Project Sponsor: EE Department Team Members: Michael Abbott, Neil Burkell
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Transcript of Project Sponsor: EE Department Team Members: Michael Abbott, Neil Burkell
Multidisciplinary Engineering Senior Design
Project 6508 Controls Lab Interface Improvement
Critical 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 EngineeringRochester Institute of Technology
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• The Digital Board is outdated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 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 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• 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
• 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 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
Lab PCwith Matlab
and Simulink
System Interface
Feedback33-100
DC Servo Motor
FeedbackPower
Supply
Gnd, +-15V, 5V
Analog to Motor +-8V to PA(+ve,-ve)
Digital from Motor 6 Grey Code + Index for Position
Analog from Motor Tachogenerator +-8V
Communication
PA +ve, PA –ve, Tachogenerator
+-, Grey code Position idicator
Mechanical Unit 33-100
Input Shaft Output Shaft
Tachogenerator
MATLAB Software Layout
Analysis & Synthesis of Design
• Multiple Concepts were developed
1) Using a DSP Development Kit
2) Using a USB Data Acquisition Board
Importing Simulink diagram into NI LabVIEW
3) Data Acquisition PCI Card in Windows
4) Separate PC with I/O Capability controlled by
MATLAB
Analysis & Synthesis of Design
• Concept 1: Using a DSP Development Kit
Simulink DSP Kit Interface Board Motor
• Concept 2: Using a USB DAQ Board
Simulink DAQ Board Interface Board MotorUSB
USB
RS232
• Both concepts found not to be feasible
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
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
Analysis & Synthesis of Design• Concept 4: Separate PC with PCI DAQ Controlled by MATLAB
Simulink Computer Interface Board MotorPCI DAQ
System Diagram
• Both concepts use the Real Time Workshop in MATLAB
System Block Diagram
Real TimeWorkshopSimulink
Generated CCode
Real TimeWorkshop
DC MotorPCI CardGenerated C
Code
xPC Kernel PCI Card
Computer
Real Time Windows Target Toolbox
xPC Target Toolbox
InterfaceBoard
Second Computer
Simulink DC MotorInterfaceBoard
Computer
PCI DAQ Card
– Measurement Computing PCI Card• 16 Analog Inputs• 2 Analog Outputs• 24 Digital Inputs or Outputs
Gantt Chart Followed
Events Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10 Week 11Receive Software
Receive PartsLearn xPC Target ToolboxLearn RTW Target Toolbox
Interface Hardware and Simulink using xPC and RTW
DebugDesign PCB Interface Board
Impliment Test PlanDemonstration
Documentaion of xPC and RTWOrder Additional Lab Setups
Winter Quarter 05-06
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 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 Outcomes
• Document the process for developing digital
controllers to be able to implement them in a
laboratory setting
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
1. Acquire 20 V peak to peak, 100 Hz sine wave using digital interface and output. Verify with oscilloscope.
Input Wave
Output Wave
Critical Parameters
2. 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
step
yMOS sspt
Critical Parameters
– Use a Simulink Integrator Controller
• Verify: -Tachogenerator voltage 1.5 V ± 5%
Step1s
Integrator
5
Gain
0.5
Constant
AnalogOutput
Analog OutputMeasurement ComputingPCI-DAS1602-16 [auto]
AnalogInput
Analog InputMeasurement ComputingPCI-DAS1602-16 [auto]
Add1Add
10 11 12 13 14 15 16 17 18 19 200
0.5
1
1.5
time [sec]
Tac
hom
eter
Vol
tage
[V
]
Results for Integrator Controller
SIMULATION RESULTTachogenerator
Voltage from Motor
Power Amplifier on Motor
Critical Parameters
– Use a Simulink PI Controller
• Verify: -Tachogenerator voltage 1.5 V ± 5%
-Transient Results within ± 5%
s+6.5
s
T ransfer Fcn
Step 2.5
Gain
0.5
Constant
AnalogOutput
Analog OutputMeasurement ComputingPCI-DAS1602-16 [auto]
AnalogInput
