Drive System Application

Closed-loop torque control and load distribution

Application describtion
for SINAMICS G120 and MICROMASTER 440
 Warranty, liability and support

Closed-loop torque control and load distribution ID-No: 23939668

Note The Application Examples are not binding and do not claim to be
complete regarding the circuits shown, equipping and any eventuality.
The Application Examples do not represent customer-specific solutions.
They are only intended to pro-vide support for typical applications. You
are responsible in ensuring that the de-scribed products are correctly
used. These Application Examples do not relieve you of the responsibility
in safely and professionally using, installing, operating and servicing
equipment. When using these Application Examples, you recognize that
Siemens cannot be made liable for any damage/claims beyond the
liability clause described. We reserve the right to make changes to these
Application Examples at any time without prior notice. If there are any
deviations between the recommendations provided in these Application
Examples and other Siemens publications - e.g. Catalogs - then the
contents of the other documents have priority.

Warranty, liability and support

Closed-loop_torque_ load_distribution_en_V1_1.doc
Copyright © Siemens AG 2009 All rights reserved

We do not accept any liability for the information contained in this

document.
Any claims against us - based on whatever legal reason - resulting from the
use of the examples, information, programs, engineering and performance
data etc., described in this Application Examples shall be excluded. Such
an exclusion shall not apply in the case of mandatory liability, e.g. under
the German Product Liability Act (“Produkthaftungsgesetz”), in case of
intent, gross negligence, or injury of life, body or health, guarantee for the
quality of a product, fraudulent concealment of a deficiency or breach of a
condition which goes to the root of the contract (“wesentliche
Vertragspflichten”). However, claims arising from a breach of a condition
which goes to the root of the contract shall be limited to the foreseeable
damage which is intrinsic to the contract, unless caused by intent or gross
negligence or based on mandatory liability for injury of life, body or health
The above provisions does not imply a change in the burden of proof to
your detriment.
Copyright© 2009 Siemens A&D. It is not permissible to transfer or
copy these Application Examples or excerpts of them without first
having prior authorization from Siemens A&D in writing.
If you have any recommendations relating to this document then please
send them to us at the following e-mail address:
mailto:[email protected]

Version ID 1.1 Issue July 2009 2/26

 Preposition

Closed-loop torque control and load distribution ID-No: 23939668

Preposition
Aim of the application
This application description was generated in order to provide users with a
better understanding of closed-loop torque control and load distribution.

Core contents of this application

The following core points are handled in this application:
• Closed-loop torque control
• Load distribution

Scope
This application does not include any specific description for
Closed-loop_torque_ load_distribution_en_V1_1.doc
Copyright © Siemens AG 2009 All rights reserved

• Winders and unwinders

Reference to the Automation and Drives Service & Support

This article is from the Internet Application Portal of the Automation and
Drives Service & Support. You can go directly to the download page of this
document using this link.
http://support.automation.siemens.com/WW/view/en/23939668

Version ID 1.1 Issue July 2009 3/26

 Preposition

Closed-loop torque control and load distribution ID-No: 23939668

Table of Contents
Table of Contents ......................................................................................................... 4
Application description................................................................................................ 5
1 Closed-loop torque control............................................................................ 5
1.1 Applications ...................................................................................................... 5
1.2 Operating behavior ........................................................................................... 5
1.3 Circuit versions ................................................................................................. 6
1.3.1 Closed-loop torque control with an encoder ..................................................... 6
1.3.2 Closed-loop torque control without an encoder ................................................ 7
1.3.3 Off command .................................................................................................... 9
1.3.4 Maximum speed ............................................................................................... 9
1.3.5 Limits .............................................................................................................. 10
1.3.6 Changing over to closed-loop torque control .................................................. 12
1.3.7 Closed-loop control by limiting the torque....................................................... 14
Closed-loop_torque_ load_distribution_en_V1_1.doc

1.4 Torque display ................................................................................................ 16

Copyright © Siemens AG 2009 All rights reserved

1.5 Speed monitoring............................................................................................ 17

2 Pre-control..................................................................................................... 18
3 Closed-loop load distribution control......................................................... 20
3.1 Problems associated with group drives .......................................................... 20
3.2 Load distribution using individual drives ......................................................... 22
3.2.1 Droop .............................................................................................................. 22
3.2.2 Master / slave drive with speed encoder ........................................................ 23
3.2.3 Master/slave drive without speed encoder ..................................................... 25
Apendix and references ............................................................................................. 26
4 References .................................................................................................... 26
4.1 Reference data ............................................................................................... 26
4.2 Internet-Link-Data ........................................................................................... 26
4.3 Historie............................................................................................................ 26

Version ID 1.1 Issue July 2009 4/26

 Application description
Closed-loop torque control

Closed-loop torque control and load distribution ID-No: 23939668

Application description

1 Closed-loop torque control

In addition to a wide range of applications where drives are used to control
the speed (variable-speed drives), there are also numerous cases where it
is necessary to control the drive torque.

