Control Design

Model-based function development according to V‑model

• Systematic development from system concept to verified series application along the V‑model
• Requirements are directly transferred into Matlab/Simulink models – no media break between specification and implementation
• Automatic code generation from validated models reduces manual errors and accelerates series transfer
• Every development stage is documented and traceable – prerequisite for functional safety and approval processes

MIL, SIL and HIL simulation

• Model-in-the-Loop (MIL): Control concepts are tested in the model before a single line of code is written
• Software-in-the-Loop (SIL): Generated code is verified against the reference model – deviations are detected early
• Hardware-in-the-Loop (HIL): Real control units are tested against simulated loads and plants – under reproducible conditions
• Fault cases and limit scenarios are systematically tested without risk to people or hardware

Rapid control prototyping

• Control concepts run on real hardware within hours – without waiting for complete series development
• Parameterization and structural changes possible during live operation – fast iterations in the early development phase
• Bridge between simulation and real system: model behavior is validated under real load conditions
• Results flow directly into the final firmware implementation – no knowledge or data loss

Sensorless control methods

• Speed and position detection without mechanical encoder – reduces cost, space and potential failure sources
• BEMF-based methods for medium and high speeds, plus HF injection methods for standstill and low-speed range
• Application-specific tuning depending on motor type, load behavior and dynamic requirements
• Particularly suitable for pumps, fans, compressors and servo drives with limited installation space

FOC algorithms for BLDC/PMSM

• Field Oriented Control (FOC) for brushless DC and synchronous motors – maximum efficiency across the entire operating map
• MTPA strategy (Maximum Torque Per Ampere) for minimum losses at given torque
• Field weakening operation for extended speed range above nominal voltage
• Implementation on Cortex-M and DSP platforms with optimized computation time for control cycles under 50 µs

Transient time-domain analyses

• Simulation of dynamic system behavior during load changes, switch-on processes and fault conditions
• Identification of critical overvoltages, current spikes and thermal loads in transient operation
• Validation of protection functions and limits before hardware is built
• Basis for dimensioning buffer capacitors, snubbers and protection circuits

Customer-specific controller models

• Development of custom control architectures for nonlinear, time-variant or coupled systems
• Cascade controllers, state-space controllers, predictive controllers (MPC) – depending on requirements for dynamics, robustness and computational effort
• Model identification from measurement data when analytical models are unavailable or too complex
• Complete parameterization, verification and handover as documented Simulink model or generated C code

Worst-case simulations

• Systematic variation of component parameters, temperatures and supply voltages to safeguard against extreme scenarios
• Monte Carlo analyses for statistical statements on manufacturing tolerances and long-term drift
• Proof of functionality across the entire operating range – basis for approvals and customer acceptance
• Early detection of design weaknesses without costly measurement series on real hardware

Integration motor/electronics/control

• Holistic system view: motor, power electronics and control are developed and optimized as a unit
• Co-simulation of electromagnetic motor model, power stage and control algorithm in one environment
• Tuning of switching frequency, dead time, filter dimensioning and controller parameters as a complete system
• Handover to series production with fully validated parameter set and commissioning documentation