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Multidisciplinary Engineering Senior Design Project 6508 Controls Lab Interface Improvement Preliminary Design Review 11/11/05. Team Members: Michael Abbott, Neil Burkell Project Sponsor: Dr. Bowman Team Mentors: Dr. Mathew, Dr. Sahin Coordinator: Dr. Phillips.

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slide1

Multidisciplinary Engineering Senior DesignProject 6508 Controls Lab Interface ImprovementPreliminary Design Review11/11/05

Team Members: Michael Abbott, Neil Burkell

Project Sponsor: Dr. Bowman

Team Mentors: Dr. Mathew, Dr. Sahin

Coordinator: Dr. Phillips

Kate Gleason College of Engineering

Rochester Institute of Technology

project overview
Project Overview
  • Current Controls Lab:
    • Current System used was purchased from Feedback for use in the Controls Lab which included Analog and Digital Control Boards to be used with a DC Motor.
      • System was designed for technicians not students
      • The Digital Board is outdated
      • Past work from a student has shown the digital board does not work
project overview1
Project Overview
  • Current Controls Lab:
    • Digital control is taught through Simulink from varying sampling time and using different methods for converting continuous to discrete transfer functions
    • There are no hardware experiments using digital controllers
  • A new Digital Board is needed for the Lab
project overview2
Project Overview
  • Needs for the Controls Lab:
    • Need to use Simulink on Lab PC
    • Need to use current Feedback 33-100 DC Servo Motor and Power Supply
  • The new digital interface must link Simulink to the existing DC motor
  • Exploration into feasible interface concepts is needed (SD I deliverable)
needs assessment
Needs Assessment
  • System must interface Simulink to the motor
  • Capture experimental results accurately
  • User friendly for the students
  • Change sampling time easily for student learning
  • Use existing equipment
  • Be expandable for future labs or projects
  • Have a finished product by the end of Winter quarter
  • Protected from students but also be accessible to be fixed
requirements developed
Requirements Developed
  • The Requirements of the Project are as follows:
    • The system shall interface MATLAB/Simulink with the Feedback Mechanical Unit (33-100 Servo Motor) already used in the Controls Laboratory.
    • The user shall input their desired Simulink block diagram in Simulink/MATLAB which will control the 33-100 Servo Motor using the MATLAB Real-Time Workshop.
    • The sampling time of the system shall be easily changeable by the user from 1 ms to 300 ms.
    • The system interface will return real-time data from the 33-100 Servo Motor to Simulink/MATLAB for analysis and modification of new outputs to control the motor according to Simulink Block Diagram.
    • The system interface shall have 4 additional digital inputs/outputs, 1 additional analog output, and 7 differential analog inputs beyond the requirement for control of the 33-100 Servo Motor which may be used in other applications.
requirements developed1
Requirements Developed
  • The Requirements of the Project (continued)
    • The system interface will acquire speed and position of the motor to be used for processing.
    • Analog inputs shall have a resolution of 16 bits and a range of +10V to -10V.
    • Analog outputs shall have a resolution of 16 bits and a range of +10V to -10V.
    • The system interface will be covered to prevent damage/access from lab users.
    • The system shall use the existing Feedback Power Supply for powering the 33-100 Servo Motor.
    • The system shall be able to perform the functions listed in current Controls Lab 8 including effects of sampling time, continuous to discrete conversion, and designing a discrete controller with specifications
slide8

Block Diagram of MathWorks Software Organization

MATLAB

Simulink

Real-Time

Target

Real-Time

Workshop

Digital Controller

overall system diagram

Feedback

Power

Supply

Lab PC

with Matlab

and Simulink

Gnd, +-15V, 5V

Communication

System

Interface

Feedback

33-100

DC Servo Motor

Analog to Motor +-8V to PA(+ve,-ve)

Analog from Motor Tachogenerator +-8V

Digital from Motor, 6 Grey Code + Index for Position

Overall System Diagram
analysis synthesis of design
Analysis & Synthesis of Design
  • Multiple Concepts were developed
    • Using an Analog Devices DSP Development Kit
    • Using a National Instruments USB Data Acquisition Board
      • Writing a driver to allow Matlab Real Time Workshop to communicate with board
      • Using NI Labview Simulation Interface Toolkit Importing Simulink into NI LabVIEW and then running experiments in LabVIEW on PC based DAQ card or external DAQ target
    • Using a National Instruments or Measurement Computing Data Acquisition PCI Card
    • Using xPC Target in Matlab to control a PC with I/O Capability
analysis synthesis of design1
Analysis & Synthesis of Design
  • Concept 1: Analog Devices DSP Development Kit

