Learning programmable limit switch and method providing real-time passive feedback

A process for providing real-time passive feedback to facilitate maintaining a cycle time in a motion control system comprising the steps of:

• providing a programmable switch capable of receiving a motion profile comprising a plurality of setpoints associated with a driver;
• determining an actual motion profile associated with said driver;
• comparing said actual motion profile to said plurality of setpoints and adjusting a plurality of trigger points in response thereto;
• and
• generating said real-time passive feedback in response to said comparing step by adjusting outputs of said programmable switch in response to said comparing step such that said cycle time is achieved and maintained.

A programmable limit switch for providing passive feedback for use in a drive system comprising a driver under the control of a controller having a position indicated device associated therewith for providing a first position count and a second position count, said switch comprising:

• programming means for receiving a first programmed setpoint corresponding to a first position of said drive system, a second programmed setpoint corresponding to a second position of said drive system, a first initial trigger point corresponding to a first position at which said drive system performs a first change from a first speed to a second speed, and a second initial trigger point corresponding to a second position at which said drive system performs a second change from said second speed to a third speed;
• determining means for determining a first actual setpoint corresponding to said first position count generated by said position indicating device and a second actual setpoint corresponding to said second position count generated by said position indicating device;
• and
• learning means for comparing said first programmed setpoint to said first actual setpoint and said second programmed setpoint to said second actual setpoint, for adjusting at least one of said first initial trigger point or said second initial trigger point to provide an adjusted first trigger point or an adjusted second trigger point, respectively, in response to said comparison so that said first and second actual setpoints are within a predetermined tolerance range of said first and second programmed setpoints, respectively.

A drive system capable of maintaining a cycle time comprising:

• a motion control system comprising:
• a position indicated device associated with a driven driver, said position indicating device being capable of generating a plurality of detected position counts;
• a programmable controller capable of receiving a desired motion profile comprising a plurality of setpoints for said driven driver and for determining an actual motion profile using said plurality of detected position counts;
• and
• a processor for comparing said actual motion profile to said plurality of setpoints and adjusting a plurality of trigger points in response thereto in order to generate a real-time passive feedback by adjusting outputs of said programmable controller in response to said comparison such that said cycle time is maintained at a desired level.