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Using PLC for control BLDC motors isn't good idea due to necessity to commutation of motor and use 3-phase power stage. Well-known compact digital motion controller with build-in servo amp from Elmo, AMC or Copley will be better solution. Macro program inside controller with I/O may keep your...

Your structure for single axis must include state space controller and observer for evaluation of some system's variables inaccessible for direct measurement - all implemented with NI software. And - if I understand true - external torque/force loop will be implemented with hardware. Also you...

Do you want implement both state space controller and hardware interface with LabVIEW pack? How much degrees of freedom have your pendulum? What is power of control system including observer?

If you looking for frameless DC motors as DC torque motors from Kollmorgen, http://www.kollmorgen.com/website/com/eng/products/motors/dc_motors/dc_torque_motors.php than Sizing & selection Tools from them would be helpful for you.

Because coils' current isn't proportional directly to load's torque/force due to dynamics, clogging, viscous damping, magnetic saturation, etc.

It seems you have problem with motor's voltage and not with power. You must check Duty cycle for Gate and Source-Drain of upper and bottom MOSFETs at max speed reference. And I hope you change speed reference with rate due to absence of limit of motor's current.

It seems your motor has resolver and not encoder. And you must configure resolver for need resolution inside corresponding option for resolver - I believe it exist inside FlexDrive.

At first, check encoder's mounting to motor shaft. At second, how looks steady-state error (vibration, un stability or random really)? - Maybe you have possibility to monitor position error?

Do you connect both motor's coils to the same amp? And if Yes, do you perform any phasing procedure before connection?

What's kind of your motor (i.e. PMBL or others)? Is 8kW cont. or peak power?

The simpler way is using Analog Output 0-10V for speed regulation (instead of PWM one) and Digital Output for Enable of speed regulator with PLC S7-200. Cheap SCR speed regulator with analog input you may find through Internet.

The another problem, except tuning of system with such very high mismatch, would be "regenerative" energy with deceleration of your flywheel. Than shunt regulator for power supply of motor amp is strongly recommended.

For tuning each servo axes separately as first step, Application Note from Galil maybe suggested: www.galilmc.com/support/appnotes/optima/note3413.pdf But I think you need dual axes controller at least with possibility to perform crossing control between axes.

OK, but I need more details of your application: - Microflex operation mode (i.e. current or velocity); - operation mode of application (i.e. velocity or position); - velocity range (min...max); - encoder resolution, etc. You may contact me directly: leonid.lega [at] gmail.com

What type of linear encoder with Hall sensor do you have? Can Microflex drive perform brushless motor's commutation with encoder only?

Modern motion controllers are closer to PAC vs PLC because except possibility to perform complex coordinated motion task for up 16 (for some controllers even up 32) servo axes, allow to perform logic task with build-in I/O or with one of field bus controlled networks as CAN, Modbus, DeviceNet,etc.

Beckhoff has wide range products for many popular field buses including of course CANopen one.

Pay attention on peak torque also - you define very high dynamic (more than 6,000 rad/s^2!) for the application.

If you need apply reactive (i.e. friction type) torque, than magnetic particle brake with current controlled torque (for example from Warner Electric) and hollow shaft encoder with standard resolution 1024 CPR would be significantly cheaper solution.

If both motors are mechanically coupled, than you need to control two axes in Gantry mode - see more details inside for example Galil website: www.galilmc.com