the three-dimensional torque model to derive a torque deviation value that is used as the health indication values, wherein the torque value from the three-dimensional torque model is selected using the actual position P and the actual velocity V; and

in response to the health indication value, generate a notification for maintenance of the motion system.

8. The motion system of claim 7 , wherein the at least one processor is configured to calculate another health indication value, and wherein the another health indication value is a friction coefficient value that is computed using only the collected motion variables used by the servo drive.

9. The motion system of claim 8 , wherein the friction coefficient value is a viscous friction coefficient value or a Coulomb friction coefficient value.

10. The motion system of claim 9 , wherein at least one of the viscous friction coefficient value and the Coulomb friction coefficient value is derived using the equation:

T=J*A+B*w+C *( dw ),

where T is the torque, J is the inertia, A is the acceleration, B is the viscous friction coefficient value, w is the velocity value, C is the Coulomb friction coefficient value, and dw is the direction of velocity.

11. The motion system of claim 7 , wherein the at least one processor is configured to calculate another health indication value, and wherein the another health indication value is a total impact value that is computed using magnitudes of changes in acceleration based on the collected motion variables.

12. The motion system of claim 11 , wherein the at least one processor is configured to calculate the total impact value by computing a sum of the magnitudes of changes in acceleration at a plurality of instances and multiplying the sum with inertia of the motion system.