Method and Apparatus for Online Simulation of Complex Motion Systems

A system for simulating an axis of motion in an industrial controller, the system comprising:

• a processor module operative to execute a control program to control operation of a controlled machine or process;
• an axis controller operative to generate a first reference signal corresponding to a desired operation of the axis of motion;
• and
• a control module in communication with the axis controller, wherein the control module corresponds to a motor drive and is operative to receive the first reference signal from the axis controller and generate a second reference signal as a function of the first reference signal;
• and
• a simulation module operative to determine at least one of an estimated velocity and an estimated position of a motor to be controlled by the motor drive, wherein the simulation module includes a dynamic gain which varies as a function of the estimated velocity of the motor.

A method for simulating an axis of motion in an industrial controller, the method comprising the steps of:

• generating a first reference signal corresponding to a desired operation of the axis of motion with an axis controller;
• transmitting the first reference signal from the axis controller to a control module wherein the control module corresponds to a motor drive and receives the first reference signal as an input;
• generating a second reference signal with the control module as an output from at least one control loop;
• receiving the second reference signal as an input to a simulation module;
• and
• determining at least one of an estimated velocity and an estimated position of a motor controlled by the motor drive with the simulation module, wherein the first reference signal is generated at a first periodic interval, the second reference signal is generated at a second period interval, and the second periodic interval is longer than the first periodic interval.