PC BASED EXPERIMENT ON MS150 MODULAR SERVO SYSTEM

MOHD. HAMZI BIN ZAKARIA

B010510066

NOVEMBER 2009

PC BASED EXPERIMENT ON MS150 MODULAR SERVO SYSTEM

MOHD. HAMZI BIN ZAKARIA

This report is submitted in partial fulfillment of the requirements for the

Bachelor of Electrical Engineering (Control, Instrumentation and Automation)

FACULTY OF ELECTRICAL ENGINEERING

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

2009

“I hereby declared that I have read through this report and found that it has comply

the partial fulfillment for awarding the degree of Bachelor of Electrical Engineering

(Control, Instrumentation, & Automation)”

Signature : ………………………………………………

Supervisor’s Name : MR. MUHAMAD KHAIRI BIN ARIPIN

Date : 16TH

NOVEMBER 2009

ii

“I hereby declared that this report is a result of my own work except for the excerpts

that have been cited clearly in the references.”

Signature : ………………………………………………

Name : MOHD. HAMZI BIN ZAKARIA

Date : 16TH

NOVEMBER 2009

iii

To my beloved parents

Mr.Zakaria Mohd Noor & Mrs. Fadmah Abd. Majid

And

Fellow Friends

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ACKNOWLEDGEMENT

First and foremost, I thank Allah the Almighty for blessing me to complete

my Final Year Project. I want to take this opportunity to record my utmost and

sincere gratitude to my supervisor, Mr. Muhamad Khairi Bin Aripin. Without him, I

can never start work on my project and to proceed until this point of development.

He has shown me guidance, important advice, and inspiration throughout my project.

He has also given me essential knowledge in doing this project. Besides, I would like

to show my appreciation to my lectures, who have taught me over the years in

UTeM. They have taught me the basic of Electrical Engineering, and this invaluable

knowledge has provided ma a firm foundation for doing this project. Most

importantly, the knowledge I required from them has prepared me for my career in

the future. I also really want to thank Mr. Jasmadi Bin Ismail and Miss Norliah Bte

Mahat, who are the UTeM laboratory technician that always helping me in this

project. Furthermore, I would like to thank my friends and fellow classmates for

sharing and discussing, knowledge with me. Their support, opinion, and advised will

be not forgotten. To my beloved family, I would like to forward my obliged to them

for their continuous support during my study period, their patience and benevolence.

Lastly, I would like to thank everyone who has contributed during my Final Year

Project. their kindness and cooperation of my paperwork is much appreciated.

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ABSTRACT

Servo system is used extensively in industrial sector nowadays and all control

systems that are implemented today are based on computer control. As the computer

and instrument had a well defined relationship, they can be connected by using

particular interfacing modules. Engineering student in control field should be

familiar with servo motor control. In order to understand the servo control system,

educational laboratory is needed.MS150 servo system is one of the laboratory

equipment that been used to study the servos but the tuning of the experiment

equipment need to be done manually. Today, direct manipulation interfaces, also

called Graphical User Interface are almost universal and by implementing this, it will

become handy to the laboratory experiments. A combination of the interface,

software, and MS150 Modular Servo System is likely to be the key to the success of

advanced laboratory experiment study. In this project, a PC based experiments on

MS150 Modular servo system was developed along with interface.

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ABSTRAK

Mesin Servo digunakan secara meluas di industri masa kini dan kebanyakan

sistem kawalan yang di aplikasikan adalah melalui kawalan daripada komputer.

