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Solar Jackets Motor Control

Andy Lian (EE) Gabriel Miranda (EE) Andrew Perez (EE) Chris McManus (EE) Drew Pearson (EE) April 25, 2011. Solar Jackets Motor Control. Project Overview. Design motor control system for the Solar Jackets solar racing vehicle Continuing work from previous group Fall 2010

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Solar Jackets Motor Control

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  1. Andy Lian (EE) Gabriel Miranda (EE) Andrew Perez (EE) Chris McManus (EE) Drew Pearson (EE) April 25, 2011 Solar Jackets Motor Control

  2. Project Overview • Design motor control system for the Solar Jackets solar racing vehicle • Continuing work from previous group • Fall 2010 • System responsibilities: • Electric motor operation • Central communication between vehicle subsystems

  3. Technical Objectives • Dynamic control of air gap motor • Functional cruise control using SBC • Regenerative braking • Load testing • Communication with vehicle subsystems

  4. Actual Design • Load testing setup conducted with motor/generator setup • Air gap control via relay system and switch • Cruise control • Throttle control

  5. System Block Diagram • Communications • RS-485 • MPPT • Battery Management • RS-232 • Motor Controller • USB • HMI • Digital I/O • Window Lift Motor • Cruise Control & Air Gap Switches • A/D Converter • 10-Turn Potentiometer

  6. SBC System Communications • Communications • RS-485 • MPPT • Battery Management • RS-232 • Motor Controller • USB • HMI • Digital I/O • Window Lift Motor • Cruise Control & Air Gap Switches • A/D Converter • 10-Turn Potentiometer

  7. SBC System Communications • Communications • RS-485 • MPPT • Battery Management • RS-232 • Motor Controller • USB • HMI • Digital I/O • Window Lift Motor • Cruise Control & Air Gap Switches • A/D Converter • 10-Turn Potentiometer

  8. SBC System Communications • Communications • RS-485 • MPPT • Battery Management • RS-232 • Motor Controller • USB • HMI • Digital I/O • Window Lift Motor • Cruise Control & Air Gap Switches • A/D Converter • 10-Turn Potentiometer

  9. SBC System Communications • Communications • RS-485 • MPPT • Battery Management • RS-232 • Motor Controller • USB • HMI • Digital I/O • Window Lift Motor • Cruise Control & Air Gap Switches • A/D Converter • 10-Turn Potentiometer

  10. SBC System Communications • Communications • RS-485 • MPPT • Battery Management • RS-232 • Motor Controller • USB • HMI • Digital I/O • Window Lift Motor • Cruise Control & Air Gap Switches • A/D Converter • 10-Turn Potentiometer

  11. SBC User Communications • Ethernet • Telnet • Login • FTP • File Transfer • Default IP Config • 192.168.0.50 • 255.255.255.0 • 192.168.0.255

  12. SBC Programs • motord • Motor control daemon • Handles state variable generation, cruise control, air gap control, & log file generation • mcon • Allows discrete user control of motor controller • mmon • Allows monitoring of state variables through terminal • capture • Continuously captures state variable data and saves it to specified CSV file

  13. motord • Features • Runs on startup • Serial timeout and recovery • Log file generation • Cruise control • Air gap control • State variable generation as separate file accessible by other programs • RS-485 communication is handled separately by a stand alone program still under development • Pavel has been heading up this effort • These programs communicate using the state variable file

  14. mcon • Features • Discrete user control • Serial line flushing • Verbose debug mode • Directly monitor message and response registers

  15. mmon • Features • Continuously monitors state variables • Displays on terminal • Non-intrusive • Simple

  16. capture • Features • Continuously monitors state variables • Stores data in CSV file • Easy import into Excel • Example program call • capture /var/capture.csv

  17. Program Interface Diagram

  18. Controller Mode Issue Serial • Controller prevents change from serial to discrete or vice-versa while coasting • Solution: • Keep controller in serial mode • Use SBC to read controller values Discrete

  19. Air Gap Adjustment • FIRST Robotics Window Lift Motor • Custom Mounting Gear

  20. Air Gap Motor Control • Currently only one speed, fast • Possibility of a slow speed • Add extra relay to turn a resistor on/off • Gives option of both a fast and a slow speed • Add resistor to existing circuit • One speed, slow • Need to ensure torque is adequate • Actual motor operating speed to be verified

  21. Air Gap Control • Relay controlled • Directional switch on control box sends signal to SBC • SBC controls relays Air Gap Adjustment Switch

  22. Air Gap Control Schematic

  23. Air Gap Control Circuit • Input 12V

  24. Air Gap Control Circuit • Input 12V • SBC Controls

  25. Air Gap Control Circuit • Input 12V • SBC Controls • On/Off Relay

  26. Air Gap Control Circuit • Input 12V • SBC Controls • On/Off Relay • Forward/ Reverse Relay

  27. Air Gap Control Circuit • Input 12V • SBC Controls • On/Off Relay • Forward/ Reverse Relay • Output to Motor

  28. Determining Air Gap Position • 10 Turn potentiometer • In-line with air gap screw • Measure voltage on wiper to determine air gap’s position

  29. Load Testing • Motor-generator setup with resistor box • Provided variable loading to verify: • General motor functionality • Cruise control capability • Control in throttle mode

  30. Diagram of Load Testing– Motor Setup • Motor control setup

  31. Diagram of Load Testing– Generator • Generator • Added to provide load for motor • Connected to motor via flange

  32. Diagram of Load Testing– Resistor Box • Resistor Box • Connected to generator • Decrease resistance to increase load on motor • Allowed simulation of drive cycles

  33. Was Load Testing Successful? • Normal operation of motor under variable load was successful • Operation of cruise control under variable load was effectively verified • Throttle control mode was tested and debugged • Data was gathered and various load profiles were created

  34. Constant Torque, Variable Load • Phase current remains constant • Proportional to torque • As load increases speed decreases

  35. Constant Speed, Variable Load • Phase current varies • As load changes speed remains constant • In cruise control

  36. Future Work • Use of pot to judge closeness to air gap extremes (ADC) • Testing of air gap adjustment system after mounting onto gear • Communication with other subsystems • Test refurbished motor • Mounting motor onto vehicle

  37. Discussion of Demo • Motor functionality • Cruise (speed) control • Manual (throttle) control • Cruise control • Maintain set speed under variable load • Disengages when braking • Air gap adjustment via SBC • Event logging

  38. Questions

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