control-systems-principles.co.uk.

Coupled drives 2: control and analysis

Coupled Drives 2: Control and analysis

Mark Readman, Hilde Hagadoorn, control systems principles.co.uk
ABSTRACT: This is one of a series of white papers on systems modelling, analysis and
control, prepared by Control Systems Principles.co.uk to give insights into important
principles and processes in control. In control systems there are a number of generic
systems and methods which are encountered in all areas of industry and technology. These
white papers aim to explain these important systems and methods in straightforward terms.
The white papers describe what makes a particular type of system/method important, how it
works and then demonstrates how to control it. The control demonstrations are performed
using models of real systems designed by our founder and senior partner Peter Wellstead,
and have been developed for manufacture by TQ Education and Training Ltd in their CE
range of equipment. This white paper uses the computer based control and simulation tool
CE20000 together with the coupled drives CE108.

1. Introduction
The coupled drive experiment is a multivariable system designed to demonstrate speed and tension
control. As described in the first white paper, two motors are connected to a jockey pulley with a belt that
acts as a flexible coupling. Dynamic coupling between the two drive motors and the jockey pulley is due
to the drive belt. By varying the speed of the motors the vertical position and the rotational speed of the
jockey pulley can be controlled. Belt driven systems are used extensively in the automotive industry
together with passive and active tension control. Tension and speed control is also an important issue in
the paper and steel industries. Normally in these areas tension is controlled by varying the web speed at
different locations. The manufactured paper or steel acts like a flexible belt. Control of vibration is also
an important issue in high performance belt driven power trains and an ongoing topic of research.

The first coupled drives white paper (see www.control-systems-principles.co.uk and go to the downloads
page), described the background and dynamics of the coupled drives process. In this white we are going
to describe the dynamics from a difference way and do a series of experiments with the CE108
equipment. The CE2000 software is used to investigate closed-loop control of the coupled drive system.
This is a multivariable control problem and will demonstrate the use of a precompensator to decouple the
open-loop dynamics into two Single Input Single Output (SISO) transfer functions. This allows SISO
design methods to be applied to the tension and speed loops.

These control exercises are illustrated in the video clips on the control systems principles web site

Inputs Outputs
ω1
U1 ω2
Coupled
Drives ω3
U2
y

Figure 1. Coupled Drives Block Diagram

In the above block diagram ω1,2 are the motor speeds and ω3 is the jockey pulley speed and y is the
tension output. We will also look at multivariable speed control where the objective is to independently
control the speed of each motor.

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2. Dynamic Equations
The Newton/Euler dynamic equations for the coupled drive system are developed in the white paper

http://www.control-systems-principles.co.uk/coupled-drives-system.pdf

Here we show an alternative way of developing the dynamic equations based on Lagrangian techniques
[1]. The notation used here will follow the above white paper. Nominal values of the units shown are
used to obtain simulated results.

Notation (units and nominal values in brackets)

θ1,2 Motor 1,2 angular position (rad)
θ 3 Jockey pulley angular position (rad)
ω1,2 Motor 1,2 pulley angular velocity (rad/sec)
ω3 Jockey pulley angular velocity (rad/sec)
x Jockey pulley linear position (m)
I1,2 Motor 1,2 inertia (8e-4 kg m 2 )
I3 Jockey pulley inertia (4e-4 kg m 2 )
m Jockey pulley mass (0.35 kg)
r Radius all pulleys (0.03 m)
k Belt stiffness (50 Nm-1 )
k0 Jockey spring stiffness (200 Nm-1 )
b1,2 Motor friction (9e-2 Nms-1 )
b3 Pulley friction (angular 1e-3 Nms-1 )
b m Pulley friction (translation 0.5 Ns-1 )
α Angle (rad)

First we write down expressions for the kinetic energy, potential energy and dissipation and assemble the
Lagrangian. Next we use Lagranges equations to obtain the dynamics. A figure of the coupled drives is
shown in the above white paper.