Komputer dan instrument selalunya mudah dan biasa dihubungkaitkan, sama ada

melalui modul antara muka. Pelajar kejuruteraan di dalam pengkhususan kawalan

seharusnya mengenal dengan lebih mendalam mengenai sistem servo ini. Dalam

usaha untuk mendalami ilmu ini, pembelajaran melalui amali adalah sangat

digalakkan. Salah satu alat yang digunakan dalam amali ini ialah MS150 Servo

System tetapi pembelajaran manual menyebabkan pembelajaran kurang efektif

kerana beberapa kelemahan tertentu. Kini, Graphical User Interface atau lebih

dikenali dengan GUI semakin banyak digunakan dan jika di aplikasikann terhadap

sistem servo ini, sedikit sebanyak akan membantu pembelajaran. Dengan kombinasi

interface, software dan MS150 Servo System bakal menjadi kunci untuk menambah

baik sistem pembelajaran amali pada masa kini. Dalam projek ini, Kawalan

Komputer terhadap MS150 Servo System dibangunkan bersama dengan antara muka.

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TABLE OF CONTENTS

CHAPTER SUBJECT PAGE

DECLARATION i

DEDICATION iii

ACKNOWLEDGEMENT iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENTS vii

LIST OF TABLES x

LIST OF FIGURES xi

LIST OF APPENDICES xiii

1 INTRODUCTION 1

1.1 Project Background 1

1.2 Project Objectives 1

1.3 Project Scopes 2

1.4 Problem Statement 2

1.5 Project Layout 2

2 LITERATURE REVIEW 4

2.1 Introduction 4

2.2 Control System 4

2.3 Process 6

2.4 System Tools 7

2.4.1 Computer 8

2.4.1.1 Matlab Simulink 9

2.4.1.2 Real-Time Workshop 9

2.4.1.3 Real-Time Window Target 11

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2.4.2 Interfacing Module 12

2.4.2.1 Parallel Interface 13

2.4.2.2 Serial Interface 13

2.4.3 Feedback MS150 Modular Servo

System 13

3 METHODOLOGY 15

3.1 Overview 15

3.2 MS150 Modular Servo System 16

3.2.1 Power Supply PS150E 18

3.2.2 DC Motor DCM 150F 19

3.2.3 Servo Amplifier SA150D 19

3.2.4 Reduction Gear Tacho Unit

GT150X 20

3.2.5 Attenuator Unit AU150B 20

3.2.6 Op Amp Unit OA150A 21

3.2.7 Experiment setup 22

3.3 Interfacing Module 24

3.3.1 Advantech PCI-1711 Data

Acquisition Card 25

3.3.2 Product specifications 25

3.3.2.1 Analog Input 25

3.3.2.2 Analog output 26

3.3.2.3 Digital Inputs 26

3.3.2.3 Digital Outputs 26

3.3.2.4 Pacer/Counter 27

3.3.2.5 General 27

3.3.3 Analog Input Connections 27

3.3.3.1 Single-ended Channel

Connections 28

3.3.3.2 Analog Output

Connections 29

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3.3.4 Feedback 33-301 Analogue