1.1 Applications

Typical applications for closed-loop torque controls are as follows

Axial winder: Axial winders are used to wind and unwind material webs,
cables, wires etc. Constant speed is not decisive – but instead constant
tension over the complete winding range. The tension is controlled using a
dancer roll, with tension measuring transducer or indirectly using the motor
Closed-loop_torque_ load_distribution_en_V1_1.doc

torque.
Copyright © Siemens AG 2009 All rights reserved

Slave drives: For mechanically coupled drives, such as e.g. traversing

drives with several driven axes or roller table drives that are then coupled
through the material then it is important to uniformly distribute the load
between the individual drive motors. For applications with single-motor
drives, the master drive is operated with closed-loop speed control and the
slave (following) drives are operated with closed-loop torque control.
Traversing/moving to a fixed endstop, actuator drives: Also here, when an
end position is reached, a defined actuating torque may not be exceeded.

1.2 Operating behavior

Equation relating to motion apply to drives with closed-loop torque control.

This means that they are only dependent on the magnitude of the motor
torque available, the magnitude of the load torque and the total moment of
inertia of the mechanical set-up.
2π Δn
Tmotor − Tload − T friction = J total ∗ ∗
60 Δt
If the motor torque is greater than the sum of the load torque and friction
torque, then the drive accelerates; if the load torque and friction torque are
greater than the motor torque, then the drive brakes. The drive only
maintains its speed if the motor torque is equal to the load torque plus the
friction torque.

Version ID 1.1 Issue July 2009 5/26

 Application description
Closed-loop torque control

Closed-loop torque control and load distribution ID-No: 23939668

1.3 Circuit versions

1.3.1 Closed-loop torque control with an encoder

Parameter range: P1300, P1500 – P1511

P1400 – P1780
Alarms -
Fault -
Function chart number 1: FP7210, FP7710

Pure closed-loop torque control systems are generally used if there is a

higher-level technology control. This technology control calculates the
necessary torque and in an emergency ensures that the drive is brought to
a standstill (zero speed) in a controlled fashion.
The closed-loop torque control with encoder is selected using parameter
Closed-loop_torque_ load_distribution_en_V1_1.doc
Copyright © Siemens AG 2009 All rights reserved

P1300 = 23. The torque setpoint and supplementary setpoint are selected
using BICO parameter P1503 (CI: Torque setpoint) or P1511 (CI:
Supplementary torque setpoint). The instantaneous setpoint and the
supplementary setpoint are added; the complete setpoint can be seen with
r1508. The setpoint is then limited to the maximum permissible value (refer
to limits). In order to obtain the setpoint for the active current, the torque
setpoint must be divided by the motor flux. The difference between the
active current setpoint and the actual value is entered into the active
current controller whose output is decisive when defining the drive inverter
output voltage. The drive inverter output frequency is defined by the speed
actual value signal received from the encoder - that is then supplemented
by the motor slip determined by the current model as well as the monitor
model of the vector control. The closed-loop vector control is continually in
the controlled state when using a speed feedback signal; the only
changeover that is made is between the current and the monitor model.

1
Please find the Function charts in the parameter list of the respective Inverter

Version ID 1.1 Issue July 2009 6/26

 Application description
Closed-loop torque control

Closed-loop torque control and load distribution ID-No: 23939668

Closed-loop_torque_ load_distribution_en_V1_1.doc
Copyright © Siemens AG 2009 All rights reserved

Figure 1-1 Closed-loop torque control with an encoder

1.3.2 Closed-loop torque control without an encoder

Parameter range: P1300, P1500 – P1511

P1400 – P1780
Alarms -
Fault -
Function chart number 1: FP7200, FP7700

Closed-loop torque control without encoder is selected using parameter

P1300 = 22. The torque setpoint and supplementary setpoint are in turn
selected using BICO parameter P1503 (CI: Torque setpoint) and P1511
(CI: Supplementary torque setpoint). The torque setpoint and the
supplementary setpoint are added; the complete setpoint can be seen with
r1508. The setpoint is then limited to the maximum permissible value (refer
to limits). In order to obtain the setpoint for the active current, the torque
setpoint must be divided by the machine flux. The difference between the
active current setpoint and the actual value is entered into the active

1
Please find the Function charts in the parameter list of the respective Inverter

Version ID 1.1 Issue July 2009 7/26

 Application description
Closed-loop torque control

Closed-loop torque control and load distribution ID-No: 23939668

current controller whose output is decisive when defining the drive inverter
output voltage. Contrary to closed-loop torque control with encoder the
speed actual value is now calculated in the monitor model.

CO: Lower trq. lim CO: Upper trq. lim Motoring power lim Regener. power lim
-99999.0 ... 99999.0 [Nm] -99999.0 ... 99999.0 [Nm] 0.0 ... 8000.0 -8000.0 ... 0.0
P1521.D (-5.13) P1520.D (5.13) P1530.D (0.75) P1531.D (-0.75)
CI: Upper trq. lim
P1522.C
(1520:0)
CI: Lower trq. lim
Torque limitation r1539
P1523.C
CO:Total lw TrqLim [Nm]
(1521:0)

r0067 CO:Total up TrqLim [Nm] Int.time cur. ctrl *)

