Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
   Not applicable. 
   STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
   Not applicable. 
   BACKGROUND OF THE INVENTION 
   The present invention relates to motor controllers and more specifically to methods and systems for identifying system inertia and load torque disturbances that are needed to properly tune motor controllers. 
   As well known in the motor control industry, motor/plant inertia identification is an important step in properly tuning a motor drive system. To this end, the way a motor and a linked load (i.e., the plant) respond to control signals (i.e., applied varying voltages) is directly related to motor/plant inertia and therefore, suitable control is directly related to plant inertia. One way to determine plant inertia has been to perform an inertia determining commissioning process prior to normal motor operation and then setting and assuming a constant system inertia value. While these processes work well, they have at least two primary shortcomings. 
   First, commissioning processes take time to complete and therefore slow the process of setting up a control/drive system. A related issue is that, typically, a skilled engineer or technician is required to properly perform a commissioning procedure and therefore there are costs associated with each additional commissioning step required to set up a drive system. 
   Second, in at least some applications system inertia changes during system operations. Where inertia changes during operation, the assumed constant value is erroneous and therefore drive control is less than optimal. 
   One solution in the case of a system where inertia changes during operation is to routinely rerun the inertia estimating commissioning procedure (e.g., once a day). This solution, however, increases the time required to maintain an accurate estimate and does not work well where system inertia fluctuates during the interim periods between recalculation. 
   BRIEF SUMMARY OF THE INVENTION 
   It has been recognized that a position feedback signal and a derivable motor torque signal can be used to continually generate a system inertia estimate during normal drive operation and the inertia estimate can then be used to continually tune the drive system. Because the inertia estimate is generated during normal operation there is no need for a separate commissioning procedure. Because the inertia estimate is continually updated the estimate is always accurate and drive control is optimized. 
   Consistent with the above, at least some inventive embodiments include a method for estimating a system inertia and a load torque in a motor controller, the method comprising the steps of providing an acceleration command signal, determining a motor position, using the motor position to generate an acceleration feedback signal, mathematically combining the acceleration feedback signal and a load torque signal to generate a system inertia estimate, mathematically combining the system inertia estimate and the acceleration command signal to generate a motor torque signal, mathematically combining the system inertia estimate and the acceleration feedback signal to generate an inertia torque and mathematically combining the inertia torque and the motor torque signal to generate the load torque estimate. 
   In at least some cases the step of providing an acceleration command signal includes providing a velocity command signal, deriving a velocity feedback signal from the motor position and subtracting the motor velocity feedback signal from the velocity command signal. In some cases the step of mathematically combining the acceleration feedback signal and the load torque signal includes filtering the load torque signal to generate a load torque difference signal, multiplying the acceleration feedback signal and the load torque difference signal to generate an inertia product signal and integrating a derivative of the inertia product signal to generate the system inertia estimate. 
   In some cases the step of mathematically combining the system inertia estimate and the acceleration command signal to generate a motor torque signal includes multiplying a derivative of the system inertia estimate and the acceleration command signal to generate a torque command signal and limiting the torque command signal to generate the motor torque signal. In some embodiments the step of multiplying a derivative of the system inertia estimate and the acceleration command signal includes low pass filtering the system inertia estimate to generate the derivative of the system inertia estimate. 
   In other cases the step of mathematically combining the system inertia estimate and the acceleration feedback signal to generate an inertia torque includes multiplying the system inertia estimate by the acceleration feedback signal to generate the inertia torque. In some cases the step of mathematically combining the inertia torque and the motor torque signal to generate a load torque estimate includes subtracting the inertia torque from the motor torque signal to generate the load torque estimate. In some cases the step of using the load torque estimate to generate the load torque difference signal includes band pass filtering the load torque estimate. 
   Other embodiments include a method for deriving a system inertia estimate and a load torque estimate in a motor controller, the method comprising the steps of providing a velocity command signal, sensing a motor position, using the motor position to generate a velocity feedback signal and an acceleration feedback signal, subtracting the velocity feedback signal from the velocity command signal to generate a velocity error signal, using the velocity error signal to generate an acceleration command signal, multiplying the acceleration feedback signal and a load torque difference signal to generate an inertia product signal, using the inertia product signal to generate the system inertia estimate, multiplying the system inertia estimate and the acceleration command signal to generate a motor torque signal, multiplying the acceleration feedback signal and the system inertia estimate to generate an inertia torque, subtracting the inertia torque from the motor torque signal to generate the load torque estimate and filtering the load torque estimate to generate the load torque difference signal. 
   In some cases the step of using the inertia product signal to generate the system inertia estimate includes scaling the inertia product signal and integrating the scaled product signal to derive the system inertia estimate. In some case the step of filtering the load torque estimate includes band pass filtering the load torque estimate. 
