Motor Workbench ECE 498X – Winter 2010

1. Motor Workbench ECE 498X – Winter 2010 Advisor: Professor Natarajan Amy Farris Tim Lukose Department of Electrical and Computer Engineering University of Michigan – Dearborn

2. Design Motivation Electric motor labs, in the past, have been unsafe for students to test hardware because of higher voltages and large motor sizes. The goal of this project was to assemble a workbench for students to run low voltage, small motors while being able to gather motor data.

3. Design Objectives • Create a workbench that will allow the testing of electric motors under load. • Collect data from the motor with a data acquisition module. • Display and store collected data on PC for student review.

4. Project Subsystems • Motor Control – Amy Farris • AC and DC motors powered for students to test • Data Acquisition – Amy Farris and Tim Lukose • Collect voltages and currents from motors • PC User Interface – Tim Lukose • Store and display data from data acquisition module • Send motor commands

5. Design Block Diagram

6. Specifications • Motors • 24V, 1 phase, AC synchronous motor • 24V DC motor • 24V Brushless DC motor • Stepper motor • Microcontroller • Read up to 24Volts • Read up to 1 Amp • PWM Output • Output to Graphical User Interface • Interface • Graphical User Interface • SCommunication

7. Motors • AC Motor • 24V AC, single phase motor powered from transformer • Relay driven outputs from PIC 16F690 to control two directions and on/off state • Design Options • 24V AC three phase induction motor

8. Motors • DC Motor • 24V DC motor control • Pulse Width Modulation from a PIC • H-Bridge power module from integrated circuit (TI - SN754410) • Controls multiple speeds, two directions, and on/off state • Design Options • Load motor designed with 90V DC controller for speed and torque control

9. Data Acquisition • Collect Motor Voltage – voltage divider circuit • Collect Motor Current – current transducer sensor from Honeywell (CSLW6B1) • Program PIC to send data collected serially to PC when requested • USB to TTL serial adaptor (FTDI-TTL-232R-5v) connected to PIC • Programmed using UART

10. Data Acquisition – Design Options • Premade data acquisition board may have been a good option so that more time could be spent towards running different motors and performing tests on loaded motors.

11. User Interface MATLAB Graphical User Interface (GUI) Motor Controls Display and Store data

12. User Interface • Settings • Speed • Direction

13. User Interface • Motor • AC Motor • DC Motor

14. User Interface • Data • Data Sheet • Start • Stop • Plot

15. Tasks for Scott Stapleton • AC Motor Power (not required for revised design) • Design 24V, 3 phase, AC power for induction motor • Configure DC load motor controls (not required for revised design) • Motor mounts and couple motors • Brushless DC motor controls design • Stepper motor controls and design

16. Conclusions • AC and DC motors run with commands from the GUI • Data is pulled from motors and transferred to GUI via USB • Data is stored on Interface as .csv file • Data is plotted in MATLAB

17. Future Enhancements • Add stepper motor and BLDC motor • Motors need more testing before being coupled • 3 phase AC induction motor and power source • 24V 3 phase AC motor controller can be designed for variable speed testing • Labview could be considered for use as data acquisition

18. Acknowledgements • Professor Natarajan – Project Advisor • Professor Miller – ECE498x instructor & advisor • Scott Stapleton – Project Partner • Walter Howell-Sayers – Anaheim Automation • Tom Kowalski – Baldor Motors • Jesse Cross – Lab Technician assistance • Professor Awad – Refresher course on MATLAB

19. Thank you!Any Questions?