CO: Outp cur limit [A] r1538 1.0 ... 50.0 [ms]
P1717.D (4.1) CO: Act. Vdc [V]
CI: Add. trq. setp *) Motor ovl fact [%]
P1511.C CO: Add. trq. setp [Nm] CO: Torque setp. [Nm] 10.0 ... 400.0 [%] Gain current ctrl. *) r0070
(0:0) r1515 P0640.D (150.0) CO: Total trq setp [Nm] 0.0 ... 5.0
r1508
P1715.D (0.25)
r0079 CO: Act. outp.volt [V] CO: Output current [A]
CI: Torque setp. *) r0072 r0068
P1503.C
x
(0:0)
y
–

r0030
CO: Fval flux setp
Tot/mot inert.rat. Inertia [kg*m^2] 50.0 ... 200.0 [%] CO: Max. outp.volt [V] CO: Torque gen.cur [A] Voltage
Asyc.
1.000 ... 400.000 0.00010 ... 1000.0 P1570.D (100.0) r0071 Mot. 3~
P0342.D (1.000) P0341.D (0.00180) Kp Tn
Max. frequency
0.00 ... 650.00 [Hz] Efficiency optimiz
P1082.D (50.00) 0 ... 100 [%]
P1580.D (0) Pulse frequency
Cont. torque boost 2 ... 16 [kHz]
–
0.0 ... 200.0 [%] P1800 (4)
Closed-loop_torque_ load_distribution_en_V1_1.doc

– P1610.D (50.0)
Copyright © Siemens AG 2009 All rights reserved

CO: Act. frequency [Hz] r0029

Acc trq boost SLVC
Max. frequency 30 ms CO: Flux gen. cur. [A]
r0063 0.0 ... 200.0 [%]
0.00 ... 650.00 [Hz] P1611.D (0.0)
P1082.D (50.00)
Scal acc. trq ctrl r0066
0.0 ... 400.0 [%] + + CO: Act. outp freq [Hz]
P1499.D (100.0)
Current Observer
model r0065 model
CO: Slip frequency [%]

Kp n-adapt. (SLVC) *) Tn n-adapt. (SLVC) *)

0.0 ... 2.5 1.0 ... 200.0 [ms]
P1764.D (0.2) P1767.D (4.0)

Figure 1-2 Block circuit diagram, closed-loop torque control without an encoder

Closed-loop controlled range / open-loop controlled range

For the closed-loop torque control without encoder (P1300 = 22) there is an
open-loop controlled range (current model) (0Hz < f < P1755) and a closed-
loop controlled range (monitor model) (P1755 < f).
In the open-loop controlled range, the torque setpoint changes the setpoint
speed using a ramp-up integrator. In this case it is important to correctly
enter the motor moment of inertia (P0341) as well as the ratio between the
motor moment of inertia and the total drive moment of inertia (P0342). The
drive accelerates faster the higher the setpoint torque and the lower the
moment of inertia. Scaling the ramp-up integrator with P1499 is used to
equalize the rate that the speed increases in the open-loop controlled and
closed-loop controlled range if a constant setpoint torque is entered.
At the same time, a stator current is impressed in the motor that is set using
the flux model as a result of
• a static component (P1610) and a
• dynamic component (P1611).
The static component must be set corresponding to the starting torque to
be provided in the worst case. For example, if for an extruder drive 150%

Version ID 1.1 Issue July 2009 8/26

 Application description
Closed-loop torque control

Closed-loop torque control and load distribution ID-No: 23939668

rated motor torque can be used as starting torque then P1610 > 150 % (+
10 – 20 % reserve) should be set. The dynamic component P1611 - that is
only active while accelerating - has, in this case, no significance. It only
makes sense to use the dynamic component if the drive involves a very
high inertia load and the steady-state (frictional) torque is low compared to
the accelerating torque to be provided.
After the changeover frequency P1755 is reached, the monitor model
becomes active and the speed actual value can now be calculated with
sufficient accuracy. The speed integrator is held in the monitor model and
the monitor alone forms the speed actual value. If the drive returns to open-
loop controlled operation, the ramp-function generator output is set to the
last actual value to avoid a setpoint step. For a setpoint torque of 0%, the
ramp-up integrator output is ramped-down to zero speed corresponding to
a fictitious friction.

Important:
Closed-loop torque control that automatically sets the speed itself is only
possible in the closed-loop controlled range - but not in the open-loop
Closed-loop_torque_ load_distribution_en_V1_1.doc
Copyright © Siemens AG 2009 All rights reserved

controlled range.
The motor current set via P1610 - that under certain circumstances can be
very high - flows in the open-loop controlled state as long as the drive is
operated with a motor frequency of < P1755; this is independent of the
magnitude of the load torque to be actually provided.

1.3.3 Off command

For closed-loop torque control with as well as without encoder (P1300 = 22,
23) the following applies:
If, with the closed-loop torque control active, a fast stop command (OFF3)
is output, then the system automatically changes over to closed-loop speed
control and the drive brakes. For a normal stop command (OFF1) the drive
is directly powered-down (the same as for an OFF2).

1.3.4 Maximum speed

Closed-loop torque control systems without the possibility to changing over

to closed-loop speed control have the problem that when a torque is
specified and the load is disconnected, the drive accelerates along the
torque limit. In order to prevent mechanical damage when this happens -
above the maximum speed (plus 3 %), a speed limiting controller reduces
the torque limits in order to prevent the drive from continuing to accelerate.

Version ID 1.1 Issue July 2009 9/26

 Application description
Closed-loop torque control

Closed-loop torque control and load distribution ID-No: 23939668

1.3.5 Limits

The complete setpoint for the torque is limited to maximum permissible

values using quite a complex circuit.