   Still other embodiments include an apparatus for estimating a system inertia and a load torque in a motor controller, the apparatus comprising a processor programmed to perform the steps of providing an acceleration command signal, determining a motor position, using the motor position to generate an acceleration feedback signal, mathematically combining the acceleration feedback signal and a load torque signal to generate a system inertia estimate, mathematically combining the system inertia estimate and the acceleration command signal to generate a motor torque signal, mathematically combining the system inertia estimate and the acceleration feedback signal to generate an inertia torque and mathematically combining the inertia torque and the motor torque signal to generate the load torque estimate. 
   In some cases the processor is programmed to perform the step of providing an acceleration command signal by providing a velocity command signal, deriving a velocity feedback signal from the motor position and subtracting the motor velocity feedback signal from the velocity command signal. In some cases the processor is programmed to perform the step of mathematically combining the acceleration feedback signal and the load torque signal by filtering the load torque signal to generate a load torque difference signal, multiplying the acceleration feedback signal and the load torque difference signal to generate an inertia product signal and integrating a derivative of the inertia product signal to generate the system inertia estimate. In some cases the processor is programmed to perform the step of mathematically combining the system inertia estimate and the acceleration command signal to generate a motor torque signal includes multiplying a derivative of the system inertia estimate and the acceleration command signal to generate a torque command signal and limiting the torque command signal to generate the motor torque signal. In some cases the processor is programmed to perform the step of multiplying a derivative of the system inertia estimate and the acceleration command signal by low pass filtering the system inertia estimate to generate the derivative of the system inertia estimate. 
   In some embodiments the processor is programmed to perform the step of mathematically combining the system inertia estimate and the acceleration feedback signal to generate an inertia torque includes multiplying the system inertia estimate by the acceleration feedback signal to generate the inertia torque. In some other cases the processor is programmed to perform the step of mathematically combining the inertia torque and the motor torque signal to generate a load torque estimate includes subtracting the inertia torque from the motor torque signal to generate the load torque estimate. In some cases the processor is programmed to perform the step of using the load torque estimate to generate the load torque difference signal includes band pass filtering the load torque estimate. 
   To the accomplishment of the foregoing and related ends, the invention, then, comprises the features hereinafter fully described. The following description and the annexed drawings set forth in detail certain illustrative aspects of the invention. However, these aspects are indicative of but a few of the various ways in which the principles of the invention can be employed. Other aspects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings. 

   
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       FIG. 1  is a schematic diagram illustrating a drive/plant system that is consistent with at least some aspects of the present invention; 
       FIG. 2  is a flow chart for estimating system inertia and a load torque that is consistent with at least some aspects of the present invention; 
       FIG. 3  is a graph illustrating actual and estimated system inertia as a function of time; and 
       FIG. 4  is a graph illustrating a motor torque, a load torque, a load torque estimate and a filtered load torque estimate derived using the inventive methods. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring now to the drawings wherein like reference numeral correspond to similar elements throughout the several views and, more specifically, referring to  FIG. 1 , the present invention will be described in the context of an exemplary controller/plant system  10  that includes first, second and third summers  12 ,  26  and  32 , respectively, a velocity regulator  14 , first, second and third multipliers  16 ,  34  and  42 , respectively, a torque/current limiter module  18 , a delay module  20 , a torque/current regulator  22 , an inertia system  24 , first, second and third low pass filters  28 ,  30  and  48 , respectively, an integrator module  46 , a analog to digital converter  36 , a scaling module  44  and first and second derivative modules  38  and  40 , respectively. 
   Referring still to  FIG. 1 , inputs to system  10  include a velocity command signal ω* and a load torque signal T L  where command signal ω* is provided by a system user the load torque signal T L  is the torque applied to the system by a load (e.g., items resting on a conveyor belt, a roll of paper being unwound by a motor, etc.). A position sensing device is linked to inertia system  24  to sense position of a motor associated therewith and provide an analog position signal to converter  36 . Converter  36 , as the label implies, converts the analog position signal to a digital position feedback signal P f  which is provided to first derivative module  38 . 
   First derivative module  38  takes the derivative of the position feedback signal P f  and thereby generates a velocity feedback signal ω f  which is provided to derivative module  40 . Second derivative module  40  take the derivative of the velocity feedback signal ω f  and thereby generates an acceleration feedback signal a f  which is provided to both multipliers  42  and  34 . 
