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Multidisciplinary Engineering Senior Design Project 6508 Controls Lab Interface Improvement Critical Design Review 2/24/05. Project Sponsor: EE Department Team Members: Michael Abbott, Neil Burkell Team Mentor: Dr. Mathew, Dr. Sahin Coordinator: Dr. Phillips.

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Project sponsor ee department team members michael abbott neil burkell

Multidisciplinary Engineering Senior DesignProject 6508 Controls Lab Interface ImprovementCritical Design Review2/24/05

Project Sponsor: EE Department

Team Members: Michael Abbott, Neil Burkell

Team Mentor: 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      • The Digital Board is outdated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 Ruben Mathew 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 was 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:

    • Interface MATLAB/Simulink with the servo DC motor

    • Simulink block diagram will control the servo DC motor

    • Sampling time easily changeable from 1 ms to 300 ms

    • Interface will return real time data and output real time signals

    • Interface will have 4 additional digital inputs/outputs, 1 additional analog output, and 7 differential analog inputs


Requirements developed1

Requirements Developed

  • The Requirements of the Project (continued)

    • Interface will acquire motor speed and position data

    • Analog inputs: resolution of 16 bits, range of +10V to -10V.

    • Analog outputs: resolution of 16 bits, range of +10V to -10V.

    • Interface will be covered

    • Use the existing Feedback Power Supply


Overall system diagram

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


Project sponsor ee department team members michael abbott neil burkell

Input Shaft

Output Shaft

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

Tachogenerator

Mechanical Unit 33-100


Project sponsor ee department team members michael abbott neil burkell

MATLAB Software Layout


Analysis synthesis of design

Analysis & Synthesis of Design

  • Multiple Concepts were developed

    • Using a DSP Development Kit

    • Using a USB Data Acquisition Board

      • Importing Simulink diagram into NI LabVIEW

    • Data Acquisition PCI Card in Windows

    • Separate PC with I/O Capability controlled by MATLAB


Analysis synthesis of design1

Analysis & Synthesis of Design

  • Concept 1: Using a DSP Development Kit

Simulink

USB

RS232

DSP Kit

Interface Board

Motor

  • Concept 2: Using a USB DAQ Board

Simulink

USB

DAQ Board

Interface Board

Motor

  • Both concepts found not to be feasible


Analysis synthesis of design2

Analysis & Synthesis of Design

  • Concept 3: PCI DAQ Card

Simulink

PCI DAQ

Interface Board

Motor

  • PCI Card meets all requirements for I/O’s

  • PCI Card is supported by Simulink and Real Time Workshop

  • Runs Inside the Windows Environment

  • No additional software would need to be purchased

  • Additional breakout hardware would be necessary

  • System Interface would not be portable

  • Measurement Computing PCI Card has best value


Analysis synthesis of design3

Analysis & Synthesis of Design

  • Concept 4: Separate PC with PCI DAQ Controlled by MATLAB

Simulink

Computer

PCI DAQ

Interface Board

Motor

Ethernet

RS232

  • PCI Card meets all requirements for I/O’s

  • PCI Card is supported by Simulink, Real Time Workshop, and xPC Target

  • Runs external from the Windows Environment

  • Additional breakout hardware would be necessary

  • System Interface would be portable

  • Measurement Computing PCI Card has best value


System diagram

System Diagram

  • Both concepts use the Real Time Workshop in MATLAB

Real Time Windows Target Toolbox

Real Time

Workshop

Generated C

Code

Simulink

PCI Card

Interface

Board

DC Motor

Computer

xPC Target Toolbox

PCI Card

Simulink

Real Time

Workshop

Generated C

Code

xPC Kernel

DC Motor

Interface

Board

Computer

Second Computer

System Block Diagram


Pci daq card

PCI DAQ Card

  • Measurement Computing PCI Card

    • 16 Analog Inputs

    • 2 Analog Outputs

    • 24 Digital Inputs or Outputs


Gantt chart followed

Gantt Chart Followed


Desired outcomes

Desired Outcomes

  • A complete working digital control system:

    • Interfaces with Simulink

    • Not dependant upon software versions

    • Simple to use

    • Can be used in other applications


Desired outcomes1

Desired Outcomes

  • Compare the differences between using PCI DAQ Card and external computer with PCI DAQ Card

    • From transient testing for the Control System Design Class

    • Using a more computationally intensive controller (Fuzzy Logic Controller) to see where each system fails


Desired outcomes2

Desired Outcomes

  • Document the process for developing digital controllers to be able to implement them in a laboratory setting


Key requirements

Key Requirements

1)Show that data can be acquired and output at the minimum sampling time of 0.001 seconds at the maximum range of±10V

2)Use interface board, Feedback Mechanical Unit 33-100, Feedback power supply, and Simulink Control Algorithm to control the speed of the motor.

3)Use interface board, Feedback Mechanical Unit 33-100, Feedback power supply, and Simulink Control Algorithm to control the position of the motor.

4)Documentation, including a user guide, working Simulink models, and a service manual.


Critical parameters

Critical Parameters

  • Acquire 20 V peak to peak, 100 Hz sine wave using digital interface and output. Verify with oscilloscope.