Control Interface 30

3.4 Computer 31

3.4.1 Model Design 31

3.4.2 Feedback DAC Ch2 DA2 32

3.4.3 Slider Gain 34

3.4.4 Analog Input 35

3.4.6 To Workspace 37

3.4.7 Display 38

3.4.8 Model Setup 39

3.4.9 Model Execution 39

3.4.10 Data Storage 43

3.5 Project Flow 44

4 RESULTS AND DISCUSSION 46

4.1 Computer Control Experiment 46

4.2 Simple Speed Control System 46

4.3 Graph Plotting 48

4.4 Discussion 54

5 CONCLUSION AND RECOMMENDATION 56

5.1 Conclusion 56

5.2 Recommendation 56

REFERENCES 58

APPENDICES 60

x

LIST OF TABLE

NO TITLE PAGE

4.1 Result of simple speed control for manual tuning 47

4.2 Result of simple speed control system for computer

tuning 48

xi

LIST OF FIGURES

NO TITLE PAGE

2.1 Closed-Loop Control System 6

2.2 The concept of a servo system 7

2.3 Basic component of servo systems 8

2.4 Overview of analog digital converter and digital analog

digital converter 8

2.5 Rapid prototyping process 10

2.6 Traditional versus rapid prototyping process 11

2.7 Real-Time Windows Target library 19

3.1 Methodology overview 15

3.2 Overview of the project 16

3.3 Block diagram of basic components of MS150

Modular Servo System 17

3.4 Electrical layout of servo motor 17

3.5 Power Supply PS150E 18

3.6 Servo Amplifier SA150D 19

3.7 Reduction Gear Tacho Unit GT150X 20

3.8 Attenuator Unit AU150B 21

3.9 Layout of Op. Amp. Unit OA150A 21

3.10 Connections for manual tuned environment 22

3.11 PC based connection setup 23

3.12 Overall connection for PC based environment 23

3.13 Interfacing servomotor system with computer 24

3.14 Single-ended input channel connection 28

3.15 Analog output and external reference input connections 29

3.16 Feedback 33-301 Analogue Control Interface 30

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3.17 Connection between Computer and servo system 31

3.18 Simulink model for simple speed control 32

3.19 DAC Unit Parameters 33

3.20 Under mask of Feedback DAC block 33

3.21 Subsystem for scaling and safety block 34

3.22 Parameters of slider gain 34

3.23 Analog Input block with display 35

3.24 Parameters for analog input and DAQCard testing 36

3.25 Card testing 36

3.26 Test result shows the board available 36

3.27 To Workspace parameters 37

3.28 Display block parameters 39

3.29 Parameters for simulation time and solver option 39

3.30 Configuration to save data at workspace 40

3.31 Configuration for Real-Time Workshop 40

3.32 System target file browser 41

3.33 Building the model 42

3.34 Workspace 43

3.35 Axes editor 43

3.36 Flow project 44

3.37 Overall project flow chart 45

4.1 Graph speed motor versus voltage reference 49

4.2 Graph error voltage versus motor speed 50

4.3 Graph motor speed versus tachogenerator voltage 50

4.4 Graph for motor speed versus voltage reference 51

4.5 Graph for error voltage versus motor speed. 52

4.6 Graph for motor speed versus tachogenerator voltage 52

4.7 Graph for motor speed versus voltage reference 53

4.8 Graph for error voltage versus motor speed. 54

4.9 Graph for motor speed versus tachogenerator voltage. 54

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LIST OF APPENDICES

NO TITLE PAGE

A PCI-1711 Block Diagram 60

B C code for RTW 61

C Generated C code for model 62

D C code for data 68

E Data Stored in Workspace 70

CHAPTER 1

INTRODUCTION

1.1 Project Background

Control system is a system or a device or set of device to manage, conduct

command, order and direct or regulate the behaviors of the other device or one system.

With it we can control or change the speed of the motor to our own desired one.

So, this proposed project is about to develop a user interface of these controllers for

controlling the speed of the motor which means user can control the servo system variable

via Personal Computer (PC). The development of user interface will be implementing

using Mathwork Matlab Simulink software. This produced system will incorporate

interactive and graphical for convenience and user-friendly.

1.2 Project Objectives

The main objectives of this project are to execute laboratory exercises for DC servo

system with aided control from Personal Computer (PC). Other purposes of this project

are:

To improve the experiment studies on analog servo control system.

To avoid difficulties with analog implementation

To implement computer control on the MS150 Modular Servo System

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1.3 Project Scope

This project may cover an experiment of servo control system, which is simple

speed control system. It also may cover:

Using Matlab Simulink/ Real-Time Workshop to run the servo system in

computer environment.

Develop user interface in computer environment.

Implement DAQCard Advantech PCI-1711 to interfacing servo system with

computer.

Using Feedback MS150 Modular Servo System for project hardware

1.4 Problem Statement

The laboratory exercise usually tuned manually. Therefore, some problem might

occur during laboratory session. Those problems are:

Less accurate in tuning the experiment equipment.

Difficult to test the designed digital servo control model.

Less accurate in data acquisition for analysis.

