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Article
Information Sections
Closed Loop Control with Variable 9
Selection
& Installation
Commissioning
& Troubleshooting
VFD
Thousands of drives and motors handle baggage at major airports Fundamentals
We’ve mentioned a few times how closed loop control is used to maintain constant temperature,
pressure etc., and how most drives have this feature built into the drive, so few external Latest Videos
components are needed. Let’s look at this in detail.
Firstly, let’s talk about the difference between open and closed loop control. If we are using a pump
to maintain pressure, we can set the speed of the pump to what we think will do the job, and hope
for the best, and maybe turn it down a little at night. This is an open loop control. Connecting and
Commissioning an Multiple motor control
A better solution is to fit a pressure transducer and connect that to a variable frequency drive Optidrive E3 with the Optidrive E3
controlling the motor which is driving the pump. The drive will now compare this actual (i.e.
measured) pressure value with the desired value (the setpoint) and will adjust the speed of the
pump continually to keep the pressure at this level – assuming you’ve set it up correctly. Because
the connection from the pressure sensor completes the loop (drive – motor – pump output –
transducer – drive) the system is known as a closed loop control system, and is shown in Figure 1.
Optidrive E3 - Standard Optidrive E3 - Input
Parameters Selection
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Let’s look at this more closely. If we multiply the error by a constant this represents a gain. If this
constant is a high value, then the slightest error and we will swing the tiller hard over on the narrow Frequently Asked
boat. Clearly potentially unstable. If the constant is a low value, our response will not be enough to
correct the error. Questions (/variable-
If we now add a ‘damping’ factor by integrating the error, this will slow down the response of the
frequency-drives/faq/)
system, which is useful on a narrow boat where control times are measured in seconds. Again, too
high an integral term and the response will be too slow; too low a value and we’ll be oscillating
again as the system will be underdamped.
If we differentiate the error signal, this will help in a few systems where overshoot must be limited,
but this is quite unusual.
Clearly, values of P, I and D for a narrow boat will be different to those for a fast system such as
winder tension control for example. So our general purpose control system within the variable
frequency drive allows setting of P, I, and D values to stabilise virtually any closed loop system.
Figure 2 shows how the error is processed in a typical PID system.
How do we do this in practice with a variable frequency drive? We have the PID controller (or just
PI controller on E3 drives) built into the drive, so we only need a suitable transducer or feedback
signal to control our variable. Like most engineering, if the basics are right the rest is pretty easy.
Make sure that the feedback signal from the transducer is giving you the values you’d expect, and
that as you speed up and slow down the motor it changes in a predictable way. Run the system
open loop at first to check this. If the transducer signal is say 2.3 to 5.7V, you can scale the
analogue input it is connected to accordingly. If the transducer voltage increases with increasing
motor speed, fine; if it falls (maybe you’re working with a vacuum pump) then you need to change
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a parameter (P-43 on E3, P3-04 on P2 and Eco) to tell the drive to work that way round. You can
also change the sources of the feedback and setpoint signals so the setpoint can come from a
fixed, stored value for example.
Once the transducer signal looks good you can enable the closed loop control in the variable
speed drive and see what happens (P-12=5 on E3, P1-12=3 on P2 and Eco). It will probably stay
nice and stable and not need any adjustments. If it’s not so stable, you can try adjusting the P and I
terms; as previously mentioned, the D term isn’t usually needed. On E3 drives, P and I are
adjusted by parameters P-41 and P-42 respectively. On P2 and Eco P3-01, P3-02 and P3-03
adjust P, I and D – all the closed loop parameters are P3-XX group.
One suggestion is to increase the P term until it oscillates, back it off a little and add a bit of I. It’s a
bit of a black art, but don’t stray too far from the default settings and learn by experience.
Controlling a narrow boat is probably harder, but at least you can stop at a pub and drown your
sorrows.
Closed loop control is often used for applications where temperature, pressure or flow rate need to
be controlled, but there are many other applications; for example, maintaining tension in a winding
system, shown in Figure 3. The dancer arm moves a potentiometer, which produces a signal
indicating tension of the material being wound. This is fed back to the variable frequency drive
which adjusts the speed of the winder to keep the tension constant.
On Eco and P2 drives there are several additional parameters which are sometimes useful. The
ramps can be turned off to improve response, various limits may be set and if there is a problem
like a burst pipe the drive can detect this and shut down, rather than run flat out and flood the
place. The Eco drive has additional features such as cascade control and PID sleep function.
These parameters are practical additions to a versatile closed loop controller.
Many variable frequency drive applications work in open loop or in conjunction with other control
systems, but for simple applications the built in closed loop control can prove extremely useful.
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