Kinetic Energy
Note in the following analysis the jockey pulley drive inertia I 3 is assumed to be zero and the mass of
the drive belt is assumed to be zero. With these assumptions the kinetic energy for the system is

1 2 1 &2 1 & 2
T= mx& + I1θ1 + I 2θ 2 (1)
2 2 2

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Potential Energy

From the kinematic relationship between the jockey pulley position and the belt shown in Figure 2, the
following expression for potential energy is obtained.

x cos(α)

x
α α

Figure 2. Calculation of Potential Energy

1 1
k ⎡⎣ r (θ1 − θ 2 )⎤⎦ + k ⎡⎣ r (θ1 − θ 3 ) − x cos(α ) ⎤⎦ +
2 2
V=
2 2 (2)
1 1
k ⎡⎣ r (θ 3 − θ 2 ) − x cos(α ) ⎤⎦ + k0 x 2
2

2 2

With the assumption

θ1 + θ 2
θ3 = (3)
2

the expression for potential energy simplifies to,

∴

2
1 ⎡r ⎤ 1
k ⎡⎣ r (θ1 − θ 2 )⎤⎦ + k ⎢ (θ1 − θ 2 ) − x cos(α ) ⎥ + k0 x 2
2
V= (4)
2 ⎣2 ⎦ 2

Dissipation
Here we only consider dissipation due to the drive motors and the jockey pulley mass.

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1 &2 1 & 2 1
R= b1θ1 + b2θ 2 + b0 x& 2 (5)
2 2 2

The jockey pulley friction b3 is assumed to be zero.

Lagrangian
The Lagrangian is obtained in the usual manner

L = T −V (6)

Dynamic Equations
We now obtain the dynamic equations using,

d ∂L ∂L ∂R
− + = ui i = 1, 2
dt ∂θ&i ∂θ i ∂θ&i
(7)
d ∂L ∂L ∂R
− + =0
dt ∂x& ∂x ∂x&

These equations can be written in the form

z + B z& + K s z = U
M && (8)

where

z = (θ1 θ 2 x) U = ( u1 u2 0)
T T
and

⎛ 3 2 3 ⎞
⎜ 2 kr − kr 2 − kr cos(α ) ⎟
⎛ I1 0 0⎞ ⎛ b1 0 0⎞ 2
⎜ ⎟
3 2 3 2
M = ⎜⎜ 0 I2 0 ⎟ , B = ⎜⎜ 0 b2
⎟ ⎟
0 ⎟ , Ks = ⎜ − kr kr kr cos(α ) ⎟ (9)
⎜0 ⎜ 2 2 ⎟
⎝ 0 m ⎟⎠ ⎜0 0
⎝ b0 ⎟⎠ ⎜ −kr cos(α ) kr cos(α ) k + 2k cos2 (α ) ⎟
⎜ 0
⎟
⎝ ⎠

Dynamic coupling between the drive motors and the jockey pulley position and rotation is due to
the drive belt. This information is contained in the stiffness matrix Ks. So it is the stiffness
matrix that provides the dynamic coupling in the dynamic equations.

0o ⎫ Max coupling
⎪
α = 30o ⎬ = Coupled drives
90o ⎪⎭ Decoupled

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For the coupled drives we take α = 30o so cos(α ) = 3 / 2 and the stiffness matrix becomes
(actually α ( x, t ) but we assume α =constant)

⎛ 3 2 3 3 ⎞
⎜ kr − kr 2 − kr ⎟
⎜ 2 2 2 ⎟
⎜ 3 3 2 3 ⎟
K= ⎜ − kr 2 kr kr ⎟ (10)
⎜ 2 2 2 ⎟
⎜ 3 3 3 ⎟
⎜− kr kr k0 + k ⎟
⎝ 2 2 2 ⎠

Transfer functions

Writing the dynamic equations in the form (Note the inertia matrix M is positive definite and
hence invertible)
z + M −1B z& + M −1K z = M −1U
&& (11)

and using Laplace transforms we get

z( s) = G( s) U ( s) (12)

where
G ( s ) = ( s 2 + M −1 B s + M −1 K ) −1
M −1 (13)

and the outputs are

z = (θ1 θ 2 x)
T

The inputs can be written as

⎛ 1 0⎞
⎛u ⎞ ⎛u ⎞
U ( s ) = ⎜⎜ 0 1 ⎟⎟ ⎜ 1 ⎟ = Kin ⎜ 1 ⎟ (14)
⎜ 0 0 ⎟ ⎝ u2 ⎠ ⎝ u2 ⎠
⎝ ⎠

