Simulation Technology HIL Hardware in the loop

Initial estimation and feasibility study

For efficiency, cost savings and in particular contemporary development of new hardware and software for power electronics, today a feasibility study based on simulation systems is vitally important. Under the slogan ‘Rapid Control Prototyping’ KEB has been using different simulation systems for years. With the HIL Systems – Hardware In The Loop – depending on the configuration, control-, driver cards circuit or power part can be embedded in the form of hardware. In the latest ultra-fast D-Space Systems, new control card software or newly developed controller circuits can be implemented and tested in advance. So the necessary processing power can be estimated beforehand, which then puts the frame on, hardware ressources for the new drive control boards.

HIL scheme "Rapid Control Prototyping - RCP"

gr_mu_hardware-in-the-loop-scheme1_en.jpg(1) HIL scheme "RCP"

In order to support customers with such specific drives in a professional manner, the simulation technology has been installed parallel to its use in R&D in the KEB Application area too.




gr_mu_hardware-in-the-loop-scheme2_en.jpg(2) HIL scheme "APPLICATION"


The exact motor data is fed into the model and adjustment of parameters creates operating conditions that are close to reality – accelerating with different moments of inertia, dynamic response under load jumps, verification of motor data by driving in S1- Operation, etc…

Required Motordatas

gr_mu_hardware-in-the-loop-scheme3_en.jpg(3) Required Motordata

Various motor types used today

The various motor types used today – HighSpeed Spindle, Medium frequency motor, High Torque Motor, Linear motor, Rod-Actuator, Discrotor Motors, Drum motors, External Rotor Motors, etc. – all are aligned with the four most commonly used basic motor designs: 

  • Asynchronous Motor
  • PM Synchronous Motor
  • IPM Synchronous Motor
  • Synchronous Reluctance Motor (SRM)

For all these types, KEB engineers have developed the necessary HIL-models and for the exact and high dynamic operation, the saturation behaviour was also implemented.

Only by considering this fully, the special controllers of the new KEB S6 and F6-drive controller generation ensure that, for example, the energetic advance of an IPM motor can be exploited and that an SRM can be driven over the complete speed range far into the field weakness, with the maximum performance.
In the past, it was sometimes a challenge to set a special drive into operation, which had already been installed into the machine. To test the physical limits – max. speed, max. acceleration, max. motor current – for finding the optimum parameters was often not possible with the integrated axis in the machine.
The first operation on the KEB-HIL system represents a completely risk-free way, so that the basic parameters are already generated before the actual operation of the real machine on the customer side.