Motion controller design considerations for Hardware-in-the-Loop testing

Motion control systems consist of an electronic control unit (ECU), electric motor drive, motor, and the load that is being controlled. The ECU and motor drive can be tested separate from the motor and load by using hardware-in-the-loop (HIL) simulation. This allows for testing of the electronics without risking damage to the motor or load. The HIL computer uses a mathematical model, based on the physical parameters of the load, to perform the simulation. A motion control algorithm is presented that not only provides desirable control of the system, but also provides very accurate measurements of the physical parameters of the load. These parameters are then entered into the HIL computer mathematical model and result in an accurate simulation of the load.