   Velocity feedback signal ω f  is provided to summer  12 . Summer  12  subtracts the velocity feedback signal ω f  from the velocity command signal ω* to generate a velocity error signal ω e  which is provided to velocity regulator  14 . Velocity regulator  14  uses the velocity error signal ω e  to generate an acceleration command signal a* which is provided to multiplier  16 . 
   Multiplier  16  multiplies a filtered system inertia estimate I e  and the acceleration command signal a* to generate a torque command signal T* which is provided to the torque/current limiter module  18 . Limiter module  18  limits the torque command value T* to within a predefined range and provides the limited value to delay module  20 . As the label implies, delay module  20  delays the limited value and generates a motor torque command signal T* m . Motor torque command T* m  is provided to the torque/current regulator  22  which regulates current applied to inertia system  24 . System  24  includes a motor and load. 
   Referring again to  FIG. 1 , multiplier  42  multiplies the acceleration feedback signal a f  by a filtered load torque difference signal T LΔ  to generate an inertia product signal. Scaler module  44  scales the inertia product signal and provides its output to integrator  46 . Integrator  46  integrates the scaled inertia product signal to generate a system inertia estimate I est . System inertia estimate I est  is provided to multiplier  34  and also to low pass filter  48 . 
   Low pass filter  48  filters out high frequency components of the system inertia estimate I est  and provides the filtered inertia estimate to multiplier  16  which is used, along with the acceleration command signal a* to generate the torque command signal T*. 
   At multiplier  34  the system inertia estimate I est  is multiplied by the acceleration feedback signal a f  to generate an inertia torque signal T l . Summer  26  subtracts the inertia torque signal T l  from the motor torque command signal T* m  to generate a load torque estimate T Lest . Load torque estimate T Lest  is provided to low pass filter  28  which filters out high frequency components of the value estimate T Lest  thereby generating a filtered load torque value T Lf1 . The filtered load torque value T Lf1  is provided to summer  32  and to low pass filter  30 . Here, filter  30  has a lower frequency set point than filter  28  and therefore filters out at least a portion of the signal passed by filter  28  corresponding to an upper range of frequencies passed by filter  28 . The output of filter  30  is provided to summer  32 . Summer  32  subtracts the output T Lf2  from filter  30  from the filtered load torque T Lf1  thereby generating the filtered load torque difference signal T LΔ  which is provided to multiplier  42 . 
   Referring to  FIG. 2 , an exemplary method  50  that is consistent with at least some aspects of the present invention is illustrated that may be performed by a processor programmed to perform the processes associated with the modules in  FIG. 1  described above. To this end, at process block  52 , a velocity command signal ω* is provided. At block  54 , motor position is sensed and at block  56  the motor position is used to generate a velocity feedback signal and an acceleration feedback signal (see modules  38  and  40  in  FIG. 1 ). At block  58 , the velocity feedback signal is subtracted from the velocity command signal to generate a velocity error signal (see summer  12  in  FIG. 1 ). At block  60 , the velocity error signal is used to generate an acceleration command signal (see regulator  14  in  FIG. 1 ). At block  62 , the acceleration feedback signal and the load torque difference signal are multiplied to generate an inertia product signal (see multiplier  42  in  FIG. 1 ). At block  64 , the inertia product signal is scaled up and integrated to generate the inertia estimate signal I est  (see  44  and  46  in  FIG. 1 ). 
   Continuing, referring still to  FIG. 2 , at block  68 , the system inertia estimate and the acceleration command signal are multiplied to generate a motor torque command signal T* m . At block  70  the acceleration feedback signal is multiplied by the system inertia estimate to generate inertia torque signal T I  (see multiplier  34  in  FIG. 1 ). At block  72 , the inertia torque signal is subtracted from the motor torque to generate a load torque estimate (see summer  26  in  FIG. 1 ). At block  74 , the load torque estimate T Lest  is filtered (see filter modules  28  and  30  in  FIG. 1 ) to generate the load torque difference signal T LΔ . 
   Referring now to  FIG. 3 , a graph is provided that includes a smooth sinusoidal system inertia value I actual  and a stepped sinusoidal estimated inertia value I est  derived using the inventive system. As shown, the inertia estimate generally tracks the actual system inertia.  FIG. 4  includes waveforms corresponding to a motor torque T M , a load torque T L  and load torque estimate T Lest  and a filtered load torque estimate T Lf1  where it can be seen that the load torque estimate T Lest  generally tracks the load torque T L  and the filtered estimate even more closely follows the load torque T L . As the inertia and load torque are calculated those values are used to modify drive control. 
   One or more specific embodiments of the present invention have been described above. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers&#39; specific goals, such as compliance with system-related and business related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure. 
   Thus, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following appended claims. 
   To apprise the public of the scope of this invention, the following claims are made:

Technology Category: 3