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Purpose

The purpose of this paper is to elaborate a robust model‐based protective control algorithm for multi‐mass motor drives that are subjected to physical and safety constraints on their variables.

Design/methodology/approach

The algorithm relies on the off‐line computed maximum robust controlled invariant set or its approximation for the given drive system and imposed constraints. It can be used to patch any existing drive control scheme with a firm constraints satisfaction guarantee. The online patch implementation is actually a simple correction of the control signal computed with the existing control scheme, with a mandatory state observer.

Findings

Performance of the patch is tested on a two‐mass drive system in combination with classical two‐mass drive speed controllers – P+I and reduced state controller. All constraints violations that exist in the presented responses obtained without the protection patch are suppressed by using the patch which shows the effectiveness of the approach. A brief implementation analysis shows that a digital signal processor could be used for online implementation of the controller with the protective patch.

Originality/value

Robust invariant sets theory is efficiently and effectively used in a new application area – protection of multi‐mass electrical drives.

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