The outputs we are interested in are the jockey pulley angular velocity and tension. Jockey pulley angular
position is defined in equation (3). By differentiating angular position we obtain angular velocity so we
can write the output equation as

⎛s s ⎞ ⎛ θ1 ⎞ ⎛ θ1 ⎞
⎛ ω3 ⎞ ⎜ 0⎟ ⎜ ⎟
⎜ x ⎟=⎜2 2 ⎜ θ 2 ⎟ = Kout ⎜⎜ θ 2 ⎟⎟ (15)
⎝ ⎠ ⎟
⎝ 0 0 1 ⎠ ⎜⎝ x ⎟⎠ ⎜x⎟
⎝ ⎠
and obtain the transfer function from motor input to jockey speed and tension

⎛s s ⎞ ⎛ θ1 ⎞
⎛ ω3 ⎞ ⎜ 0⎟ ⎜ ⎟
⎜ x ⎟=⎜2 2 θ (16)
⎝ ⎠ ⎟ ⎜⎜ 2 ⎟⎟
⎝ 0 0 1 ⎠⎝ x ⎠

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so finally
⎛ ω3 ⎞ ⎛ u1 ⎞
⎜ x ⎟ = P( s ) ⎜ u ⎟ (17)
⎝ ⎠ ⎝ 2⎠
where
⎛G Gω ⎞ ⎛ Gω 0 ⎞ ⎛ 1 1⎞
P( s ) = Kout G ( s ) Kin = ⎜ ω = (18)
⎝ −G x Gx ⎠⎟ ⎝⎜ 0 Gx ⎠⎟ ⎝⎜ −1 1⎠⎟
and
1
Gω =
2( Is + b)
(19)
3kr
Gx =
( Is + 3kr )(2ms + 2k0 + 3k ) − 3k 2 r 2
2 2 2

Note the damping factors in the tension transfer function have been neglected for simplicity.

Also note that above calculations are more easily performed using a symbolic manipulation package such
as DERIVE. The sensor gain matrix is approximately
⎛K 0 ⎞ ⎛ 0.001 0 ⎞
K sen = ⎜ speed = (20)
⎝ 0 K tension ⎟⎠ ⎜⎝ 0 10 ⎟⎠
Using the variable values above gives the model dynamics and multiplying by the sensor gain gives
⎛ 1 ⎞
0
⎛G 0 ⎞ ⎜ 0.3s + 1 ⎟
K sen ⎜ ω =⎜ ⎟ (21)
⎝ 0 Gx ⎠⎟ ⎜ 0 −185600 ⎟
⎜
⎝ ( s 2
+ 11s + 150 )( s 2
+ 1.6 s + 800 ) ⎟⎠

3. Tension and Jockey speed control

Writing the coupled drives transfer function as shown in equation (22) suggests using a constant
precompensator to decouple the jockey speed and tension dynamics.
⎛ ω3 ⎞ ⎛ Gω 0 ⎞ ⎛ 1 1⎞ ⎛ u1 ⎞
⎜ x ⎟=⎜ 0 Gx ⎟⎠ ⎜⎝ −1 1⎟⎠ ⎜⎝ u2 ⎟⎠
(22)
⎝ ⎠ ⎝

This allows the MIMO system to be treated as two SISO systems. Applying the pre-compensator
⎛ 1 −1 ⎞
K ( s) = ⎜ ⎟ (23)
⎝1 1 ⎠
decouples jockey speed and tension so that the decoupled system becomes,

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⎛ 1 ⎞
⎜ 0.3s + 1 0 ⎟
P( s ) K ( s) = ⎜ ⎟ (24)
⎜ 0 −185600 ⎟
⎜
⎝ ( s + 11s + 150)( s + 1.6s + 800) ⎟⎠
2 2

Both these transfer functions are stable but notice that a sign change has occurred in the tension
dynamics. The block diagram in Figure 3. below shows the plant with decoupling pre-compensator. Now
r1(s) and r2(s) are the control inputs and ω3(s) and y(s) are the jockey pulley speed and tension outputs
respectively.

