Controls Lab Interface Improvement - Multidisciplinary Engineering Senior Design Project

1. Multidisciplinary Engineering Senior DesignProject 6508 Controls Lab Interface ImprovementCritical 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 Engineering Rochester Institute of Technology

2. 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 • System was designed for technicians not students • The Digital Board is outdated • Past work from a student Ruben Mathew has shown the digital board does not work

3. 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

4. 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)

5. 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

6. 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

7. 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

8. Overall System Diagram Feedback Power Supply Lab PC with Matlab and Simulink Gnd, +-15V, 5V Communication System Interface Feedback 33-100 DC Servo Motor Analog to Motor +-8V to PA(+ve,-ve) Analog from Motor Tachogenerator +-8V Digital from Motor 6 Grey Code + Index for Position

9. Input Shaft Output Shaft PA +ve, PA –ve, Tachogenerator +-, Grey code Position idicator Tachogenerator Mechanical Unit 33-100

10. MATLAB Software Layout

11. Analysis & Synthesis of Design • Multiple Concepts were developed • Using a DSP Development Kit • Using a USB Data Acquisition Board • Importing Simulink diagram into NI LabVIEW • Data Acquisition PCI Card in Windows • Separate PC with I/O Capability controlled by MATLAB

12. Analysis & Synthesis of Design • Concept 1: Using a DSP Development Kit Simulink USB RS232 DSP Kit Interface Board Motor • Concept 2: Using a USB DAQ Board Simulink USB DAQ Board Interface Board Motor • Both concepts found not to be feasible

13. 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

14. Analysis & Synthesis of Design • Concept 4: Separate PC with PCI DAQ Controlled by MATLAB Simulink Computer PCI DAQ Interface Board Motor 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

15. System Diagram • Both concepts use the Real Time Workshop in MATLAB Real Time Windows Target Toolbox Real Time Workshop Generated C Code Simulink PCI Card Interface Board DC Motor Computer xPC Target Toolbox PCI Card Simulink Real Time Workshop Generated C Code xPC Kernel DC Motor Interface Board Computer Second Computer System Block Diagram

16. PCI DAQ Card • Measurement Computing PCI Card • 16 Analog Inputs • 2 Analog Outputs • 24 Digital Inputs or Outputs

17. Gantt Chart Followed

18. 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

19. 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

20. Desired Outcomes • Document the process for developing digital controllers to be able to implement them in a laboratory setting

21. 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.

22. Critical Parameters • Acquire 20 V peak to peak, 100 Hz sine wave using digital interface and output. Verify with oscilloscope. Output Wave Input Wave

23. Critical Parameters • 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

24. Results for Integrator Controller 1.5 1 Tachometer Voltage [V] 0.5 0 10 11 12 13 14 15 16 17 18 19 20 time [sec] Critical Parameters • Use a Simulink Integrator Controller • Verify: -Tachogenerator voltage 1.5 V ± 5% Power Amplifier on Motor SIMULATION RESULT Tachogenerator Voltage from Motor

25. Results for Integrator Controller 1.5 1 Tachometer Voltage [V] 0.5 0 10 11 12 13 14 15 16 17 18 19 20 time [sec] Critical Parameters • Use a Simulink PI Controller • Verify: -Tachogenerator voltage 1.5 V ± 5% -Transient Results within ± 5% Power Amplifier on Motor SIMULATION RESULT Tachogeneartor Voltage from Motor

26. Critical Parameters • Use a Simulink One Pole Controller • Verify: -Tachogenerator Voltage within ± 5% Theoretical Steady State Error -Transient Results within ± 5% Power Amplifier on Motor SIMULATION RESULT Tachogenerator Voltage Output from Motor

27. Critical Parameters • 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 Output Shaft Voltage from Motor Input Shaft Voltage from Motor

28. Critical Parameters • 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 Motor Connector Test Points Simulink Diagram PCI Connectors PCB LAYOUT

29. 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

30. 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

31. Interface Design -Interface connections needed PCI DAQ Card 6 Analog Inputs 1 Analog Output 6 Digital Inputs Interface Board Motor Board 5 Analog Sensors 1 Analog Input 6 Digital Outputs

32. 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

33. 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

34. 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

35. 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 Computer RS-232 Computer PCI Card PCI Card PCI Card Interface Board Interface Board Interface Board Motor Board Motor Board Motor Board One Computer Solution Two Computer Solution

36. Testing Results • Integrator Results

37. Testing Results • PI Controller Results

38. Testing Results • One Pole Controller Results

39. Testing Results • Two Pole, One Zero Controller Results

40. Testing Results Output Shaft • Position Control Results Input Shaft

41. Testing Results • Power Supply Noise Results

42. Testing Results • Fuzzy PI Controller Implementation Performance Comparison

43. Computer Computer RS-232 Computer PCI Card PCI Card PCI Card Interface Board Interface Board Interface Board Motor Board Motor Board Motor Board One Computer Solution Two Computer Solution Conclusions -Both designs successful -Both can be used in Current Control Systems Design Lab -Two Computer Setup can be used in multiple applications

44. Thank You Dr. PhillipsDr. MathewKen SnyderJim StefanoJacob Slezak

45. Questions ?

46. Single Computer Setup BOM Two Computer Setup BOM

47. Production Plan