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Training Document 8-1 Closed loop control structure servo mode
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Training Document 8-2 Closed loop control structure servo mode
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Training Document 8-3 Closed loop control structure servo mode
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Training Document 8-4 Closed loop control structure servo mode
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Training Document 8-5 Closed loop control structure servo mode
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Training Document 8-6 Closed loop control structure servo mode
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Training Document 8-7 Closed loop control structure servo mode
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Training Document 8-8 Closed loop control structure servo mode
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A cascade control comprising several integral control loops is used to control

the drives.
The control loops viewed from inside to out are as follows:
• Current/torque controller
A
• Speed controller
ES

• Position controller/technology controller

Cascaded control loop structures have the advantage that they can be put into
operation stepwise from inside to out.
ID

This closed-loop control structure is fixed and is adapted to the particular

application via the parameterization.
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Training Document 8-9 Closed loop control structure servo mode
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Overview The closed-loop control structure is displayed in several screens in the

STARTER.
The signal characteristics in the control structure are displayed by moving from
one screen to the next.
A
The functions shown here are processed in the CU:
• Speed controller
ES

• Torque setpoints
• Torque limitation
ID

• Current setpoint filter

• Current controller
The function referred to here with "Power unit" is performed in the Motor
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Module.
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Training Document 8 - 10 Closed loop control structure servo mode
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Speed controller The speed controller controls the motor speed using the actual values from the
encoder (operation with encoder) or the calculated actual speed value from the
electric motor model (operation without encoder).

Speed setpoint Several sources are available for the speed setpoint:
A
• Fixed setpoint (when setpoint channel is enabled)
ES

• Motorized potentiometer (when setpoint channel is enabled)

• Analog input of the TB30 or TM31
ID

• Via PROFIDRIVE (via PROFIBUS or PROFINET telegram)

• Position controller output
EM

Actual speed value The actual speed value is output from the motor encoder or it is calculated in
encoderless mode from the electric motor model.
K

Adaptation Speed-dependent adaptation of control parameters gain factor Kp and the

integral time Tn is possible.
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Training Document 8 - 11 Closed loop control structure servo mode
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Torque setpoints The source of the respective torque setpoint mainly depends on the closed-loop
control function selected. In speed-controlled mode, the speed controller
calculates a torque that it supplies to the function "Torque setpoints".
In torque-controlled mode, the torque setpoint is wired directly to a
supplementary torque 1, 2 or 3. In position-controlled mode, in some cases, a
A
torque offset is generated by a torque pre-control which is also wired to a
ES

supplementary torque 1, 2 or 3.
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Training Document 8 - 12 Closed loop control structure servo mode
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Limits The torque setpoint can be limited by the following characteristics:

• Upper torque limit
• Lower torque limit
• Current limit
A
• Power limit
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Protection The torque limits and current limits serve to protect the mechanical equipment,
the motor and the power units.
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Training Document 8 - 13 Closed loop control structure servo mode
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Torque limit (upper) The "Upper torque limit" must be specified as a positive value in Nm, otherwise
the motor will be accelerated up to its maximum speed.

Torque limit (lower) The "Lower torque limit" must be specified as a negative value in Nm, otherwise
the motor will be accelerated up to its maximum speed in the negative direction.
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Training Document 8 - 14 Closed loop control structure servo mode
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Current limit Depending on the operating mode, the effective current limit is formed as a
function of the following characteristics:
• Current limit
• Maximum motor current
A
• Maximum possible current of the power unit (Motor Module)
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Training Document 8 - 15 Closed loop control structure servo mode
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Power limits A separate power limit can be specified in kW for motor mode and generator
mode.
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Training Document 8 - 16 Closed loop control structure servo mode
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Current controller The current controller is designed as a closed-loop PI controller that controls a
torque generating current setpoint and a field-generating current setpoint.

