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DC Motor Control Project

DC Motor Control Project. Group A ALEXANDER M FUNK LAM D NGUYEN JAKEISHA D THOMPSON PAULETTE J VERNON ERIC G ZAISER 12/03/01. Introduction. Motor Design Motor Construction Problems Control Design Control Problems Final Results Conclusion. Project Overview.

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DC Motor Control Project

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  1. DC Motor Control Project Group A ALEXANDER M FUNK LAM D NGUYEN JAKEISHA D THOMPSON PAULETTE J VERNON ERIC G ZAISER 12/03/01

  2. Introduction • Motor Design • Motor Construction Problems • Control Design • Control Problems • Final Results • Conclusion

  3. Project Overview • Design, construct, and control a dc homemade motor, commutation system, control system, and a speed measurement device such that the machine assembly rotates at selected speeds • Create a detailed web-page to outline the development process

  4. Specifications • The outer diameter of the rotor: 1.5 and 4.5 inches. • The length of the rotor housing: 2 and 6 inches. • A commutator must be built. • Standard magnets must be used • Supply jacks must be supplied for an unknown resistance

  5. Schedule

  6. Motor Design • Four Pole Motor • Simplex Lap Winding • 45 windings • 26 gauge Copper Wire • Steel Stator – 3.5“ inner diameter and 4” outer diameter • 16 magnets(1” by ½“ by ¼“) acting as 4 poles • JB Weld to place magnets • Steel rotor-2” diameter • 25 1/8” thick, 2.5” outer diameter discs; 12-0.35” diameter holes

  7. Motor Design • 4 brushes alternating at 90° • 3/8” Shaft • Polyurethane lamination

  8. DC Permanent Magnet Motor

  9. 4 Pole Simplex Lap Winding

  10. Commutator • 1.5 inch inner diameter copper pipe • 12 segments required for four pole operation • Vinyl insulation from the shaft • Brush contact • 12 segments (2 x 0.78 inches ) • Epoxy to fill in slots

  11. Motor Construction Problems • Uneven commutator bars • Drilling through copper for hooks • Commutator bars popping off • Misalignment of magnets in the stator • Fitting the bearings onto the shaft • Sliding of shaft as motor was spinning • Friction in commutator from lack of epoxy

  12. The Final Product

  13. Control Basic • Hardware Setup • Initial Research Regarding Motors • Limited Theoretical Modeling • “Control Theory” group shifted to “Test & Fix” Group

  14. Encoder Open Loop/Bonus day PID implementation Tweaking/Tuning Competition Control Implementation

  15. Control System in Simulink

  16. Control Problems • Encoder-related • Mounting • Cable • Motor-related • Friction • Drift/alignment • Simulink-related • Disappearing feedback

  17. Final Results • Bonus Day :300 rpm 10 points • Competition Day: 1st Place • Average Steady State Error of +/- 5.33 RPM • Transient score of .4165

  18. Transient Response

  19. Conclusion • Motor design was outstanding • Steady state control was outstanding • Control system was outstanding Group A is Great!!

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