1.5 Report Outline

Layout of the thesis will tell the flow of the whole thesis and its contents. This

could be the referring section for this project.

Chapter 1 shows the introduction of the project, the abstract as the initial summary

for whole project. It also contains a brief introduction that gives the idea of the whole

project. Problems that bring the idea to implement this project also stated in this chapter.

3

This chapter also includes the main objectives of the project and the scope of whole

project.

Chapter 2 contains the theory of the whole project. It comprises the element that

need to be covered in this project. The theories of the project are based from the references

that will be guidance for the project.

Chapter 3 indicates the methodology to complete and success the project. Project

methodology is about defining fundamental principles, rules and manners to complete the

project. It is a way to use all available techniques, tools and approaches used to achieve

predetermined objectives. It shows the flow of the project from the beginning and

illustrates with the flow chart that review the important methods that should be considered

by developers before a project is carried out. It is important for a developer to demonstrate

an awareness of methodological tools available and the understanding that is suitable for

the project.

Chapter 4 likewise point out the results and discussion of the project. The

developed real-time data simulation system will be shown in the result part. For the

discussion part, the system will be compare with manual tuning experiment to make sure it

is in accurate condition.

Chapter 5 shows the final conclusion and suggestion for future work for this

project. The suggestion includes the idea how to make this simulation package more

reliable and efficient in the future.

CHAPTER 2

LITERATURE REVIEW

2.1 Introduction

Machine Servo is used extensively in industrial sector nowadays because of its

advantages. It includes shorter positioning time, higher accuracy, better reliability,

improved repeatability (consistency), coordinated movement and servo clamping

[6],[11],13] For this case, servo control system is very important. As for the engineering

student in control field, they should be familiar with this system and in order to achieve it,

laboratory educational is needed. Instead of manual laboratory educational, discovery

learning also can be applied by giving the freedom for student to choose their own

procedures rather than just following the outlines [2],[6],[13]. Refer to [5], manual

laboratory exercises can now be enhanced or upgraded to the automatically tuned with the

aid from computer. With the technology that available nowadays, graphical user interface

also can be developed along with the laboratory exercises as refer to[3],[5],[9],[12].

2.2 Control System

Control system is a system or a device or set of device to manage, conduct

command, order and direct or regulate the behavior of the other device or one system. In

Control system there are two type of system. Open loop system and closed loop system[5].

5

One type of control system is Open Loop control system. It also called linear

control system or non-feedback control system. This type of system may compute its input

into a system using only the value of set point from the input and its model of the system.

A characteristic of the open-loop controller is that it does not use feedback to determine if

its input has achieved the desired goal. This means that the system does not observe the

output of the processes that it is controlling. Consequently, a true open-loop system can not

engage in machine learning and also cannot correct any errors that it could make as refer to

[5-6].

It also may not compensate for disturbances in the system. Open-loop control is

useful for well-defined systems where the relationship between input and the resultant state

can be modeled by a mathematical formula. For example determining the voltage to be fed

to an electric motor that drives a constant load, in order to achieve a desired speed would

be a good application of open-loop control. If the load were not predictable, on the other

hand, the motor's speed might vary as a function of the load as well as of the voltage, and

an open-loop controller would therefore not be sufficient to ensure repeatable control of

the velocity. An open-loop controller is often used in simple processes because of its

simplicity and low-cost, especially in systems where feedback is not critical. A typical

example would be a conventional washing machine, for which the length of machine wash

time is entirely dependent on the judgment and estimation of the human operator.

Generally, to obtain a more accurate or more adaptive control, it is necessary to feed the

output of the system back to the inputs of the controller. This type of system is called a

closed-loop system [5-6].

