System and method for managing automation systems with jerk compensation

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.