System and method for managing automation systems with jerk compensation
View Patent ↗A method for managing an automation system involving asynchronous and synchronous zones, the method including: determining when a moving element enters a merge zone between an asynchronous zone and a synchronous zone; calculating additive jerk to be applied to the moving element, In some cases, the additive jerk is based on predetermined compensation profiles; determining if the master position change is different than a base logged; if so, interpolating additive jerk based on movement characteristics of the moving element; in either event, applying the additive jerk to the moving element; and determining if the merge is completed and, if yes, ending the merge and continue with synchronous operation but, if no, returning to calculating the additive jerk and repeat. A system including a processor/controller and a memory including instructions, which when executed by the processor/controller, perform the method.
1 . A method for managing an automation system involving asynchronous and synchronous zones, the method comprising:
providing a master signal comprising base movement characteristics;
determining predetermined compensation profiles based on the base movement characteristics to be applied to a second automation element comprising a moving element;
determining when the moving element enters a merge zone between an asynchronous zone and a synchronous zone, wherein the moving element is to be controlled synchronously with the first automation element;
calculating additive jerk to be applied to movement characteristics of the moving element, wherein the additive jerk is based on the predetermined compensation profiles;
determining if a master signal position change is different than the base movement characteristics of the master signal previously logged;
if so, interpolating additive jerk based on the master signal position change compared to the base movement characteristics;
in either event, applying the additive jerk to the movement characteristics of the moving element;
determining if the merge is completed, if yes, ending the merge and continue with synchronous operation but, if no, returning to calculating the additive jerk and repeat.
2 . A method according to claim 1 , wherein the predetermined compensation profiles are determined in advance.
3 . A method according to claim 1 , wherein the predetermined compensation profiles comprise a velocity compensation profile and a position compensation profile.
4 . A method according to claim 1 , wherein calculating additive jerk based on predetermined compensation profiles comprises determining the movement characteristics of the moving element based on the compensation profiles.
5 . A method according to claim 1 , further comprising determining if the moving element needs to stop prior to or within the merge zone to allow synchronization.
6 . A method according to claim 5 , further comprising calculating a minimum stop position based on maximum entry velocity.
7 . A method according to claim 1 , further comprising:
determining a lowest possible time remaining to enter the synchronous zone;
determining if the moving element needs to stop based at least in part on the lowest possible time;
if so, stop the moving element at a minimum stopping position and determine when to start moving and next possible index;
in either case, determining velocity compensation and position compensation profiles to match velocity and position; and
determining the movement characteristics for the moving element based on the compensation profiles.
8 . A system for managing an automation system involving asynchronous and synchronous zones, the system comprising:
a master controller for controlling a first synchronous element, the master controller providing a master signal, wherein the master signal comprises base movement characteristics;
a second controller for controlling a second synchronous element based on the master signal, wherein the second synchronous element is different from the first synchronous element and comprises a moving element moving on a conveyor;
a configuration module for configuring predetermined compensation profiles for the second synchronous element based on the base movement characteristics;
a memory storing instructions that, when executed by the second controller, cause the second controller to:
determine when the moving element enters a merge zone between an asynchronous zone and a synchronous zone;
calculate additive jerk to be applied to movement characteristics of the moving element, wherein the additive jerk is based on the predetermined compensation profiles;
determine if a master signal position change is different than the base movement characteristics of the master signal previously logged;
if so, interpolate additive jerk based on the master signal position change compared to the base movement characteristics;
in either event, apply the additive jerk to the movement characteristics of the moving element;
determine if the merge is completed, if yes, end the merge and continue with synchronous operation but, if no, return to calculating the additive jerk and repeat.
9 . A system according to claim 8 , wherein the predetermined compensation profiles are determined in advance.
10 . A system according to claim 8 , wherein the predetermined compensation profiles comprise a velocity compensation profile and a position compensation profile.
11 . A system according to claim 8 , wherein calculating additive jerk based on predetermined compensation profiles comprises determining the movement characteristics of the moving element based on the compensation profiles.
12 . A system according to claim 8 , further comprising determining if the moving element needs to stop prior to or within the merge zone to allow synchronization.
13 . A system according to claim 12 , wherein the instructions further comprise causing the second controller to calculate a minimum stop position based on maximum entry velocity.
14 . A system according to claim 8 , wherein the instructions further comprise causing the second controller to:
determine a lowest possible time remaining to enter the synchronous zone;
determine if the moving element needs to stop based at least in part on the lowest possible time;
if so, stop the moving element at a minimum stopping position and determine when to start moving and next possible index;
in either case, determine velocity compensation and position compensation profile to match velocity and position; and
determine the movement characteristics for the moving element based on the compensation profiles.