A closed-loop control system is one in which an input forcing function is

determined in part by the system response. The measured response of a physical system is

compared with a desired response. The difference between these two responses initiates

actions that will result in the actual response of the system to approach the desired

response. This in turn drives the difference signal toward zero. Typically the difference

signal is processed by another physical system, which is called a compensator, a controller,

or a filter for real-time control system applications [5-6]. A closed-loop control system can

be represented by the general block diagram shown in Figure 2.1:

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Figure 2.1: Closed-Loop Control System from [5]

In this configuration a feedback component is applied together with the input R.

The difference between the input and feedback signals is applied to the controller. In

responding to this difference, the controller acts on the process forcing C to change in the

direction that will reduce the difference between the input signal and the feedback

component. This, in turn, will reduce the input to the process and result in a smaller change

in C. This chain of events continues until a time is reached when C approximately equals

R. A closed-loop system is able to regulate itself in the presence of disturbance or

variations in its own characteristics. In this respect, a closed-loop system has a distinct

advantage over an open-loop system as refer to [5-6].

2.3 Process

In servo task, a command signal from user’s interface panel comes into the servo’s

‘positioning controller’. This was a device that stores information about jobs to activate the

motor/ load or change speed/ position. The servo control amplifier will receive the signal

and level up to appropriate levels to move the servo motor. The supply voltage from power

supply needs to be converts to match input of the motor [5],[7]. The Figure 2.2 illustrated

the concept of servo system as refer to[7].

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Figure 2.2: The concept of a servo system

After the load begins to move, there is other device that also moves to provide a

feedback signal to the controller. This device can be a tachometer, resolver or encoder as

refer from[7]. In this servo system, process variable such as position and speed of the

motor is control. The system can be fully control by computer if the computer control the

process variable [11],[5-6],[7].Refer to [11], in order to complete the project, 3 element is

needed to develop. Those 3 elements were computer (software), interfacing and hardware.

2.4 System Tools

Three elements are needed to develop. All of them were basic component of

servomotor systems. The components are shown as Figure 2.3 below [11].

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Figure 2.3: Basic component of servo systems.

2.4.1 Computer

Personal Computer, (PC) will be the controller that send signal to the servo

amplifier before it level up the signal to the proper level that move the DC motor. PC input

is digital while servo system input is analog, so the translator is needed. In this case,

interfacing will be the translator from [1],[4-5],[8],[11]. The figure 2.3 refers to [5] show

the overview of analog to digital converter and digital to analog converter.

Figure 2.4: Overview of analog digital converter and digital analog digital converter

sensor

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2.4.1.1 Matlab Simulink

Simulink is a software package that can be model, simulate, and analyze systems

whose outputs change over time. These systems are always referred to as dynamic systems.

Simulink can also be used to explore the behavior of a wide range of real-world dynamic

systems, including electrical circuits, shock absorbers, braking systems, and many other

electrical, mechanical, and thermodynamic systems. There are two step processes in

simulating dynamic systems with Simulink. First, a user creates a block diagram, using the

Simulink model editor, which graphically depicts time-dependent mathematical

relationships among the system's inputs, states, and outputs. The user then commands

Simulink to simulate the system represented by the model from a specified start time to a

specified stop time. In order to control the project in real time, real-time workshop is

needed [16].

2.4.1.2 Real-Time Workshop

Real-Time Workshop generates optimized, portable, and customizable ANSI C or

C++ code from Simulink models to create unrelated implementations of models that

operate in real-time and non-real-time in a multiplicity of target environments. Generated

code can run on PC hardware, DSPs, microcontrollers on bare-board environments, and

with commercial or proprietary real-time operating systems (RTOS). Real-Time Workshop

lets the speed up of simulations, build in intellectual property protection, and operate

across a wide variety of real-time rapid prototyping targets. The advantage of using this

simulink real-time workshop is that it consists of automatic program building that allows

making design changes directly to the block diagram, putting algorithm development

(including coding, compiling, linking, and downloading to target hardware) under control

of a single process, compare to the traditional process. This also known as rapid

prototyping process as refer to [16] . Figure 2.5 illustrated the flow process