Current setpoint The torque generating current setpoint is determined from the torque setpoint.
The field generating current setpoint is determined by SINAMICS itself.
A
ES

Actual current value The actual current value is determined by the current transformers on the Motor
Module and, within the context of the motor model, resolved into a torque
generating current setpoint Iq and a field generating current setpoint Id. The
ID

actual current values are available to the CU via the DRIVE-CLiQ connection
and therefore also to the current controller.
EM

Adaptation The P gain of the current controller can be reduced (depending on the current)
by means of current controller adaptation. Current controller adaptation can be
deactivated with the setting p1402.2 = 0.
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Training Document 8 - 17 Closed loop control structure servo mode
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Power unit Information for the power unit is displayed here. The current or voltage flow
within the power unit is displayed graphically. You can enter the power unit
operating values and show the rms phase currents under PWM (Pulse Width
Modulation) .
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Training Document 8 - 18 Closed loop control structure servo mode
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Optimization In a control loop, it is necessary to adapt the controller to the controlled system
in order for the controller to satisfy the requirements.
As a cascade control, the closed-loop control is made up of the following
controllers:
A
• Current/torque controller
• Speed controller
ES

• Position controller
The manipulated variable of the higher-level control loop is the command
variable for the lower-level control loop in this context.
ID

Cascaded control structures are put into operation from inside to out. The
higher-level control loop is not closed and set until the lower-level control loop is
EM

working properly.
Advantages of
cascade control Step-by-step commissioning of the control loops from inside to out
(Current  Speed  Position); independent settings. Lower-level controllers
K

form an equivalent time delay for the higher-level system and therefore
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influence the command variable dynamics of the entire system.

This disadvantage can be compensated by precontrol of the lower-level control
loop. Simple limitation of the inner controlled variables by limiting the command
BR

variables of the outer controller.The effects of nonlinearities are limited. The

higher-level controller has a controlled system with less nonlinearity.
Reduced delay times through compensation in the lower-level control
loop.Disturbance values are immediately responded to and more quickly
compensated in the lower-level controller.

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Training Document 8 - 19 Closed loop control structure servo mode
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Core objectives Controller optimization is based primarily on the requirements of the respective
application. Whereas for drilling and milling, demanding requirements are
placed on surface quality, for bottling, packing and conveying, a highly dynamic
response and high speed are required.
Disturbance variables arising in the process must be responded to in the same
A
manner.
ES

This means that a common optimization strategy cannot produce the desired
result.
The core objectives are therefore:
ID

• Dynamic response
• Stability
• Accuracy
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• Ruggedness
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Training Document 8 - 20 Closed loop control structure servo mode
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Transfer behavior The transfer behavior describes the dependence of an output signal on an input
signal.
This transfer behavior can be described as a function:
as a quotient of a function of the output signal and of the input signal.
A
The transfer behavior can be analyzed by means of:
• Step response:
ES

Many applications have a simple system (rigid system, two mass oscillators),
where this analysis is sufficient
• Frequency response analysis:
ID

Required for complex systems (e.g. multi-mass oscillators)

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Transfer function The transfer function is unknown in most cases.

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Training Document 8 - 21 Closed loop control structure servo mode
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Step response The controller optimization in the time domain can be carried out via an analysis
of the step response. In this context, a setpoint step is applied to the controller
input and the actual value traced.
The controller is modified by changing control parameters so that the actual
value reaches the setpoint as desired.
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Optimization When optimizing a PI controller via a step response, several steps are required.
The P component should always be optimized first.
On starting optimization, the I component must therefore be set extremely low to
ID

enable the required effect of the P component to be identified:

 Set Tn to a large value
The controlled response must then be observed with step-by-step increases in
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Kp. As soon as the actual value begins to oscillate slightly, Kp must be reduced
by approximately 50% to allow sufficient scope for optimizing the I component.
As soon as Kp has been set optimally, to optimize the I component, Tn is
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reduced step-by-step until a small oscillation occurs again in the actual value.
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Then it is recommended that Tn is increased to double the value to give the

control loop sufficient stability despite the highly dynamic response.
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Training Document 8 - 22 Closed loop control structure servo mode
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Current controller The current controller is responsible for ensuring that the required current flows
through the motor despite all lags.

Controlled system Put simply, the controlled system comprises two lag elements.
A
1. Converter lag:
• Switching delays
ES

• Delays in current measurement

• Sampling times
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2. Motor delays
• Delay time due to motor inductance
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Note The delay time of the converter is small compared to the delay time in the
motor.
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Training Document 8 - 23 Closed loop control structure servo mode
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Requirements The actual value should quickly follow the setpoint. The controller is optimized
to the control response. The typical optimization method here is the absolute
value optimum, where a small overshoot up to 4.3% is permissible. This method
represents an appropriate compromise between dynamics and stability.
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Disturbances The compensation of disturbances is not relevant in the current controller.
ES

Possible disturbances in current control loop: Fluctuations in the DC link

voltage. Since these disturbances are slower than the current controller cycle,
they can be neglected here.
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Training Document 8 - 24 Closed loop control structure servo mode
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SIEMENS motor With SIEMENS motors that have a DRIVE-CLiQ connection or can be selected
from the list of SIEMENS motors in the STARTER, the rated motor data and the
equivalent circuit diagrams are already available. The current controller is pre-
optimized at the factory in this case.
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Training Document 8 - 25 Closed loop control structure servo mode
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Speed controller The speed controller controls the required speed at the motor.

