Automated Industrial Wind Tunnel

Network Control with LabVIEW

Matt Draear

Advisor: Dr. MalinowskiAdvisor: Dr. Malinowski

1

Presentation Outline

• Overview of Old Hardware

• Overview of New Hardware

• Details of New Hardware

• FPGA LabVIEW Code

• Real-Time Controller LabVIEW Code

• Wind Tunnel Test Results• Wind Tunnel Test Results

2

Old Hardware Overview

3

New National Instruments Hardware

4

Wind Tunnel

Router

National Instruments cRio

Computer

Remote

LabView

Operator

Internet

NI 9472

NI 9505

NI 9205

NI 9211FPGA

Real

Time Cont.

Relay Fan On/Off

Relay Damper Direction

Relay Damper On/Off

Actuator #1 Feedback

Actuator #2 Feedback

Actuator #3 Feedback

Lift Force

Drag Force

Ambient Air Pressure

Wind Tunnel Air Pressure

Ethernet

System Diagram With New Hardware

Webcams

Operator

Interface

Ethernet

NI 9505

NI 9505

NI 9505

Cont. Lift Force

Future Thermocouple #1

Future Thermocouple #2

Actuator #1 Motor

Actuator #2 Motor

Actuator #3 Motor

5

National Instruments cRIO – 9074

6

Analog Input NI - 9205

7

Thermocouple Input NI - 9211

8

Digital Output NI - 9472

9

Motor Controller NI - 9505

10

FPGA Interface

http://www.mit.bme.hu/system/files/oktatas/targyak/7258/criodevgudfull.pdf

11

Downloading LabVIEW Code to FPGA

http://www.mit.bme.hu/system/files/oktatas/targyak/7258/criodevgudfull.pdf

12

LabVIEW Project with

FPGA / Real Time Controller / IO

13

FPGA Front Panel

14

Hardware I/O

Actuator PID Control Loop

Actuator Control PWM

Wind Speed PID Control Loop

FPGA LabVIEW Code

Wind Speed PID Control Loop

Damper Control PWM

15

Hardware I/O

FPGA LabVIEW Code

16

Hardware I/O Interface With FPGA

17

Actuator PID Control Loop

FPGA LabVIEW Code

18

Actuator PID Control Loop

19

Linear Actuator Distance Versus Setpoint

30

40

50

60

70

Act

ua

tor

Ex

ten

sio

n (

mm

)

Setpoint

0

10

20

0

0.1

2

0.2

4

0.3

6

0.4

8

0.6

0.7

2

0.8

4

0.9

6

1.0

8

1.2

1.3

2

1.4

4

1.5

6

1.6

8

1.8

1.9

2

2.0

4

2.1

6

Act

ua

tor

Ex

ten

sio

n (

mm

)

Time (s)

Position

20

Actuator Control PWM

FPGA LabVIEW Code

21

Actuator Control PWM Generation

22

Wind Speed PID Control Loop

FPGA LabVIEW Code

Wind Speed PID Control Loop

23

Wind Speed PID Control Loop

24

Wind Speed Versus Setpoint

Win

d S

pee

d (

Mil

e P

er H

ou

r)W

ind

Sp

eed

(M

ile

Per

Ho

ur)

Time (Seconds)

25

FPGA LabVIEW Code

Damper Control PWM

26

Damper Control PWM Generation

27

Hardware I/O

Actuator PID Control Loop

Actuator Control PWM

Wind Speed PID Control Loop

FPGA LabVIEW Code

Wind Speed PID Control Loop

Damper Control PWM

28

Real Time Target LabVIEW Code

29

Real Time Target LabVIEW Code

Startup Code

Inputs From FPGA

Measurement Conversions

Output To FPGA

Automated Test Control

Graph and Data Acquisition

Test Time Counter

30

Real Time Target LabVIEW Code

Startup Code

31

Startup Code

Enable(1)/Disable(0) Lower Limit (mm) Upper Limit (mm)

