Motor drive, production system and method thereof with quality measuring and mechanism diagnosing functions using real and virtual system modules

A production system, comprising:

• a production device selectively operated in a system identification mode, a processing mode or an idle mode, wherein the production device manufactures a processed product in the processing mode, wherein the production device comprises:
• at least one motor;
• at least one sensor configured to sense the at least one motor and a motor-related mechanism to acquire at least one operation parameter;
• at least one controller configured to provide a processing strategy;
• and
• at least one drive connected with the at least one motor and the at least one controller to receive the at least one operation parameter from the at least one sensor and drive operations of the motor according to the processing strategy, wherein the drive comprises:
• a real system driving module, wherein when the production device is in the processing mode, the real system driving module generates a mechanism real operation parameter information according to the processing strategy of the controller and an external force disturbance;
• and
• a virtual system driving module comprising a quality measurement and mechanism diagnosis parameter processing module, wherein when the production device is in the system identification mode, the quality measurement and mechanism diagnosis parameter processing module creates at least one virtual mechanism model, wherein when the production device is in the processing mode or the idle mode, the quality measurement and mechanism diagnosis parameter processing module generates a mechanism stimulation operation parameter information according to the processing strategy of the controller, the mechanism real operation parameter information and the at least one virtual mechanism model;
• a server connected with the controller;
• and
• a quality measurement and mechanism diagnosis module installed in at least one of the controller and the server, wherein the quality measurement and mechanism diagnosis module performs a quality measurement operation, performs a mechanism diagnosis operation and/or adjusts the processing strategy according to the mechanism real operation parameter information and the mechanism stimulation operation parameter information.

An operating method for a production system, the production system comprising a production device, a server and a quality measurement and mechanism diagnosis module, the production device comprising at least one motor, at least one sensor, at least one controller and at least one drive, the drive comprising a real system driving module and a virtual system driving module, the quality measurement and mechanism diagnosis module being installed in at least one of the controller and the local server, the operating method comprising steps of:

• (S1) the production device entering a system identification mode, and the virtual system driving module of the drive creating at least one virtual mechanism model;
• (S2) the controller generating a processing strategy and sending the processing strategy to the drive to drive operations of the motor;
• (S3) the production device entering a processing mode, the real system driving module of the drive generating a mechanism real operation parameter information according to the processing strategy of the controller and an external force disturbance and the virtual system driving module generating a mechanism stimulation operation parameter information according to the processing strategy of the controller, the mechanism real operation parameter information and the at least one virtual mechanism model, wherein the mechanism real operation parameter information includes a motor driving command and a motor operation parameter information, and the mechanism stimulation operation parameter information includes a pre-estimated external force disturbance;
• and
• (S4) the production device manufacturing at least one processed product, wherein the quality measurement and mechanism diagnosis module performs a quality measurement operation on the processed product according to the motor operation parameter information and the pre-estimated external force disturbance.