Rated mot. current Motor temperatur

0.01 ... 10000.00 [A] Inverter temperatur CO: Outp cur limit
P0305.D (3.25) i2t inverter r0067
Motor ovl fact [%] Imax
10.0 ... 400.0 [%]
Motor stall
P0640.D (150.0)
protection
From flux setpoint Id
CO: Upper trq. lim
-99999.0 ... 99999.0 [Nm] CO: Upper trq. lim
P1520.D (5.13) CI: Upper trq. lim r1526
P1522.C
(1520:0)
r1538
MIN
+ CO:Total up TrqLim
Regener. power lim Power limitation
-8000.0 ... 0.0
P1531.D (-0.75) Speed limitation
controller
Motoring power lim M [Nm] =
(only for torque
Scal. low trq. lim 0.0 ... 8000.0 1000 ⋅ P [kW ] control)
CO: Lower trq. lim -400.0 ... 400.0 [%] P1530.D (0.75) 2⋅π⋅f
-99999.0 ... 99999.0 [Nm] P1525.D (100.0)
P1521.D (-5.13) CI: Lower trq. lim act. frequency -1
MAX −
P1523.C r1539
(1521:0)
CO:Total lw TrqLim
r1527
*)
CO: Lower trq. lim

CI: Add. trq. setp **) CO: Add. trq. setp

r1515
Closed-loop_torque_ load_distribution_en_V1_1.doc

P1511.C
Copyright © Siemens AG 2009 All rights reserved

(0:0) CO/BO: Stat 2 ctrl

r1407
**) CO/BO: Stat 2 ctrl r1407.8
CI: Torque setp. r1538
r1407
P1503.C r1407.8 FP7900
to current control
(0:0)
r1407 and FP7500 a
r1407.9 r1508
r1539 r0079
CO/BO: Stat 2 ctrl CO: Torque setp.
CO: Total trq setp [Nm]
r1407
r1407.9
CO/BO: Stat 2 ctrl

Figure 1-3 Mode of operation of the torque limits

Torque limits
To start, the permanently programmable torque limits P1520 and P1521
are entered into the limit circuit; these can be set to a maximum of 400% of
the rated motor torque. Further, variable torque limits with BICO
interconnection (e.g. via an analog input) can be entered using P1522 and
P1523.

Current limiting
Several measured values from the motor and drive inverter are entered into
the current limiting. The current limit for the motor is set as overload limit in
P0640 (referred to P0305) and displayed in r0067. When the overload
protection function intervenes (I2t), r0067 is reduced with respect to P0640
– assuming that this response was selected in P0610. Using the actual
field-generating current component Isd,set the current limit is converted into
the limit of the torque-generating current component Isq,set. The torque limit
is obtained by multiplying this with the actual rotor flux.

Tmax = Ψ ∗ I sq max = Ψ * (I 2max − I sdset

2
)

Version ID 1.1 Issue July 2009 10/26

 Application description
Closed-loop torque control

Closed-loop torque control and load distribution ID-No: 23939668

Power limiting
Using this limit circuit, the torque is adapted, especially for drives operating
in the field-weakening range. The torque limits r1526 and r1527 are active
for the constant torque range up to the rated frequency of the drive. Above
the rated frequency, with the same power, the torque must be reduced by
the factor 1/f. For the constant power range, the permissible torque is
calculated from the drive inverter output frequency as well as the maximum
power when motoring (P1530) or the maximum power when regenerating
(P1531). The power is also entered in kW here - just the same as when
setting the motor power in P0333. It should be noted that the motor stall
torque decreases with 1/f2; therefore curves 1/f and 1/f2 intersect and from
this point onwards onwards the drive can only be operated with the so-
called stall power.

Resultant
torque limit
|M Power Stall
Closed-loop_torque_ load_distribution_en_V1_1.doc

|
Copyright © Siemens AG 2009 All rights reserved

limitation limitation

Torque limitation

1 1
r1526 ~ ~
f f2
r1527

P1530
P1531

|f act|
Constant Constant f stall Stall
torque power power

Figure 1-4 Power limiting

An arithmetic circuit determines the maximum and minimum permitted

torque limits between the programmable torque limit values and the limit
values that are obtained from the motor stall protection, the motor/drive
inverter temperature monitoring and the power limiting. Speed limiting is
also active. A minimum is used from the different limits. This minimum is
cyclically computed in the drive inverter and is displayed in parameters
r1538 and r1539. If the torque setpoint is limited in the drive inverter, then
this is displayed using the following diagnostic parameters

• r1407 bit 08 upper torque limit active

• r1407 bit 09 lower torque limit active

Version ID 1.1 Issue July 2009 11/26

 Application description
Closed-loop torque control

Closed-loop torque control and load distribution ID-No: 23939668

Important:
In addition, using current limiting, the maximum torque that can be
achieved with the motor is influenced. If the torque limits are increased this
only results in increased torque if a higher current can also flow. To achieve
this, it may be necessary to adapt the current limit.

1.3.6 Changing over to closed-loop torque control

Parameter range: P1300, P1500 – P1511

P1400 – P1780
Alarms -
Fault -
Function chart number 1: FP7700, FP7710
Closed-loop_torque_ load_distribution_en_V1_1.doc
Copyright © Siemens AG 2009 All rights reserved

For closed-loop speed control with encoder (P1300 = 21) and without
encoder (P1300 = 20) it is possible to changeover to closed-loop torque
control (slave drive) using BICO parameter P1501. This changeover can be
controlled both by external events as well as events in the drive inverter
itself (e.g. the load torque monitoring function). The torque setpoint and
supplementary torque setpoint can be selected using parameter P1500 as
well as also using BICO parameter P1503 (CI: Torque setpoint) or P1511
(CI: Supplementary torque setpoint). The supplementary torque is effective
for closed-loop torque and for closed-loop speed control. As a result of this
feature, a pre-control torque can be implemented for the speed control
using the supplementary torque setpoint.
When changing over from closed-loop torque control to closed-loop speed
control, the integral component of speed controller r1482 is set so that a
torque step does not occur in the control.