Actuator #1 1 70 160

Actuator #2 1 0 199

WindTunnelConfigSettings.CSV

Actuator #2 1 0 199

Actuator #3 0 0 199

32

Real Time Target LabVIEW Code

Inputs From FPGA

Output To FPGA

33

FPGA I/O

Inputs From FPGA Outputs To FPGA

34

Real Time Target LabVIEW Code

Measurement Conversions

35

y = 20.555x + 0.0314

0

0.5

1

1.5

2

2.5

0 0.02 0.04 0.06 0.08 0.1 0.12

Lift

Fo

rce

Ib

s

Sensor Output Voltage

Lift Force Sensor Voltage to Ibs

y = 9.2584x + 0.0033

-1.5

-1

-0.5

0

0.5

1

1.5

-0.15 -0.1 -0.05 0 0.05 0.1 0.15

Dra

g F

orc

e I

bs

Sensor Output Voltage

Drag Force Sensor Voltage to Ibs

36

y = 6009.7x + 79473

0

20000

40000

60000

80000

100000

120000

0 1 2 3 4 5 6

Ab

solu

te A

ir P

ress

ure

Pa

Sensor Output Voltage

Ambient Air Pressure Sensor Voltage to Pa

y = 689.48x

0

1000

2000

3000

4000

5000

6000

7000

8000

0 2 4 6 8 10 12

Re

lati

ve

Air

Pre

ssu

re P

a

Sensor Output Voltage

Wind Tunnel Air Pressure Sensor Voltage to Pa

37

Measurement Conversions

38

Measurement Conversion Sub VIs

SensorConvRT.VI

WindSpeedCalcRT.VI

SensorConvRT.VI

39

Real Time Target LabVIEW Code

Automated Test Control

40

Automated Test Control

41

Automated Test Control

42

Automated Test Control

43

Real Time Target LabVIEW Code

Graph and Data Acquisition

44

Graphing and Data Acquisition

45

Step

Step

Time (s)

Wind

Speed

#1 Actuator

Position (mm)

#2 Actuator

Position (mm)

#3 Actuator

Position (mm)

0 20 50 120 90 0

1 15 50 90 90 0

2 15 50 150 90 0

3 20 70 120 90 0

WindSpeedTest.CSV

3 20 70 120 90 0

4 15 70 90 90 0

5 15 70 150 90 0

6 20 60 120 90 0

7 15 60 90 90 0

8 15 60 150 90 0

9 15 80 120 90 0

10 15 90 120 90 0

46

Data Acquisition Sub VIs

FilePathRT.VI

FileSetupRT.VI47

Real Time Target LabVIEW Code

Test Time Counter

48

Test Time Counter

49

Real Time Target LabVIEW Code

Startup Code

Inputs From FPGA

Measurement Conversions

Output To FPGA

Automated Test Control

Graph and Data Acquisition

Test Time Counter

50

Test Results and Debugging

51

60

80

100

120

140

160

Plot From Test Data Recorded to Spreadsheet

-40

-20

0

20

40

Time (s) 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

Wind Speed Set Point (MPH) Wind Speed (MPH) Linear Actuator #1 Setpoint (mm)

Linear Actuator #1 Position (mm) Drag Force Ibs x10 Lift Force Ibs x10

52

[1] Ben Morrison and Mike Firman. “Web Enabled Wind Tunnel System”, Senior

Project, Electrical and Computer Engineering Department, Bradley University, March

2010, http://cegt201.bradley.edu/projects/proj2010/webwind/

[2] Nick Detrempe and Daniel Monahan. “Automated Industrial Wind Tunnel Controller”,

Senior Project, Electrical and Computer Engineering Department, Bradley University, April

2012, http://cegt201.bradley.edu/projects/proj2012/aiwt/

[3] NI CompactRIO, National Instruments, [Online] 2012, http://www.ni.com/compactrio

Sources

53

NI 9505 Wiring Diagram

54

NI 9472 Wiring Diagram

55

NI 9205 Wiring Diagram

56

NI 9211 Wiring Digram

57