Compact geared servo drives are a common part of modern industrial automation; thus, their proper modelling is a necessary part for the application and control design. The presented paper focuses on the mathematical model of the cycloidal gearbox, which is used in the compact actuator with a permanent magnet synchronous motor. A measurement procedure to obtain the necessary gearbox parameters is presented along with its mathematical model. A new approach was used to model the stiction and nonlinear gearbox friction behaviour in all four quadrants. A simulation of the actuator with the modelled gearbox is described and its results are compared with the real system measurement. Obtained results show a high match between simulation and experimental results and confirm the correctness of the simulation model.

The aim of the presented paper is to introduce the reader to hardware-in-the-loop (HIL) simulation in electric drives, the motivation for its usage and its benefits. Basic information about HIL simulation in general and the connection to electric drives is followed by an explanation of the main principle of the dynamic emulation of mechanical loads for electric drives, which is a special case of HIL simulation. Next, the description of the three main methods of load emulation and their mathematical background are presented in the order of historical appearance: the emulation with compensator and tracking controller, the emulation based on non-linear control and the emulation with feed-forward compensation with the use of inverse dynamics.

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