At the same time, the output of the ramp-function generator r1170 is set to
the speed actual value so that a step does not occur in the P component of
the speed controller.

1
Please find the Function charts in the parameter list of the respective Inverter

Version ID 1.1 Issue July 2009 12/26

 Application description
Closed-loop torque control

Closed-loop torque control and load distribution ID-No: 23939668

Droop

Pre-
control
Kp T n0

– *) PI
r1538 r1538
Speed
Freq. setpoint controller
–
Ti Torque
setpoint
r1539 r1539
Act. frequency
CI: Torque setp.
P1503.C
(0:0)
BI:-> torque ctrl.
P1501.C
(0:0)
CI: Add. trq. setp
P1511.C
(0:0)
Closed-loop_torque_ load_distribution_en_V1_1.doc

Ti Kp Tn
Copyright © Siemens AG 2009 All rights reserved

*) nur aktiv, wenn die Vorsteuerung aktiviert ist SLVC: P1452 P1470 P1472
(P1496 > 0) VC: P1442 P1460 P1462

Figure 1-5 Changeover, speed/torque control (master/slave drive)

Closed-loop / open-loop controlled range

Refer to closed-loop torque control, 1.3.1 and 1.3.2

Off command
If, with the closed-loop torque control active, a fast stop command (OFF3)
is output, then the system automatically changes over to closed-loop speed
control and the drive brakes. For a normal stop command (OFF1) a
changeover is not made. Instead, the system waits until a higher-level
control stops the drive so that then the pulses can be inhibited there. This is
necessary in order to allow master and slave drives to stop together. As an
alternative, a circuit can be configured using the free function blocks. This
circuit then initiates an OFF2 command.

Version ID 1.1 Issue July 2009 13/26

 Application description
Closed-loop torque control

Closed-loop torque control and load distribution ID-No: 23939668

Figure 1-6 Connecting an OFF 1 command for closed-loop torque control

Maximum speed
Refer to the maximum speed 1.3.4

Limits
Closed-loop_torque_ load_distribution_en_V1_1.doc
Copyright © Siemens AG 2009 All rights reserved

Refer to the limits 1.3.5

1.3.7 Closed-loop control by limiting the torque

Parameter range: P1300, P1500 – P1511

P1400 – P1780
Alarms -
Fault -
Function chart number 1: FP7200, FP7210, FP7700, FP7710
A torque limit control function is used if the drive predominantly operates in
the speed-controlled range but must provide defined torques in specific
operating states.

For closed-loop torque control using the limits, the drive is operated with
sensorless closed-loop speed control SLVC (P1300 = 20) or closed-loop
speed control VC with encoder (P1300 = 21). The speed controller must be
over-controlled (the speed setpoint is multiplied by a factor) so that there is
a sufficient voltage range (stroke) available at the speed controller output.
The overcontrol value is selected so that the speed increase when the load
torque is withdrawn is not too high - on the other hand the controller
remains at the limits even during dynamic operations. A defined torque limit
can now be specified by connecting parameters P1522 and P1523 to fixed
setpoints, analog inputs, interfaces. This circuit has the advantage that

1
Please find the Function charts in the parameter list of the respective Inverter

Version ID 1.1 Issue July 2009 14/26

 Application description
Closed-loop torque control

Closed-loop torque control and load distribution ID-No: 23939668

when the load is withdrawn the drive accelerates as a maximum up to the

setpoint speed plus the overcontrol. Further, calibrating the speed actual
value is completely uncritical as long as the error does not reach the
overcontrol level. This is an advantage that should not be underestimated -
e.g. for rolls that are subject to continuous wear.

CO: Upper trq. lim Motoring power lim

-99999.0 ... 99999.0 [Nm] 0.0 ... 8000.0
P1520.D (5.13) P1530.D (0.75) Regener. power lim
-8000.0 ... 0.0
P1531.D (-0.75)
CI: Upper trq. lim
P1522.C
(1520:0)
CI: Lower trq. lim
P1523.C Int.time cur. ctrl *)
(1521:0) Torque
limitation 1.0 ... 50.0 [ms]
P1717.D (4.1) CO: Act. Vdc [V]
Gain of n-ctrl. Tn of n-ctrl. Motor ovl fact [%] Gain current ctrl. *) r0070
Max. frequency 0.0 ... 2000.0 25 ... 32001 [ms] 10.0 ... 400.0 [%] 0.0 ... 5.0
0.00 ... 650.00 [Hz] 1 P1460.D (3.0) P1462.D (400) P0640.D (150.0) P1715.D (0.25)
CO: Lower trq. lim CO: Act. outp.volt [V] CO: Output current [A]
P1082.D (50.00) CO:Setp. after RFG [Hz]
-99999.0 ... 99999.0 [Nm] r0072 r0068
r1170 P1521.D (-5.13)
from setpoint x
channel y
− – –
Max. frequency
r0030
0.00 ... 650.00 [Hz]
P1082.D (50.00) CO: Torque gen.cur [A] Voltage
Asyc.
CO: Fval flux setp Mot. 3~
50.0 ... 200.0 [%] CO: Max. outp.volt [V] Kp Tn
P1570.D (100.0) r0071
Filter time n_act. Scal acc. prectrl.
0 ... 32000 [ms] 0.0 ... 400.0 [%]
P1442.D (4)
Closed-loop_torque_ load_distribution_en_V1_1.doc