⎛ r1 ( s ) ⎞ ⎛ ω3 ( s) ⎞
⎜ r ( s) K(s) P(s) ⎜ x( s) ⎟
⎝ 2 ⎠ ⎝ ⎠

Figure 3. Diagonalising Precompensator K(s)

Open-Loop Dynamics
In this experiment we first obtain the decoupled open-loop step response of the jockey speed and tension
dynamics. This illustrates the use of a pre-compensator to decouple jockey speed from the tension control
loop. The CE2000 program shown in Figure 3 is used for the open-loop experiments. To examine the
decoupled jockey speed dynamics the tension input is set to zero and a square wave is applied to the
speed input. This applies the same control signal to both motors. The nominal speed of the jockey pulley
was set to –2.0 Volts. The jockey speed output is the response to the square wave input while the tension
output shows little interaction Figure 4.

Figure 4. Open-Loop Jockey Speed and Tension Testing

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To examine the decoupled tension dynamics the jockey speed input is set to a nominal –2.0 Volts. A
Open-loop Speed Step Response

Speed Input (Volts)

1

-1
0 1 2 3 4 5 6 7 8 9 10
0

Tension (Volts)
-0.5

-1
0 1 2 3 4 5 6 7 8 9 10
-1.5
Speed (Volts)

-2

-2.5

-3
0 1 2 3 4 5 6 7 8 9 10
Time (Sec)

Figure 5. Open-Loop Jockey Speed Step Response

square wave is applied to the tension input. In Figure 5 we have shown the raw tension output and the
filtered tension output. The lowpass filter
1− β
F ( z) = (25)
1 − β z −1
is used to filter the raw tension data where β=0.95. Notice that in this case there is some interaction with
the jockey speed. The tension dynamics contains a pair of under damped poles with natural frequencies of
25 and 18 rad/sec respectively.

Open-loop Tension Step Response

1
Tension (Volts)

-1
0 5 10 15 20 25
1
Tension (Volts)

-1
0 2 4 6 8 10 12 14 16 18 20
-1.5
Speed (Volts)

-2

-2.5

-3
0 2 4 6 8 10 12 14 16 18 20
Time (Sec)

Figure 6. Open-Loop Jockey Tension Step Response

Jockey Speed control

The decoupled transfer function can be approximated by the transfer function and controlled by a PI
controller,

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1
P( s ) = τ ≈ 0.3
τ s +1 (26)
K
Kω ( s ) = K p + I
s

The loop gain is

K p s + Ki
L( s ) = P ( s ) K ( s ) = (27)
s(τ s + 1)

and the sensitivity and complementary sensitivity functions are

1
s( s + )
1 τ
S ( s) = =
1 + L( s ) (1 + K p ) Ki
s2 + s+
τ τ
(28)
Kp K
(s + i )
τ Kp
T ( s ) = L( s ) S ( s ) =
(1 + K p ) K
s2 + s+ i
τ τ

The proportional and integral gains for jockey speed control can be tuned online. In this experiment the
following values were chosen.

K p = 1.0, Ki = 5.0

Substituting the above values into the transfer function gives the closed-loop step dynamics

3.33( s + 5)
T ( s) =
s + 6.6676s + 16.67
2

and step response shown in the Figure 6 below.

The position of the zero in the complementary sensitivity function T(s) can have a big effect on the

Figure 7. Simulated Closed-Loop Jockey Speed Step Response

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transient response. See Dorf chapter 5 for details.

Tension Control
From the model of the coupled drive system the nominal decoupled tension dynamics can be
approximated by the transfer function,
−185600
P( s ) = (29)
( s + 11s + 150)( s 2 + 1.6s + 800)
2

This is a stable transfer function with two pairs of complex poles. There are a fast underdamped pair of
poles with a natural frequency ~5Hz due to the jockey position, and a slow slightly under-damped pair of
poles with a natural frequency of approximately 2Hz due to rotational elastic coupling between the two
motors and the jockey pulley. Note the actual natural frequencies of the pair of complex poles will
depend on the actual version of the CE108 that is being used. The negative sign is the result of using the
pre-compensator and affects the controller implementation. As with the jockey speed control we want the
closed-loop tension dynamics to track a step change in the tension reference. A stable transfer function
can always be made closed-loop stable by making the loop gain small enough (remember the small gain
theorem). However, in this case to achieve closed-loop stability the controller gain has to be made quite
small. Then the closed-loop response will be not much different to the open-loop response and the steady
state error will be large. The steady state error can be removed by using an integral controller. This also