Output Wave

Input Wave


Critical parameters1

Critical Parameters

  • Velocity control of motor to a reference of 1.5 V (600 RPM) recorded on both an Oscilloscope and by MATLAB

    Transient Results include Rise Time, Overshoot, Peak Time


Critical parameters2

Results for Integrator Controller

1.5

1

Tachometer Voltage [V]

0.5

0

10

11

12

13

14

15

16

17

18

19

20

time [sec]

Critical Parameters

  • Use a Simulink Integrator Controller

    • Verify: -Tachogenerator voltage 1.5 V ± 5%

Power Amplifier on Motor

SIMULATION RESULT

Tachogenerator Voltage from Motor


Critical parameters3

Results for Integrator Controller

1.5

1

Tachometer Voltage [V]

0.5

0

10

11

12

13

14

15

16

17

18

19

20

time [sec]

Critical Parameters

  • Use a Simulink PI Controller

    • Verify: -Tachogenerator voltage 1.5 V ± 5%

      -Transient Results within ± 5%

Power Amplifier on Motor

SIMULATION RESULT

Tachogeneartor Voltage from Motor


Critical parameters4

Critical Parameters

  • Use a Simulink One Pole Controller

    • Verify:-Tachogenerator Voltage within ± 5% Theoretical Steady State Error

      -Transient Results within ± 5%

Power Amplifier on Motor

SIMULATION RESULT

Tachogenerator Voltage Output from Motor


Critical parameters5

Critical Parameters

  • Position control of motor output shaft from a initial value of 270 degrees to 90 degrees

    • Use a Simulink Feedback Controller

      • Verify:-Transient results within ± 5% of analog control

Output Shaft Voltage from Motor

Input Shaft Voltage from Motor


Critical parameters6

Critical Parameters

  • Documentation:

    • Include all Simulink diagrams used in testing

    • Step by step user guide on how to setup both xPC and RTW Target toolboxes and systems

    • Full system design including part numbers, PCB layout files, and schematics of Feedback system

Motor Connector

Test Points

Simulink Diagram

PCI Connectors

PCB LAYOUT


Major design challenges

Major Design Challenges

  • Documentation on Feedback System was lacking

    • Traced servo DC motor board and analog board to develop schematics to understand the different signals

    • Establishing control of the servo DC motor with results similar to the analog controller

      • Preliminary testing using breakout box and wires with sockets verified the correct signals needed


Major design challenges1

Major Design Challenges

  • Understanding and using Real Time Workshop using xPC Target Toolbox and Real Time Windows Target Toolbox

    • Read manuals on both toolboxes and performed tutorials

  • Noise when reading sensor data from the servo DC motor board

    • Traced to Feedback switching power supply

    • Noise eliminated when using HP power supply currently in lab


Interface design

Interface Design

-Interface connections needed

PCI DAQ Card

6 Analog Inputs

1 Analog Output

6 Digital Inputs

Interface Board

Motor Board

5 Analog Sensors

1 Analog Input

6 Digital Outputs


Analysis of design

Analysis of Design

  • Failure Analysis was done for the system

    • Measurement Computing contacted to find absolute max ratings for PCI card

    • Maximum input/output voltages of Feedback system investigated

    • Motor board and PCI card were determined to be safe from damage


Analysis of design1

Analysis of Design

  • Safety codes were investigated

    • OSHA code that applies:

      Guarding of live parts.

      1910.303(g)(2)(i)

      Except as required or permitted elsewhere in this subpart, live parts of electric equipment operating at 50 volts or more shall be guarded against accidental contact by approved cabinets or other forms of approved enclosures, or by any of the following means:

    • Highest rated voltage on interface board is 30 V

    • Design safe for laboratory setting


Final design

Final Design

-Interface board is redesigned with the previous connections but with different test point locations and additional pads in case extra circuitry is desired

-Larger holes will be designed into the interface board to be able to put a Plexiglas cover


Final design1

Final Design

-For Control Design Lab Real Time Windows Target Toolbox meets the criteria for all controllers that would be implemented

-For other higher level classes the xPC Target Toolbox should be utilized (Fuzzy Logic, Modern Control, Signal Processing, etc)

Computer

Computer

RS-232

Computer

PCI Card

PCI Card

PCI Card

Interface

Board

Interface

Board

Interface

Board

Motor

Board

Motor

Board

Motor

Board

One Computer Solution

Two Computer Solution


Testing results

Testing Results

  • Integrator Results


Testing results1

Testing Results

  • PI Controller Results


Testing results2

Testing Results

  • One Pole Controller Results


Testing results3

Testing Results

  • Two Pole, One Zero Controller Results


Testing results4

Testing Results

Output Shaft

  • Position Control Results

Input Shaft


Testing results5

Testing Results

  • Power Supply Noise Results


Testing results6

Testing Results

  • Fuzzy PI Controller Implementation Performance Comparison


Conclusions

Computer

Computer

RS-232

Computer

PCI Card

PCI Card

PCI Card

Interface

Board

Interface

Board

Interface

Board

Motor

Board

Motor

Board

Motor

Board

One Computer Solution

Two Computer Solution

Conclusions

-Both designs successful

-Both can be used in Current Control Systems Design Lab

-Two Computer Setup can be used in multiple applications


Thank you

Thank You

Dr. PhillipsDr. MathewKen SnyderJim StefanoJacob Slezak


Questions

Questions

?


Project sponsor ee department team members michael abbott neil burkell

Single Computer Setup BOM

Two Computer Setup BOM


Project sponsor ee department team members michael abbott neil burkell

Production Plan


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