P1496.D (0.0) Efficiency optimiz Pulse frequency

Copyright © Siemens AG 2009 All rights reserved

Tot/mot inert.rat. 0 ... 100 [%] – 2 ... 16 [kHz]

1.000 ... 400.000 P1580.D (0) P1800 (4)

From Encoder P0342.D (1.000)

r0029
Inertia [kg*m^2]
0.00010 ... 1000.0 CO: Flux gen. cur. [A]
P0341.D (0.00180)
r0066
+ + CO: Act. outp freq [Hz]
r0063 CO: Act. frequency [Hz] Current Observer
model r0065 model
CO: Slip frequency [%]

Kp n-adapt. (SLVC) *) Tn n-adapt. (SLVC) *)

0.0 ... 2.5 1.0 ... 200.0 [ms]
P1764.D (0.2) P1767.D (4.0)

Figure 1-7 Closed-loop torque limit control

Off command
The OFF1 and OFF3 commands are still available as the drive still
continuous to operate in the closed-loop speed controlled mode.

Maximum speed
If the torque limit is increased to the maximum, then the drive goes back
into the closed-loop speed controlled mode. This prevents the drive from
accelerating in an uncontrolled fashion.

Limits
Refer to the closed-loop torque control 1.3.4

Version ID 1.1 Issue July 2009 15/26

 Application description
Closed-loop torque control

Closed-loop torque control and load distribution ID-No: 23939668

1.4 Torque display

Depending on the control type, the displayed torque differs.

Closed-loop vector control

For vector control types, the torque is obtained from
3 Lm
Tmotor = ∗ ∗ Z p ∗ Ψrd ∗ I sq
2 LR
with Tmotor: Motor torque
Lm: Magnetizing inductance
LR: Rotor inductance
Zp: Pole pair number
Ψrd: Rotor flux
Isq: Torque-generating current
Closed-loop_torque_ load_distribution_en_V1_1.doc
Copyright © Siemens AG 2009 All rights reserved

It must be clearly observed that the torque that is obtained is the so-called
electrical torque - the mechanical torque output at the shaft is less than the
electrical torque by the electrical losses and the friction.

v/f characteristics
When using the v/f characteristics, the active current Isq corresponding to
the torque is not calculated by the vector transformation, it is obtained as
follows:

V ∗ I S ∗ cos ϕ − RS2 ∗ I S
I sq =
E
with Isq: Torque-generating current
V: Terminal voltage
IS: Stator current
RS: Stator resistance
E: Counter-voltage

By defining several quantities, this display is not so accurate over the

control range as the display for closed-loop vector control.

Version ID 1.1 Issue July 2009 16/26

 Application description
Closed-loop torque control

Closed-loop torque control and load distribution ID-No: 23939668

1.5 Speed monitoring

For closed-loop torque control systems, normally, the torque to be

controlled is important and not so much the speed. This means that if a
closed-loop torque control or closed-loop torque limiting is used based on
closed-loop speed control the speed encoder monitoring should be
disabled using P0492 = 0 to avoid Fault F0090. The encoder monitoring
function checks whether the speed setpoint and actual value move within a
specific window - if this window is violated Fault F0090 is output.
Closed-loop_torque_ load_distribution_en_V1_1.doc
Copyright © Siemens AG 2009 All rights reserved

Version ID 1.1 Issue July 2009 17/26

 Application description
Pre-control

Closed-loop torque control and load distribution ID-No: 23939668

2 Pre-control
The control behavior of the speed control loop can be improved so that the
speed controller of the drive inverter also generates values for the current
setpoints from the speed setpoint (corresponding to the torque setpoint).
This torque setpoint Tmotor, that is calculated from
Δn Δn
T = P1496 ⋅ J ⋅ = P1496 ⋅ P 0341 ⋅ P 0342 ⋅
motor total Δt Δt

is input / used as pre-control value for the current controller via adaption
elements directly as additive reference variable [command variable]
(enabled using P1496).
For quick commissioning and the complete parameterization, motor
moment of inertia P0341 is directly calculated. Factor P0342 between the
total moment of inertia and motor moment of inertia must be manually
determined.
Closed-loop_torque_ load_distribution_en_V1_1.doc
Copyright © Siemens AG 2009 All rights reserved

Droop

Pre-control P0341 P0342

r1518

Kp Tn
P1496

r1084 =0 PI r1538 r1538

– Speed
>0 – controller
Freq. setpoint
Torque
Ti setpoint
r1539 r1539

Act. frequency Ti Kp Tn
SLVC: P1452 P1470 P1472
VC: P1442 P1460 P1462

Figure 2-1 Pre-control circuit

When correctly adapted the speed controller only has to equalize disturbing
quantities in its own control loop - and this is achieved with relatively small
changes to the manipulated variable. On the other hand, setpoint changes
are routed past the speed controller and are therefore executed faster.
The effect of the pre-control quantity can be adapted depending on the
application using pre-control factor P1496. For P1496 = 100 %, the pre-
control is calculated according to the motor and load moment of inertia
(P0341, P0342). A symmetrizing filter is automatically used so that the
speed controller does not act against the torque setpoint. The time constant
of the symmetrizing filter corresponds to the equivalent delay time of the
speed control loop. The speed controller pre-control is correctly set (P1496