Figure 8. A comparison of the loop gain L(s) and

closed-loop gain T(s) when using integral control.

improves the stability margins by rolling off the loop gain well below the pole frequencies. A Bode
magnitude plot comparing the open-loop gain with the closed-loop gain is show in Figure 8. The closed-
loop bandwidth of 2rad/sec or 0.3 Hz is approximately a decade below the smallest mode. A further
increase in closed-loop robustness is obtained by rolling off the loop gain faster resulting in the following
compensator where the pole time constant is τ.
K
K x ( s) = τ ≈ 0.4 (30)
s(τ s + 1)

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Assuming a sampling interval of Ts=50 ms, the ZOH digital controller is

0.003z −1 + 0.002876 z −2
K x ( z) = (31)
1 − 1.882 z −1 + 0.8825 z −2

Figure 8. is a simulation of the step response using the compensator shown above. For comparison also
shown is the step response using integral control only. Notice that the additional lag improves the step
response. The time constant in the low pass filter can be tuned to give best performance on a particular
CE108.

Figure 9. Simulated Closed-Loop Tension

Step Response

The next figure shows the transient response when the CE108 is started up. This compares the integral
controller to the integral plus lag controller. The robust controller gives improved rejection of the
periodic disturbance occurring at the chosen jockey pulley speed.

Figure 10. Experimental Closed-Loop Transient Response

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Experimental Results: Jockey Speed and Tension Control

Putting it all together, the pre-compensator K(s) is used decouple the jockey speed and jockey tension
dynamics. Jockey speed is controlled using the speed controller Kω(s), while the tension is controlled
using the tension controller Kx(s) obtained in the previous section. Note, due to a sign change in the
tension dynamics introduced by the pre-compensator the tension feedback loop is positive.

-
+
rω Kω(s) ω3
K(s) P(s)
-
rx Kx(s) x
+

Fig 11. Tension and Speed Control

Figure 12. CE2000 Program For Speed and Tension Control

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control-systems-principles.co.uk. Coupled drives 2: control and analysis

Closed-loop Speed and Tension Step Response

3 3

2.5 2.5

Speed (Volts)
2 2

1.5 1.5

1 1
0 5 10 15 20 25

0.5 1
Tension (Volts)

0.5

0 0

-0.5

-0.5 -1
0 5 10 15 20 25
Time (Sec) Time (Sec)

Figure 13. Closed-Loop Tension and Speed Step Response

Controlling the fast tension dynamics

The tension control loop has fast dynamics. These were not controlled in the previous sections where the
closed-loop bandwidth was kept below the natural frequency of the fast dynamics which were treated as
an uncertainty. A more interesting problem is to examine how we can actively control the fast dynamics.
To examine the fast tension dynamics we can initially displace the jockey pulley and examine the
resulting transient response. This will allow us to estimate the natural frequency and damping ratio. Set
the input to both motors to zero using the CE2000 program shown in Figure 3. Next depress the tension
bar to until –2.0 Volts is indicated on the tension sensor. Release the tension bar and record the resulting
transient response. This transient response is shown in the above Figure. The dominant dynamics are
underdamped with a frequency of approximately 4.5Hz and a damping ratio of ζ=0.1. These numbers are
Jockey Pulley Transient Response
1.5

0.5

0
Voltage (Volts)

-0.5

-1

-1.5

-2

-2.5
0 0.5 1 1.5 2 2.5 3 3.5
Time (Sec)

Figure 14. Experimental Open-Loop Tension Dynamics

only approximate and will be slightly different for each CE108 coupled drive. To control the tension will
require a sampling time of around 10ms.

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4. Motor Speed Control

In this section we show experimentally that it is possible to independently control the speed of the two
motors. This is interesting because this is not possible using the model obtained in the previous sections.
Due to symmetry the transfer function from motor inputs to motor speed outputs does not have full rank
and therefore the model cannot be decoupled using feedback or a precompensator. A block diagram of
the system is shown below.

