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Do you use standard Master-Slave configuration - i.e. Slave controlled by Master encoder? Do you have high or low difference between both rolls' diameters? What's happens if you keep Gear ratio constant? i.e. one of motor load is increased?

It seems that you must change Gear Ratio from step to step according to difference in motors' load.

Standard PLC have limiting features for process control if has ones at all. The better way is using Process Controller with referred feature if you find ones.

It seems that current command isn't reach friction level in spite of load absence for 1st case. And with higher current command for 2nd case you can overcome friction, but due to existence of current loop only (without not velocity or not position loops), velocity going up to max value...

Why is "evaluation board"? You can buy servo amplifier for your bldc hub motor 48V/20A from leading manufacturers as Elmo, AMC, Copley, etc.

1. You need define range of Kp and kd (i.e. low and high limits) as well. 2. You must take absolute value of e(t) 3. Changing of kd is effective for dynamics but not for steady state

The dynamic braking resistor operates during deceleration phase doesn't allowing increase DC bus voltage above safety level. During operation the resistor simly connected to DC bus by switch (internal for driver). Most of modern amplifier has such option and it maybe used further during...

You can use tacho of master roll as speed command for smaller slave roll. The tacho of slave roll maybe used for slave VFD as speed feedback if it possible. But you must scale a speed slave signal for move web at the same linear speed. But if you need higher level of synchronization...

Motion controller has some features for high performance motion control vs PLC as interface for digital/analog encoders with MHz frequencies, advanced PID-filter with velocity/acceleration feed forward, internal low pass/Notch filters, dual loop, position compare and position capture, etc. With...

Do you use a gyroscope as feedback for both control loops of two wheels? Do you have separate control loops for each wheel? Do you have take into account mechanical crossing between wheels?

You need check some following issues: 1. Do PLC output pulses have amplitude and width according to stepper driver Spec? 2. Do you use High Speed Output of PLC? 3. Do you keep "Direction" Input of stepper driver at GND or Vcc level? 4. Do you use any acceleration/deceleration with...

It seems that you talk about system resolition in mrad. And this question is more related to encoder resolution then motor. Also response time more related to servo performance.

The possible reason for noise is instability of velocity loop usually leading to current ripple with audible noise and therefore for overheating. The right way is take current monitor shape for check a noise frequency. And you can set low pass filter or change Pi-filter for appropriate damping...

The precise potentiometer with analog input in your controller is simpler option enough for asked accuracy. Unlike potentiometer both other position sensors as abs. encoder or resolver are need in digital encoding devices. But you must be care about sensor-to-shaft attachment for...

Maybe such current changes with speed from 2500RPM to 3000RPM is a load phenomena? What kind of load you investigate?

The Interface between PLC S7-200 and speed controller for DC motor must include Analog speed signal +/- 10V (PLC Analog Output), Enable (PLC Digital Output) and Fault (PLC Digital Input). If you need low speed range, than use scr drives. In case in high speed range, PWM drives will be suggested...

Some questions before all: 1. Do you not limited by DC bus with actual back-EMF ratio? 2. Do your sensor for trap commutation works properly? 3. Do you check motor current?

For calculating of motion time you can use Profiler Calculator from Copley - http://www.copleycontrols.com/Motion/Java/calculator-Scurve.html Please pay attention that move time only (i.e. without Settling time) can be calculated by such way.

The right way for your test could be using any digital servo controller with resolver feedback - for example from Elmo - http://www.elmomc.com/products/elmo-digital-servo-drives-main.htm That can you possibility to test all components separately and even together. But in any case...

Or "We compared the performance of the standard PID controller tuned by by 5 different ways (methods)".