Automated Industrial Wind Tunnel Network Control...
Transcript of Automated Industrial Wind Tunnel Network Control...
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