Modelling Method for Efficient Virtual Control Prototyping and Straightforward Migration to a Rapid Control Prototyping System

Closed-Loop Controller (CLC) development by virtual control prototyping uses a variety of methods. One approach is to develop the CLC in a purely virtual System Simulation (SysSim) followed by the validation via Rapid Control Prototyping (RCP). This paper presents a modelling method that ensures an efficient modelling of the controlled system and a straightforward migration of the CLC from the SysSim to RCP. The proposed model architecture is the basis for the seamless integration of the CLC in different environments. Based on this, a method for an efficient modelling of the controlled system is described and demonstrated by the example of a motor test bench. The dominant physical effects that stimulate mechanical resonances are identified and analysed, namely the deadtime of the B6-inverter and the cogging torque of the permanent magnet synchronous machines (PMSM). Consequently, a detailed description is provided of the modelling method of the B6-inverter, the PMSM and the rotational power transmission. A comparison of the system behaviour in SysSim and RCP demonstrates the effectiveness of the presented method for virtual prototyping.