Analog InputMeasurement ComputingPCI-DAS1602-16 [auto]
Add1Add
10 11 12 13 14 15 16 17 18 19 200
0.5
1
1.5
time [sec]
Tac
hom
eter
Vol
tage
[V]
Results for Integrator Controller
SIMULATION RESULT
Tachogeneartor Voltage from
Motor
Power Amplifier on Motor
Critical Parameters
– Use a Simulink One Pole Controller
• Verify: -Tachogenerator Voltage within ± 5% Theoretical Steady State Error
-Transient Results within ± 5%
1
s+5
T ransfer Fcn
Step 20
Gain
0.5
Constant
AnalogOutput
Analog OutputMeasurement ComputingPCI-DAS1602-16 [auto]
AnalogInput
Analog InputMeasurement ComputingPCI-DAS1602-16 [auto]
Add1Add
10 11 12 13 14 15 16 17 18 19 20-0.2
0
0.2
0.4
0.6
0.8
1
1.2Results for One Pole Controller
SIMULATION RESULT
Tachogenerator Voltage Output
from Motor
Power Amplifier on Motor
Critical Parameters
3. 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
1
Gain
AnalogOutput
Analog OutputMeasurement ComputingPCI-DAS1602-16 [auto]
AnalogInput
Analog Input1Measurement ComputingPCI-DAS1602-16 [auto]
AnalogInput
Analog InputMeasurement ComputingPCI-DAS1602-16 [auto]
Add
0 1 2 3 4 5 6 7 8 9 10-10
-5
0
5
time [sec]
Pos
ition
Vol
tage
s [V
]
Feedback Position Results (Motor Initially at 270 degrees and moved to 90 degrees)
Output Shaft Voltage
Input Shaft Voltage
Input Shaft Voltage from
Motor
Output Shaft Voltage from
Motor
Critical Parameters
4. 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
s+6.5
s
T ransfer Fcn
Step 2.5
Gain
0.5
Constant
AnalogOutput
Analog OutputMeasurement ComputingPCI-DAS1602-16 [auto]
AnalogInput
Analog InputMeasurement ComputingPCI-DAS1602-16 [auto]
Add1Add
PCB LAYOUT
Simulink DiagramTest
Points
PCI Connectors
Motor Connector
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 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 connections needed
Motor Board
5 Analog Sensors1 Analog Input
6 Digital Outputs
PCI DAQ Card
6 Analog Inputs1 Analog Output6 Digital Inputs
Interface Board
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 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
-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 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 ComputerRS-232
PCI CardPCI Card
InterfaceBoard
InterfaceBoard
MotorBoard
MotorBoard
Computer
PCI Card
InterfaceBoard
MotorBoard
Two Computer SolutionOne Computer Solution
Testing Results• Integrator Results
Control Algorithm OS (%) % Error OS Tr (sec) % Error Tr Tp (sec) % Error Tp
Integrator Controller (Analog) 38.10 6.46 0.68 7.94 1.09 4.78
Integrator Controller (RTW) 39.60 2.77 0.65 3.17 1.06 1.89
Integrator Controller (xPC) 39.48 3.07 0.64 1.59 1.06 1.89
Integrator Controller (Simulation) 40.20 1.30 0.66 4.76 1.09 4.59
Integrator Controller (Theoretical) 40.73 --- 0.63 --- 1.04 ---
10 11 12 13 14 15 16 17 18 19 20-1.5
-1
-0.5
0
0.5
1
1.5
2
time [sec]
Tac
hom
eter
Vol
tage
[V
]
Results for Integrator Controller (Results Shifted for Viewing Purposes)
Analog Control Board Result
Simulation Control Result
Digital Control MATLAB Real Time Windows Result
Digital Control MATLAB xPC Target Result
step
yMOS sspt
Testing Results• PI Controller Results
Control Algorithm OS (%) % Error OS Tr (sec) % Error Tr Tp (sec) % Error Tp
PI Controller (Analog) 24.30 3.57 0.27 3.85 0.46 2.68
PI Controller (RTW) 25.80 2.38 0.27 3.85 0.47 3.79
PI Controller (xPC) 25.35 0.60 0.26 0.00 0.46 2.68
PI Controller (Simulation) 25.20 --- 0.26 --- 0.45 ---
10 10.5 11 11.5 12 12.5 13 13.5 14 14.5 15-1.5
-1
-0.5
0
0.5
1
1.5
2
time [sec]
Tac
hom
eter
Vol
tage
[V
]
Results for PI Controller (Results Shifted for Viewing Purposes)
Analog Control Board Result
Simulation Control Result
Digital Control MATLAB Real Time Windows Result
Digital Control MATLAB xPC Target Result
step
yMOS sspt
Testing Results
• One Pole Controller Results
Control Algorithm OS (%) % Error OS Tr (sec) % Error Tr
One Pole Controller (Analog) 27.03 8.68 0.35 4.48One Pole Controller (RTW) 28.01 5.37 0.35 4.48One Pole Controller (xPC) 28.10 5.07 0.35 4.48One Pole Controller (Simulation) 27.03 8.68 0.35 4.48One Pole Controller (Theoretical) 29.60 --- 0.34 ---
