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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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Team Members: Michael Abbott, Neil Burkell Project Sponsor: Dr. Bowman

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Team members michael abbott neil burkell project sponsor dr bowman

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      • The Digital Board is outdated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


Team members michael abbott neil burkell project sponsor dr bowman

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


Team members michael abbott neil burkell project sponsor dr bowman

PA +ve, PA –ve, Tachogenerator +-, Grey code Position indicator

Mechanical Unit 33-100


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)


Gantt chart of fall quarter

Gantt Chart of Fall Quarter


Sd ii project plan

SD II Project Plan


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


Questions suggestions

Questions?Suggestions?


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