Controlled system Put simply, the controlled system comprises two lag elements.
• Current controller lag:
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 The current controller is displayed simply as a first-order lag element with
a lag time that results from the lag times of the current control system
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• Lag in the mechanical system

 is described by the mechanical time constant
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Components I component: motor, mechanical system (poss. 2 I components)

Equivalent time constant for current controller (appox. 3 ms as PT1)
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Equivalent time constant for speed sensing (calculated or measured) 100 ms

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Training Document 8 - 26 Closed loop control structure servo mode
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Requirements The speed controller must react quickly to changes in the specified speed.
At the same time, it must compensate for disturbance variables fast.
Disturbance variables are, for example:
• Load changes
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• Pumps
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In this way, the speed controller is also set to match the disturbance
compensation:
Optimum command variables (superimposed position controller): BO
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Optimum disturbance variables from process, load changes: SO

The reaction to the change in disturbance variable is analyzed.
Characteristic response to change in command variable for speed controller:
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43% overshoot
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Training Document 8 - 27 Closed loop control structure servo mode
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Training Document 8 - 28 Closed loop control structure servo mode
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In the Automatic Controller Setting screen form, you can configure an automatic
setting of the speed controller for SINAMICS drive units. The necessary steps
for this calculation can be controlled from this screen. The calculated parameter
values of the speed controller are displayed and can then either be rejected or
adopted for the drive.
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Features The automatic speed controller setting has the following features:
• Damping resonance effects in the speed-controlled system
• Automatic setting of the gain factor Kp and the integral time Tn of the speed
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controller

Note The speed setpoint filter and the reference model are not adapted by the
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automatic speed controller setting.

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Training Document 8 - 29 Closed loop control structure servo mode
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Technology controller The technology controller can be used as a superimposed controller,

e.g.:
• Position controller
• Pressure controller
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• Tension controller
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• Fill level controller

• Flow controller
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Training Document 8 - 30 Closed loop control structure servo mode
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Position control The position controller has the task of moving the drive to a specified target
position. The precondition for this is that the actual position is sensed by an
encoder. The measurement of the actual position is indicated as the integration
of the velocity in the signal flow.
The position controller is often set up as a P controller, since the system already
A
has an integration element.The gain factor of the position controller is called the
ES

Kv factor.
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Training Document 8 - 31 Closed loop control structure servo mode
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Optimization The position controller is designed so that the drive does not overshoot beyond
the specified end position.
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Training Document 8 - 32 Closed loop control structure servo mode
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Precontrol The conventional position control concept (P controller) always requires a

deviation (following error = FE) between position setpoint and actual position
value. This deviation can lead to an unwanted axis behavior, such as contour
errors, poor dynamics (performance characteristics during rise time).
The task of the precontrol is to compensate these disadvantages. The
A
precontrol calculates the axis (setpoint) velocity directly from the position
ES

setpoints by differentiation, multiplies it with the KPC factor, then transfers it

directly to the position controller output. In the best case, the precontrol setpoint
will cause the axis to move at the velocity calculated by the interpolator.
ID

If the actual axis position were immediately returned to the position controller,
the following error would be 0. The position controller would then only have to
deal with the task of correcting disturbance-induced fluctuations of the real
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actual axis position.

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Training Document 8 - 33 Closed loop control structure servo mode
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Torque precontrol The innermost control loop can also be precontrolled by specifying the
acceleration or the torque on the current controller. The precontrol can also be
used to specify the motor torque setpoints.
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Training Document 8 - 34 Closed loop control structure servo mode
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Safety information Please note that:

• The course instructions have been produced for:
 A course held by a course leader
 Activities carried out on special training equipment
A
• The training equipment is operated under laboratory conditions.
ES

In case of doubt, always ask your course leader – particularly when handling
components that carry electrical current or which can move.
• When carrying out work on equipment, the safety information in the
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associated product documentation must always be observed!