Tp (sec) % Error Tp Vss (V) % Error Vss
One Pole Controller (Analog) 0.55 5.83 1.2150 3.61One Pole Controller (RTW) 0.54 4.85 1.2186 3.92One Pole Controller (xPC) 0.54 4.85 1.2158 3.68One Pole Controller (Simulation) 0.54 4.85 1.1728 0.01One Pole Controller (Theoretical) 0.52 --- 1.1727 ---
10 11 12 13 14 15 16 17 18 19 20-1.5
-1
-0.5
0
0.5
1
1.5
Time [sec]
Tac
hom
eter
Vol
tage
[V
]
Results for One Pole Controller (Results Shifted for Viewing Purposes)
Analog Control Board Result
Simulation Control Result
Digital Control MATLAB Real Time Windows Result
Digital Control MATLAB xPC Target Result
step
yMOS sspt
Testing Results
• Two Pole, One Zero Controller Results
Sampling Time [sec] 0.0250 0.0375 0.0500 0.1000 0.2000
Simulation OS [%] 15.000 19.900 24.600 39.800 --
Single Computer [% Error] 3.000 2.010 2.439 3.015
Two Computer [%Error] 0.667 1.508 1.626 3.769
Simulation Tr [sec] 0.429 0.430 0.413 0.410 --
Single Computer [% Error] 0.233 3.488 3.030 6.098
Two Computer [% Error] 3.263 1.163 0.606 7.317
Simulation Tp [sec] 0.600 0.610 0.625 0.650 --
Single Computer [% Error] 0.000 0.000 0.000 0.000
Two Computer [% Error] 0.000 0.000 0.000 0.000
0 2 4 6 8 10 12 14 16 18 20-0.2
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
Time [s]
Tac
hoge
nera
tor
Vol
tage
[V
]
RTW Target Step Response for Different Sampling Times with ZOH Equivalent Discrete Controller
0.0375 Sampling Time
0 2 4 6 8 10 12 14 16 18 20-3
-2
-1
0
1
2
3
4
Time [s]
Tac
hoge
nera
tor
Vol
tage
[V
]
RTW Target Step Response for Different Sampling Times with ZOH Equivalent Discrete Controller
0.2 Sampling Time
Testing Results
• Position Control Results
0 1 2 3 4 5 6 7 8 9 10-10
-5
0
5
time [sec]
Pos
ition
Vol
tage
s [V
]
Feedback Position Results (Motor Initially at 270 degrees and moved to 90 degrees)
Output Shaft Voltage
Input Shaft Voltage
0 1 2 3 4 5 6 7 8 9 10-10
-5
0
5Analog Board Feedback Position Results (Motor Initially at 270 degrees and moved to 90 degrees)
time [sec]
Pos
ition
Vol
tage
s [V
] Output Shaft Voltage
Input Shaft Voltage
Output Shaft
Input Shaft
Testing Results• Power Supply Noise Results
10 11 12 13 14 15 16 17 18 19 20-0.2
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
time [sec]
Ta
cho
me
ter
Vo
ltag
e [V
]
Plot of Tachometer Voltage vs. Time for Different Power Supplies (Shifted for Viewing Purposes)
HP E3631A Power Supply
Feedback 01-100 Power Supply
Testing Results• Fuzzy PI Controller Implementation
Performance Comparison
Sampling Frequency
Single Computer Experiment: Processor
Percentage
Two Computer Experiment: Task Execution Time
1 kHz 4% 49 μs
2 kHz 7% 50 μs
4 kHz 14% 53 μs
8 kHz 29%--Stopped Running 51 μs
10 kHzStopped Running
Immediately54 μs
Conclusions
-Both designs successful
-Both can be used in Current Control Systems Design Lab
-Two Computer Setup can be used in multiple applications
Computer ComputerRS-232
PCI CardPCI Card
InterfaceBoard
InterfaceBoard
MotorBoard
MotorBoard
Computer
PCI Card
InterfaceBoard
MotorBoard
Two Computer SolutionOne Computer Solution
Thank You
Dr. PhillipsDr. MathewKen SnyderJim Stefano
Jacob Slezak
Questions
?
Item Itemized Cost Qty. TotalInterface PCB (3 min. order) $17.00 1 $17.00
50 Pin Connector $1.47 2 $2.9434 Pin Connector $1.14 1 $1.14PCI-DAS1602/16 $715.50 1 $715.50
C100FF-2 (50 Pin Ribbon Cable) $44.10 1 $44.10
Total Cost Per Station $780.68
Complete Lab Station $780.68 8 $6,245.44
Single Computer Setup BOM
Two Computer Setup BOM
Item Itemized Cost Qty. TotalInterface PCB (3 min. order) $17.00 2 $34.00
50 Pin Connector $1.47 4 $5.8834 Pin Connector $1.14 2 $2.28PCI-DAS1602/16 $715.50 2 $1,431.00
C100FF-2 (50 Pin Ribbon Cable) $44.10 2 $88.20RS-232 Cable $8.00 1 $8.00
xPC Target License (One Year for Entire Lab) $600.00
Total Cost Per Pair $1,569.36
Total Cost for Lab (Hardware) $1,569.36 4 $6,277.44
Total Cost for Lab with Software $6,877.44
Production Plan
Week 1 Week 2 Week 3 Week 4 Week 5 Week 6
Order PCI Card from Measurement Computing
Receive PCI CardsInstall PCI Cards into PC'sOrder PCB BoardsReceive PCB BoardsPopulate PCB BoardsTest Setups