5.5 An introduction to closed loop control

This section describes the basic principles of closed loop control. If you are familiar with closed loop control go straight to section 5.6.1.

When there is a requirement to move an axis, the NextMove BXII control software translates this into a demand output voltage. This is used to control the drive (servo amplifier) which powers the motor. An encoder or resolver on the motor is used to measure the motor’s position. Every 1ms (adjustable using the LOOPTIME keyword) the NextMove BXII compares the demanded and measured positions. It then calculates the demand needed to minimize the difference between them, known as the following error.

This system of constant measurement and correction is known as closed loop control.

[For the analogy, imagine you are in your car waiting at an intersection. You are going to go straight on when the lights change, just like the car standing next to you which is called Demand. You’re not going to race Demand though - your job as the controller (NextMove BXII) is to stay exactly level with Demand, looking out of the window to measure your position ].

The main term that the NextMove BXII uses to correct the error is called Proportional gain (KPROP). A very simple proportional controller would simply multiply the amount of error by the Proportional gain and apply the result to the motor [ the further Demand gets ahead or behind you, the more you press or release the gas pedal ].

If the Proportional gain is set too high overshoot will occur, resulting in the motor vibrating back and forth around the desired position before it settles [ you press the gas pedal so hard you go right past Demand. To try and stay level you ease off the gas, but end up falling behind a little. You keep repeating this and after a few tries you end up level with Demand, travelling at a steady speed. This is what you wanted to do but it has taken you a long time ].

If the Proportional gain is increased still further, the system becomes unstable [ you keep pressing and then letting off the gas pedal so hard you never travel at a steady speed ].

To reduce the onset of instability, a term called Velocity Feedback gain (KVEL) is used. This resists rapid movement of the motor and allows the Proportional gain to be set higher before vibration starts. Another term called Derivative gain (KDERIV) can also be used to give a similar effect.

With Proportional gain and Velocity Feedback gain (or Derivative gain) it is possible for a motor to come to a stop with a small following error [ Demand stopped so you stopped too, but not quite level ]. The NextMove BXII tries to correct the error, but because the error is so small the amount of torque demanded might not be enough to overcome friction.

In this situation, a term called Integral gain (KINT) can be used. This sums the error over time, so that the motor torque is gradually increased until the positional error is reduced to zero [ like a person gradually pushing harder and harder on your car until they’ve pushed it level with Demand]. However, if there is large load on the motor (it is supporting a heavy suspended weight for example), it is possible for the output to increase to 100% demand. This effect can be limited using the KINTLIMIT keyword which limits the effect of KINT to a given percentage of the demand output. Another keyword called KINTMODE can even turn off integral action when it’s not needed.

The remaining gain terms are Velocity Feed forward (KVELFF) and Acceleration Feed forward (KACCEL).

MN1904

Operation 5-11

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Baldor BXII installation manual An introduction to closed loop control
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BXII specifications

The Baldor BXII is a robust and versatile industrial motor known for its high performance and reliability in various applications. Designed for use in demanding environments, the BXII series is particularly favored in the food processing, petrochemical, and material handling industries. Its construction and technological features distinctly differentiate it from other motors in the market, enhancing efficiency and durability.

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