No feedback system: Sensorless operation

Without a feedback system, the following error (following error = actual position - target position) is much harder to optimize than when operating with Hall sensors and/or incremental encoders.

Step 1: Optimization of the velocity controller

1. Ensure that the voltage constant of the motor 8011:31 "Voltage constant" is set correctly.
2. Set the parameter 8010:60 "Sensorless max. acceleration" to a lower value, otherwise the velocity jump can become too big. e.g. 2000 °/s2.
3. Reduce the parameter 8010:5E "Sensorless offset voltage scaling" to approx. 50 ... 80%.
4. Set the parameter 8010:17 "Position loop proportional gain" to 0.
The position controller is disabled.
Interference of the position controller with the velocity controller is prevented.
5. Set the parameter 8010:5B "Velocity loop proportional gain (voltage mode)" to 0.
6. Set the parameter 8010:5C "Velocity loop voltage feed forward gain (voltage mode)" to 100%.
7. Set the parameter 8010:5F "Sensorless observer bandwidth" to a lower value. e.g. 50 Hz.
8. Gradually increase the parameter 8010:5F "Sensorless observer bandwidth" until oscillation occurs. Then reduce by 50%.
9. Configure the integral component of the velocity controller in parameter 8010:5A "Velocity loop integral time (voltage mode)" to be rather sluggish.
10. Gradually increase the proportional component 8010:5B "Velocity loop proportional gain (voltage mode)" until the actual velocity in the scope begins to oscillate.
11. Reduce the proportional component by 20%.
The 20% serves as a control reserve for abrupt movements.
12. If the velocity overshoots: slightly reduce the parameter 8010:5C "Velocity loop voltage feed forward gain (voltage mode)".
13. If necessary, increase the parameter 8010:60 "Sensorless max. acceleration" back to the required dynamics.
The velocity controller is optimized.

Step 2: Optimization of the position controller

Requirement: the velocity controller is optimized.
1. Gradually increase the proportional component 8010:17 "Position loop proportional gain" until oscillation occurs.
2. Reduce the proportional component by 20%.
The 20% serves as a control reserve for abrupt movements.
The position controller is optimized.