Multi-dimensional motion performance modeling and real-time monitoring of a motion system

A non-transitory computer-readable storage medium containing program instructions for motion performance modeling and monitoring a motion system with an electric motor, wherein execution of the program instructions by one or more processors of a computer system causes the one or more processors to perform steps comprising:

• driving the electric motor to perform at least one sequence of motions;
• collecting multiple sets of motor operating variables as the electric motor is driven to perform the at least one sequence of motions, wherein each of the multiple sets of motor operating variables includes at least a motor current value, a motor position value and a motor velocity values that are synchronously collected at each moment in time, wherein the motor current value represents a current that is applied to drive the electric motor and the motor position value represents position data from an encoder;
• creating a baseline motion performance model of the motion system using the collected multiple sets of motor operating variables, wherein the baseline motion performance model includes points defined by the multiple sets of motor operating variables, each of the points representing at least one motor current value, one motor position value and one motor velocity value that were synchronously collected, wherein the baseline motion performance model of the motion system is a three-dimensional baseline motion performance model and wherein each of the points of the baseline motion performance model is represented by one motor current value, one motor position value and one motor velocity value, wherein creating the baseline motion performance model includes using an n by m grid defined by ranges of motor position values and motor velocity values, wherein first n by m array values are created for positive motor current values as maximum or average positive values and second n by m array values are created for negative motor current values as minimum or average negative values;
• after the baseline motion performance model of the motion system has been created, operating the electric motor;
• collecting multiple sets of real-time motor operating variables as the electric motor is operated, wherein each of the multiple sets of real-time motor operating variables includes at least a real-time motor current value, a real-time motor position value and a real-time motor velocity values that are synchronously collected;
• and
• computing deviation values between values of the baseline motion performance model and the collected real-time motor operating variables to determine a performance state of the motion system, wherein each deviation value is a difference between one real-time motor current values and a corresponding motor current value for a same pair of motor position and motor velocity values.

A motion system comprising:

• an electric motor;
• a motor controller configured to drive the electric motor to perform at least one sequence of motions;
• and
• a motion performance modeling and monitoring (MPMM) module, the MPMM module being configured to:
• collect multiple sets of motor operating variables as the electric motor is driven during a baseline modeling period, wherein each of the multiple sets of motor operating variables includes at least a motor current value, a motor position value and a motor velocity values that are synchronously collected at each moment in time, wherein the motor current value represents a current that is applied to drive the electric motor and the motor position value represents position data from an encoder;
• create a baseline motion performance model of the motion system using the collected multiple sets of motor operating variables, wherein the baseline motion performance model includes points defined by the multiple sets of motor operating variables, each of the points representing at least the motor current value, the motor position value and that motor velocity values that were synchronously collected, wherein the baseline motion performance model of the motion system is a three-dimensional baseline motion performance model and wherein each of the points of the baseline motion performance model is represented by one motor current value, one motor position value and one motor velocity value, wherein the baseline motion performance model is created using an n by m grid defined by ranges of motor position values and motor velocity values, wherein first n by m array values are created for positive motor current values as maximum or average positive values and second n by m array values are created for negative motor current values as minimum or average negative values;
• after the baseline motion performance model of the motion system has been created, collect multiple sets of real-time motor operating variables as the electric motor is driven during a normal operating period, wherein each of the multiple sets of real-time motor operating variables includes at least a real-time motor current value, a real-time motor position value and a real-time motor velocity values that are synchronously collected;
• and
• compute deviation values between values of the baseline motion performance model and the collected real-time motor operating variables to determine a performance state of the motion system, wherein each deviation value is a difference between one real-time motor current values and a corresponding motor current value for a same pair of motor position and motor velocity values.