The training documents alone are not sufficient.
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Training Document 8 - 35 Closed loop control structure servo mode
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Task The settings for the current controller have been pre-assigned automatically by
the software on the basis of the motor order number selected.
The task here is to check the settings on the basis of the measuring function.
A
1. Dearchive the project "S120_Servo_1", load the data to the CU and test the
drives.
ES

2. Select the measuring function via the "Commissioning" directory in the

"Servo_02" drive object.
ID

3. The following parameters should be set:

EM

• Measuring function: Current controller setpoint change

• The other parameters are set automatically but may be modified for
measurement.
K

• The recorded parameters are also selected automatically.

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4. The measurement must be started via the setpoint change.

BR

5. Select the "Assume control priority" button and start the measurement by
pressing the green button.

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Result The result of the measurement is shown in the time diagram. Measure the rise
and recovery time.
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Training Document 8 - 37 Closed loop control structure servo mode
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Task For third-party motors, the electrical parameters can be determined by

stationary measurement. This method of determining the motor parameters
must be carried out prior to current controller optimization.
If Siemens motors are used, current controller optimization can be carried out
without measurement of the motor parameters.
A
ES

1. Select the stationary measurement in the following way:

>> Servo_02 > Commissioning > Stationary/turning measurement
ID

and then perform the following steps:

2. Select the measuring mode: >> stationary measurement

EM

3. Activate the measurement by pressing the button

"Activate measurement". The control panel is automatically opened for this
K

drive.
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4. In the opened control panel, press the button

"Assume control priority!“ and accept the safety note
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5. Set the "Enables" check mark, and then press the "green" button to start the
measurement.

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Result The measurement has been performed and the measurement results with the
stored values are then shown in a table.

6. Accept the data determined in the stationary measurement:

A
>> Accept values
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The values are accepted but not saved to ROM. To retain the values after
switch-on, the data must be saved to ROM and downloaded to the PG and
saved on the hard disk.
ID

Note The current controller only operates with the new values after the determined
EM

values have been accepted.

If the values are not accepted, then the current controller continues to operate
with the previous values.
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Training Document 8 - 39 Closed loop control structure servo mode
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Task The settings for the speed controller have been pre-assigned automatically by
the software.
The task here is to check and optimize the settings on the basis of the
measuring function.
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1. Select the measuring function via the "Commissioning" directory in the
ES

"Servo_02" drive object.

The following parameters should be set:
ID

Measuring function: "Speed controller setpoint jump (after speed setpoint

filter)"
The other parameters are set automatically but may be modified for
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measurement.
The recorded parameters are also selected automatically.
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2. The measurement must be started via the setpoint change.

AS

Select the "Assume control priority" button and start the measurement by
pressing the green button.
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Training Document 8 - 40 Closed loop control structure servo mode
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Basic procedure The PI controller consists of a proportional (P) component and an integral (I)
component. The question therefore arises as to which component should be
optimized first.
The P component has an immediate effect on the setpoint/actual value
comparison, but the I component has a delayed effect due to its time constant,
A
so you must always begin by optimizing the P component.
ES

On starting optimization, the I component must therefore be set extremely low to

enable the required effect of the P component to be identified:
 Set Tn to a large value.
ID

Then apply the setpoint step change to the controller and observe the controlled
response. If the change in actual value is still extremely slow, increase Kp step-
by-step. If the actual value starts to oscillate, reduce Kp accordingly.
EM

As soon as Kp has been set optimally, to optimize the I component, Tn is

reduced step-by-step until the first undershoot occurs in the actual value.
If necessary, with a further reduction in Tn, the height of the first overshoot
K

can be reduced.
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Training Document 8 - 41 Closed loop control structure servo mode
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Task The speed controller parameter P gain and integral time must be adapted to the
mechanical conditions.
Before you carry out automatic optimization to determine this parameter, both
parameters should be changed manually and the result evaluated using a
setpoint step change.
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ES

1. Open the screen

>> Servo_02 > Open-loop/closed-loop control > Speed controller
ID

2. Modify the parameters there

- P gain and
EM

- Integral time

3. Then start the measurement.

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Note If the STARTER is connected to the drive unit (online mode), the changes to the
P gain and integral time parameters are adopted immediately after input.
After optimization, the parameters must be saved to ROM and downloaded to
BR

the PG and stored there.

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Training Document 8 - 42 Closed loop control structure servo mode