PRODUCTION TECHNOLOGY Archieven

Long story short

KU Leuven’s M-Group was looking for more than just another electric motor lab—they needed a flexible and transparent platform that could seamlessly connect simulation with real-world behavior.

In collaboration with Imperix, CTRL Engineering developed a rapid prototyping test bench that bridges MATLAB/Simulink simulations with actual motor dynamics.

This real-time platform enables hands-on learning, experimentation, and algorithm validation—from speed and torque control all the way down to PWM signal generation on industrial-grade hardware.

The Challenge: Not just black-box motor drives

Most academic motor labs either stop at simulation or depend on closed, black-box motor drives that can only be parameterized. As a result, students and researchers rarely gain insight into the inner current, torque, and speed control loops—let alone modify them.

KU Leuven’s M-Group set out to change that. They wanted a fully open and transparent platform that exposes every layer of motor control, from PWM generation to torque regulation, all within MATLAB and Simulink. The goal was to allow users not just to observe but to design, test, and tune every control loop in real time.

Achieving this level of openness required more than simulation models or off-the-shelf drives. It demanded real-time FPGA processing, industrial-grade motors and encoders, a regenerative DC power supply for flexible test conditions, and robust safety systems capable of handling high-performance experiments without compromise.

The solution: a rapid prototyping playground

CTRL Engineering and Imperix partnered to design and deliver a modular rapid prototyping test bench for motor control research and education.

At it’s core lies a high-performance real-time platform that combines a powerful CPU with a directly integrated MATLAB/Simulink SDK and an FPGA. The FPGA processes encoder pulses with microsecond precision, providing high-frequency rotor speed feedback and enabling deterministic execution of control loops.

The setup integrates with existing Bosch Rexroth e-motors from KU Leuven’s laboratory, equipped with resolvers that deliver realistic mechanical dynamics. An active regenerative DC power supply ensures flexible and repeatable test conditions, while a comprehensive Pilz safety system protects both users and equipment during operation.

CTRL Engineering managed the complete electrical system design, including cabinet layout, wiring, and seamless integration of motors, sensors, and safety circuits—transforming the existing hardware into a unified and transparent test environment.

As part of the commissioning phase, CTRL Engineering went beyond the hardware setup. We developed and deployed a MATLAB/Simulink implementation of Field-Oriented Control (FOC), including both speed and torque control loops, to demonstrate and validate the platform’s full capabilities. The implementation includes the modeling of d–q current and torque control loops, the application of Clarke and Park transformations, real-time current feedback and rotor position estimation through encoder signals, PWM generation with deterministic timing towards the current phase gates, and closed-loop speed and torque regulation for dynamic load testing.

Results: simulation meets industrial reality

The new test bench enables KU Leuven’s students and researchers to experiment directly with industrial-grade motor control. Algorithms such as FOC and DTC can now be developed in Simulink, deployed in real time, and validated against real torque and current responses. High-frequency data acquisition allows users to analyze switching events, control stability, and transient response with unmatched clarity.

The platform supports a broad range of applications—from fundamental control education to advanced R&D in predictive control, sensorless estimation, and multi-motor coordination. Thanks to its modular structure and scalable architecture, it can easily accommodate future upgrades in power electronics, control hardware, or safety systems.

Why it matters to you? From reactive to proactive maintenance

For KU Leuven, this platform bridges the gap between modeling and real-world validation. For CTRL Engineering, it underlines our capability to deliver end-to-end rapid prototyping solutions—from Simulink model to real-time PWM—enabling safer, faster, and more transparent motor control development.

This project illustrates how CTRL Engineering translates complex control theory into real, operational hardware. By combining our expertise in control systems, FPGA programming, and industrial integration, we create environments where learning, testing, and innovation converge.