Inputs Outputs
ω1
U1 Coupled
Drives ω2
U2

Figure 15. Speed Control

In the experiment independent PI controllers used to control the speed of each motor. As in the previous
section a pre-compensator can be introduced to reduce interaction between motor speeds.

Open-Loop Speed Dynamics

To examine the open-loop speed dynamics both motor inputs are set to a nominal voltage of 3 Volts. The
input voltages are alternatively toggled by ±1.0 Volt. The Figures below shows the output voltages for
motor 1 (blue), motor 2 (green) and the jockey pulley speed (red). In this experiment the motors and the

Figure 16. CE2000 Program For Speed Control

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belt rotate clockwise. After passing over the jockey pulley the belt passes over motor 2. Note that the
jockey pulley speed tracks motor 2 speed and not that average of the two speeds as predicted by the
model. If the belt direction is reversed then the after passing over the jockey the pulley passes over motor
1. The jockey pulley speed will track motor 1 speed.

Open-Loop Step response for Wm1, Wm2, and Jockey speed with V1=1, V2=0 Open-Loop Step response for Wm1, Wm2, and Jockey speed with V1=0, V2=1
1 1

0.8 0.8

0.6 0.6

0.4 0.4

Voltage (Volts)
0.2
Voltage (Volts)

0.2

0 0

-0.2 -0.2

-0.4 -0.4

-0.6 -0.6

-0.8 -0.8

-1 -1
0 5 10 15 0 5 10 15
Time (Sec) Time (Sec)

Figure 17. CE108 Open-Loop Speed Step Response

A section of the step response is shown in the figure below. This allows us to estimate the following
simple model for the two speed outputs.

Open-Loop Step response for Wm1, Wm2, and Jockey speed with V1=1, V2=0

0.8

0.6
Voltage (Volts)

0.4

0.2

-0.2
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Time (Sec)

Figure 18. Step Response

⎛ ω1 ( s ) ⎞ ⎛ u1 ( s ) ⎞
⎜ ω ( s ) ⎟ = P( s ) ⎜ u ( s) ⎟ (32)
⎝ 2 ⎠ ⎝ 2 ⎠

⎛ 0.6 0.4 ⎞ 1
P( s ) = ⎜ ⎟ (33)
⎝ 0.4 0.6 ⎠ ( 0.5s + 1)

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Multivariable Speed Control

In this section we demonstrate multivariable speed control using the coupled drives. The objective is to
independently control the speed of each motor. To do this a PID controller
Ki
C ( s) = K p + (34)
s

is used to control the speed of each motor. The nominal reference speed of both motors is set to 2 Volts.
The figure below shows the closed-loop step response when a step of 0.5 Volts is applied to motor 1.
After a small initial disturbance the speed of motor 2 is maintained close to 2 Volts while the speed of
motor 1 follows the reference input to 2.5 Volts. Similarly when the reference input to motor 2 is 2.5
Volts motor 2 the speed of motor 2 follows the reference while the speed of motor 1 is maintained close
to the reference voltage.

Closed-loop Speed Step Response

3

2.5
Speed (Volts)

1.5

1
0 1 2 3 4 5 6 7 8 9 10
Time (Sec)
3

2.5
Speed (Volts)

1.5

1
0 1 2 3 4 5 6 7 8 9 10
Time (Sec)

Figure 19. Experimental Closed-Loop Speed

Control

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5. A Final Word
It is not possible to answer questions about our white papers, unless we have a contract with your
organisation. For more information about the CE2000 Control and Simulation Software go to the TQ
Education and Training web site using the links on our web site www.control-systems-principles.co.uk or
use the email [email protected]. There are many books and tutorial papers that will help you with the
theoretical background of control for the coupled drives, we are particularly indebted to the references
listed below. For a web search of references, try key words such as coupled drives and tension control,
belt drives and dancer.

6. References

1. Wellstead P. E Introduction To Physical Modelling Systems, Academic Press 1979

2. Dorf, R C and Bishop, R H, Modern Control Systems, (9th Ed) Prentice Hall 2000.

3. Readman, M. C, Flexible Joint Robots, CRC Press, 1994

4. Torkel Glad and Lennart Ljung, Control Theory Multivariable and Nonlinear Methods, Taylor and Francis 2000.

5. http://www.control-systems-principles.co.uk/coupled-drives-system.pdf

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