Version ID 1.1 Issue July 2009 18/26

 Application description
Pre-control

Closed-loop torque control and load distribution ID-No: 23939668

= 100 %, calibrated using P0342) if the I component of the speed controller

(r1482) doesn't change during ramp-up or ramp-down in the range n > 20%
* P0310. Using the pre-control it is also possible to approach a new speed
setpoint without any overshoot (prerequisite: The torque limiting does not
intervene and the moment of inertia remains constant).
Oscillograms of a setpoint step with and without pre-control are shown in
the following diagram. The measurements were carried-out with the drive
provided in the demonstration case. The drive was set to closed-loop speed
control with encoder, the motor data identification and after this the
automatic speed controller optimization were carried-out. The setpoint step
(setpoint jump) of approx. 31% in 212 ms and the speed response can be
seen in the two diagrams at the top and bottom left. The speed actual value
overshoots the setpoint by approx. 14%. In the two diagrams at the top and
bottom right, pre-control was activated with 100%. The overshoot for
measurements without pre-control can no longer be identified in them.
Closed-loop_torque_ load_distribution_en_V1_1.doc
Copyright © Siemens AG 2009 All rights reserved

Figure 2-2 Setpoint step with and without pre-control

Important:
When using pre-control, a response without overshoot is only guaranteed if
the setpoint up and down ramps are set so that the drive can track the
setpoint without going into torque limiting.

Version ID 1.1 Issue July 2009 19/26

 Application description
Closed-loop load distribution control

Closed-loop torque control and load distribution ID-No: 23939668

3 Closed-loop load distribution control

For mechanically coupled drives, such as e.g. traversing drives with several
driven axes, or roller table drives that are coupled through a material web it
is important that the load is evenly distributed across the individual drive
motors. Depending on the particular application, this can be realized using
a group drive with one drive inverter or using individual drives each
equipped with its own drive inverter.

3.1 Problems associated with group drives

The simplest way of distributing loads evenly for mechanically coupled

drives with motors having the same power rating is to form a group drive. In
this case, all of the motors are connected to one drive inverter and are
therefore supplied with the same stator frequency. As a result of the
mechanical coupling, for an identical drive arrangement (the same gearbox
ratio, the same roll diameter etc.), the motors have the same speed. The
Closed-loop_torque_ load_distribution_en_V1_1.doc
Copyright © Siemens AG 2009 All rights reserved

only way that the load can be unevenly distributed is as a result of different
slip characteristics of individual motors. According to DIN VDE 0530,
deviations of up to 20% are possible. In this case, one counter-measure is
to use motors that have been specifically selected for the application. For
traversing unit drives, problems can also occur with traveling wheel (bogey
wheel) diameters that differ slightly. The speed differences that are
obtained (as a result of traveling wheel diameters) have that much more
effect on the load distribution, the lower the rated motor slip.
The load distribution between two motors with different slip characteristics
is shown in Fig. 3-1. The drive with the steeper characteristic assumes the
highest proportion of the load torque.

Version ID 1.1 Issue July 2009 20/26

 Application description
Closed-loop load distribution control

Closed-loop torque control and load distribution ID-No: 23939668

Closed-loop_torque_ load_distribution_en_V1_1.doc
Copyright © Siemens AG 2009 All rights reserved

Figure 3-1 Load distribution for different slip characteristics

In Fig. 3-2, the two motors have different speeds due to mechanical
inaccuracies. Even with the same slip characteristic, in this case, the motor
with the highest speed would takeover less of the load torque.

Figure 3-2 Load distribution at different speeds

Version ID 1.1 Issue July 2009 21/26

 Application description
Closed-loop load distribution control

Closed-loop torque control and load distribution ID-No: 23939668

Group drives cannot be used for uniform load distribution at different motor
power ratings if technological requirements oppose these (e.g. redundancy)
or if the speed differences are too high.

3.2 Load distribution using individual drives

For individual drives with motors having the same power rating, a similar
behavior can be achieved as for a group drive by entering the same
setpoint at all drive inverters. In order to achieve - as far as possible - the
same stator frequencies, the setpoints should be digitally entered. Further,
the same ramp-up and ramp-down times must be set for all of the drive
inverters. When using the v/f characteristic, the slip compensation must be
disabled. Otherwise, the load will not be able to be distributed using the
motor slip. There are various methods of evenly distributing the load across
several drives.
Closed-loop_torque_ load_distribution_en_V1_1.doc
Copyright © Siemens AG 2009 All rights reserved

3.2.1 Droop

Droop acts so that when the load torque increases, the speed setpoint is
linearly reduced; this has the effect that a single drive is relieved (load is
reduced) if the torque demanded from it becomes excessively high. At the
rated motor torque, the speed is reduced by the factor that has been set.
The value of the droop must be determined on a system-for-system basis.
Generally, it is approximately the same magnitude as the motor slip. All of
the drives must be parameterized with closed-loop vector control (VC or
SLVC) and the ramp-up and ramp-down times of the ramp-function
generator must be identical. Further, all of the drives must be supplied with
the same speed setpoint. The following parameters must be set for droop:
P1488 source, droop determines the quantity on which the droop
is to be dependent
P1489 scaling, droop should be set to a % of the rated speed
setpoint
P1492 enable, droop

