System and method for automatic runtime position sensor offset calibration in a linear motion system

A system for automatic sensor offset determination in a linear drive system, the system comprising:

• a track defining a path along which a plurality of movers travel;
• a plurality of position sensors spaced along the track, wherein each of the plurality of position sensors generates a feedback signal responsive to at least one of the plurality of movers traveling past the position sensor;
• a memory device operative to store the feedback signal from each of the plurality of position sensors and to store a plurality of sensor offset values, wherein each sensor offset value corresponds to one of the plurality of position sensors;
• and
• a processor in communication with the memory device, wherein the processor receives the feedback signal from each of the plurality of position sensors and the processor is operative to:
• (a) store the feedback signal from each of the plurality of position sensors in the memory device when no mover is traveling past the position sensor,
• (b) generate a new sensor offset value for each of the plurality of position sensors as a function of the stored feedback signal from each of the plurality of position sensors and of a previously stored sensor offset value for each of the plurality of position sensors, and
• (c) overwrite the sensor offset value previously stored in the memory device with the new sensor offset value for each of the plurality of position sensors.