Analog Devices EZ-KIT

analysis synthesis of design2
Analysis & Synthesis of Design
  • Concept 1 Feasibility: Analog Devices DSP Development Kit
    • Need DSPDeveloper software to interface Simulink’s Real Time Workshop with DSP boards
    • DSPdeveloper requires outdated versions of Matlab, Simulink, and VisualDSP
    • With software communication works very well with Audio Video DSP Development Kit
    • System Interface would be portable and could be used in other laboratories
    • None of the available development kits met our I/O requirements
analysis synthesis of design3
Analysis & Synthesis of Design
  • Concept 2: National Instruments USB DAQ Board

NI USB DAQPAD

analysis synthesis of design4
Analysis & Synthesis of Design
  • Concept 2 Feasibility: National Instruments USB DAQ Board
    • Board has necessary I/O Capabilities
    • System Interface would be portable and could be used with any other PC with Labview
    • Not supported by Simulink’s Real Time Workshop
    • Information from MathWorks states that using Simulink with USB is very difficult if not impossible
    • Labview Simulation Interface Toolkit could be used to convert Simulink Diagram to a Labview DLL but would require student’s knowledge of Labview programming to interface the device
analysis synthesis of design5
Analysis & Synthesis of Design
  • Concept 3: National Instruments/Measurement Computing PCI DAQ Card
analysis synthesis of design6
Analysis & Synthesis of Design
  • Concept 3 Feasibility: National Instruments/Measurement Computing PCI DAQ Card
    • PCI Card meets all requirements for I/O’s
    • PCI Card is supported by Simulink and Real Time Workshop
    • No additional software would need to be purchased
    • Additional breakout hardware would be necessary
    • System Interface would not be portable
    • Only NI cards supported by MathWorks are E-Series (top of the line $$)
    • Measurement Computing PCI Card is cheaper
analysis synthesis of design7
Analysis & Synthesis of Design
  • Concept 4: Using xPC Target in Matlab to control a PC with I/O Capability
analysis synthesis of design8
Analysis & Synthesis of Design
  • Concept 4: Using xPC Target in Matlab to control a PC with I/O Capability
    • 5 Different PC configurations supported by MathWorks were explored:
      • xPC Targetbox from MathWorks with needed I/O’s
      • General Standards PC/104 Board with needed I/O’s
      • Real Time Devices PC/104 Board with needed I/O’s
      • Dell PC with PCI DAQ Card from National Instruments or Measurement Computing
      • Shuttle Barebones PC with PCI DAQ Card from National Instruments or Measurement Computing
analysis synthesis of design9
Analysis & Synthesis of Design
  • Concept 4 Feasibility: Using xPC Target in Matlab to control a PC with I/O Capability
    • Need to add xPC Target Toolbox to MathWorks license
    • Each configuration is already supported by MathWorks
    • Each configuration would have the necessary I/O Configuration
    • System interface would be portable
    • Expandable for other projects and labs
    • Each configuration is very different in price per seat
bom costs
BOM & Costs

Concepts 1-3 Bill of Materials and Lead Times

bom costs1
BOM & Costs

Concept 4 Bill of Materials and Lead Times

bom costs2
BOM & Costs

Concept 4 Bill of Materials and Lead Times (Continued)

bom costs3
BOM & Costs
  • Bill of Materials common to all concepts:
    • Prototype Board $4.29
    • 34-Way Ribbon Cable Male Connector $3.64 (50 day lead time)
our recommendation for implementation
Our Recommendation for Implementation
  • Concept 4 with a PC104 board from Real Time Devices or the Shuttle PC with a PCI DAQ Card from either NI or Measurement Computing covers all of the needs and is most feasible for implementation by the end of winter quarter
    • Lowest cost per seat
    • Portable interface
    • Supported by MathWorks
    • Expandable
anticipated design challenges risk
Anticipated Design Challenges/Risk
  • Risks:
    • Lead time on parts
    • Availability of connectors
  • Design Challenges:
    • Hardware compatibility issues
    • Wiring I/O from interface to motor
    • Organizing received data from interface
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