Version ID 1.1 Issue July 2009 22/26

 Application description
Closed-loop load distribution control

Closed-loop torque control and load distribution ID-No: 23939668

Droop input source

0 ... 3
Droop scaling P1488.D (0)
0.0 ... 0.50
P1489.D (0.05) 0
CO: Droop freq. [Hz] 0
r1490
1

0 2
CO:Int.outp n-ctrl [Nm]
3
r1482
Enable droop 0 1
0 ... 1
Pre-
P1492.D (0)
control
r1538

– PI r1538 r1538
Filter Speed
Freq. setpoint controller r1539
–
Torque
r1539 r1539 setpoint
Filter
Act. frequency

Figure 3-3 Block diagram of the droop feedback for MICROMASTER MM440
Closed-loop_torque_ load_distribution_en_V1_1.doc
Copyright © Siemens AG 2009 All rights reserved

Droop is the simplest method of implementing closed-loop load distribution

control. However, it can only be applied if the drives are only used in the
motoring mode and if they are more or less operated under steady-state
conditions - i.e. at constant speed. The master/slave drive principle should
be used for drives that must be accelerated and braked frequently with high
speed changes.

3.2.2 Master / slave drive with speed encoder

For master/slave drives, a uniform load distribution is achieved over the

complete speed range by transferring the torque setpoint of the speed-
controlled master drive to the torque-controlled slave drives. The torque
setpoint can either be transferred using an analog output or using peer-to-
peer data transfer with the PROFIBUS profile. The closed-loop vector
control for both the master as well as also the slave drive should be
operated with encoder (VC).

Version ID 1.1 Issue July 2009 23/26

 Application description
Closed-loop load distribution control

Closed-loop torque control and load distribution ID-No: 23939668

Kp Tn
Drive 1
Freq. setpoint Freq. setpoint PI
r1538
Speed
– controller
Torque
Ti setpoint
Act. frequency
r1539
CO: Total trq setp [Nm]
r0079

BI:-> torque ctrl.

P1501.C
(0:0)

Kp Tn
Drive 2
Closed-loop_torque_ load_distribution_en_V1_1.doc
Copyright © Siemens AG 2009 All rights reserved

Freq. setpoint PI
r1538
Speed
– controller
Torque
Ti setpoint
Act. frequency
r1539

CI: Torque setp.

P1503.C
(0:0)

BI:-> torque ctrl.

P1501.C
(0:0)

Figure 3-4 Block diagram, master / slave drive closed-loop vector control with encoder

In the simplest case, the slave drives are permanently set in the closed-
loop torque control mode using parameter P 1501. If the drive accelerates
to higher speeds as a result of a mechanical fault (e.g. the drive belt
breaks), then it is stopped at the latest when the programmed maximum
frequency is reached. The drive can only be stopped using OFF 2 or OFF
3.
The more elegant solution is to changeover the closed-loop torque control
of the slave drives to closed-loop speed control depending on internal
monitoring functions. The changeover can be made using the

Load torque monitoring

If the permissible programmed torque is exceeded or fallen below, then
closed-loop speed control is selected to avoid uncontrolled acceleration -
e.g. if the drive belt breaks. Depending on how the load torque monitoring

Version ID 1.1 Issue July 2009 24/26

 Application description
Closed-loop load distribution control

Closed-loop torque control and load distribution ID-No: 23939668

is parameterized (alarm/fault), monitoring parameter r2198.11 or r2198.12

can be used to make the changeover.

3.2.3 Master/slave drive without speed encoder

If a speed encoder is not used, disturbance-free, smooth operation of the

closed-loop load distribution control over the complete speed control range
is only conditionally guaranteed. Under certain circumstances here, when
starting from standstill, the subsequent control must be first inhibited and
can only be enabled from approx. 10 % of the speed. Monitoring parameter
r1751.2 can be used to implement this; it is at a low signal level (SLVC
open-loop controlled) below the changeover threshold parameterized using
P1755 and is at a high (SLVC closed-loop controlled) above the
changeover threshold.
Closed-loop_torque_ load_distribution_en_V1_1.doc
Copyright © Siemens AG 2009 All rights reserved

Version ID 1.1 Issue July 2009 25/26

 Apendix and references
References

Closed-loop torque control and load distribution ID-No: 23939668

Apendix and references

4 References
4.1 Reference data

This list is in no way complete and only reflects a selection of suitable

references.

Tabelle 4-1
Subject area Title
/1/ STEP7 Automatisieren mit STEP7 in AWL und SCL
Hans Berger
Publicis MCD Verlag
ISBN 3-89578-113-4
Closed-loop_torque_ load_distribution_en_V1_1.doc

/2/
Copyright © Siemens AG 2009 All rights reserved

4.2 Internet-Link-Data

This list is in no way complete and only reflects a selection of suitable

references.

Tabelle 4-2
Subject area Title
\1\ Siemens A&D Customer Support
\2\ Parameter list MICROMASTER 440

4.3 Historie
Tabelle 4-3 Historie
Version Datum Änderung
V1.0 30.10.2006 Fist Eddition

Version ID 1.1 Issue July 2009 26/26