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Dynamic Load Simulation

Dynamic Load Simulation. Team #26 Nathaniel Hakes Lisa Barsamian Gary Thiakos. Introduction. Electric motor manufacturers need to design motors for a variety of real-world applications. A single, programmable system to provide different motor loads would simplify motor development.

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Dynamic Load Simulation

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  1. Dynamic Load Simulation Team #26 Nathaniel Hakes Lisa Barsamian Gary Thiakos

  2. Introduction Electric motor manufacturers need to design motors for a variety of real-world applications. A single, programmable system to provide different motor loads would simplify motor development.

  3. Objective: To build an electric motor test system from off-the-shelf components to dynamically simulate different types of loads.

  4. Advantages • Inexpensive, readily-available parts • Customizable load conditions • PC-based test monitoring • Instantaneous load data • Data trend plots

  5. Components • PC User Interface • Digital Signal Processor • Motor Drive • Load Machine • Test Motor • Computer Data Interface

  6. Operating System

  7. Motor Drive • Kollmorgen Sx10 Servo Drive • Runs load motor as a generator • Motionlink Software

  8. Motionlink Software

  9. Drive Layout

  10. Analog I/O • Input • + 10 Volts • Torque controller opmode • Voltage proportional to current command • Output • + 10 Volts • Voltage proportional to actual motor current

  11. Position Encoder • Pair of quadrature pulses  90 degrees out of phase • Index Pulse  once per revolution

  12. Load Machine • Kollmorgen B-206-C Servomotor • Permanent magnet • Max cont. current 10 A • Max cont. torque  6.84 N-m • Controlled by drive

  13. Digital Signal Processor • Texas Instruments TMS320C24x evaluation module • TMX320F240 fixed-point DSP controller • 12 bit, 4 channel DAC • 10 bit, 2 channel ADC • RS-232 compatible serial port • 3- 16 bit, general purpose timers • Quadrature encoder pulse interface

  14. Data Acquisition & PC Interface By National Instruments PC-MIO-16E-1 Data Acquisition Card • Inputs analog voltage from drive • Inputs quadrature encoder pulses from drive LabVIEW 6i • Software interface to data acquisition card • Graphical user interface

  15. I/0 Connector • LabVIEW receives drive encoder output • Reads motor current from drive

  16. Real-time Measurements • Motor current • Received from the motor drive • Torque constant • Given .50481ft-lb/A converted to .684 N-m/A • RPM • Calculated from quadrature encoder pulses (frequency / 512 pulses per rev.) x 60 sec • Power (watts) • Torque (N-m) x angular velocity (rad/sec)

  17. LabVIEW Schematic

  18. LabVIEW Front Page

  19. Testing Procedure • Specific torque coefficients ‘a0’,’a1’, and ‘a2’ entered into the DSP • Test motor run at different speeds • Actual motor torque compared to DSP torque command using LabVIEW

  20. Challenges • LabVIEW processing speed based on speed of PC, and number and complexity of measurements made. • DSP  serial port interface did not work reliably

  21. Successes • System controls load within approximately 2% of desired load profile • Can easily display test information using a PC to document motor test data

  22. Additional Analysis • Analyze frequency content of power and torque fluctuations • Save data to a spreadsheet file for later analysis.

  23. Cost LABOR • (3 engineers)*(9 weeks)*(8 hrs/week)*($35/hour)*2.5 = $18900 PARTS Complete Turn-Key System • National Instruments LabVIEW Pro. Dev. System = $3495 • National Instruments PCI-MIO-16E-1 Data Acquisition Card = $1795 • National Instruments SH68-68-EP Shielded DAQ Cable = $95 • National Instruments SCB-68 Shielded I/O Connector Block = $295 • Torque-controlled AC motor drive, AC machine, and cables = $3585  • Texas Instruments TMS320C24x evaluation board (DSP) = $199 • TOTAL PARTS FOR TURN-KEY SYSTEM = $9464 Retrofitted System (same as above but without drive and motor) • TOTAL PARTS FOR RETROFITTED SYSTEM = $5879  GRAND TOTALS: • Parts and labor for turn-key system: $28364 • Parts and labor for retrofitted system: $24779

  24. Thanks To: • Professor Krein • Julio Urbina • Jason Wells • Dan Block • The Machine Shop (for fixing everything we blew up)

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