controls lab 6508 cdr

8/6/2019 Controls Lab 6508 CDR

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Multidisciplinary Engineering Senior Design

Project 6508 Controls Lab Interface

ImprovementCritical Design Review

2/24/05Project Sponsor: EE Department

Team Members: Michael Abbott, Neil Burkell

Team Mentor: Dr. Mathew, Dr. Sahin

Coordinator: Dr. Phillips

Kate Gleason College of EngineeringRochester Institute of Technology



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• The Digital Board is outdated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



Project Overview• Current Controls Lab:

– Digital control is taught through Simulink from varying

sampling time and using different methods for convertingcontinuous to discrete transfer functions

– There are no hardware experiments using digital controllers• A new Digital Board is needed for the lab



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 theexisting DC motor

• Exploration into feasible interface concepts was

needed (SD I deliverable)



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



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 to300 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



Requirements Developed

• The Requirements of the Project (continued)

– Interface will acquire motor speed and positiondata

– 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



Overall System Diagram

Lab PC

with Matlab

and Simulink

System

Interface

Feedback

33-100DC Servo Motor

Feedback

Power

Supply

Gnd, +-15V, 5V

Analog to Motor +-8V to PA(+ve,-ve)

Digital from Motor 6 Grey Code + Index

for Position

Analog from Motor Tachogenerator +-8V

Communication



PA +ve, PA –ve,

Tachogenerator

+-, Grey code

Position idicator

Mechanical Unit 33-100

Input Shaft Output Shaft

Tachogenerator



MATLAB Software Layout



Analysis & Synthesis of Design

• Multiple Concepts were developed

1) Using a DSP Development Kit

2) Using a USB Data Acquisition Board

Importing Simulink diagram into NI LabVIEW

1) Data Acquisition PCI Card in Windows

2) Separate PC with I/O Capability controlled by

MATLAB




• Concept 1: Using a DSP Development Kit

Simulink DSP Kit Interface Board Motor

• Concept 2: Using a USB DAQ Board

Simulink DAQ Board Interface Board Motor USB

USB

RS232

• Both concepts found not to be feasible




• 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



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

Analysis & Synthesis of Design• Concept 4: Separate PC with PCI DAQ Controlled by MATLAB

Simulink Computer Interface Board Motor PCI DAQ



System Diagram

• Both concepts use the Real Time Workshop in MATLAB

System Block Diagram

Real Time

WorkshopSimulink

Generated C

Code

Real Time

Workshop

DC MotorPCI CardGenerated C

Code

xPC Kernel PCI Card

Computer

Real Time Windows Target Toolbox

xPC Target Toolbox

Interface

Board

Second Computer

Simulink DC MotorInterface

Board

Computer



PCI DAQ Card

– Measurement Computing PCI Card

• 16 Analog Inputs

• 2 Analog Outputs

• 24 Digital Inputs or Outputs



Gantt Chart Followed

Events Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10 Week 11

Receive Software

Receive Parts

Learn xPC Target Toolbox

Learn RTW Target Toolbox

Interface Hardware and Simulink

using xPC and RTWDebug

Design PCB Interface Board

Impliment Test Plan

Demonstration

Documentaion of xPC and RTW

Order Additional Lab Setups

Winter Quarter 05-06



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



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



Desired Outcomes

• Document the process for developing digital

controllers to be able to implement them in a

laboratory setting



Key Requirements

1) Show that data can be acquired and output at the minimumsampling 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 tocontrol the speed of the motor.

3) Use interface board, Feedback Mechanical Unit 33-100,Feedback power supply, and Simulink Control Algorithm tocontrol the position of the motor.

4) Documentation, including a user guide, working Simulinkmodels, and a service manual.



Critical Parameters

1. Acquire 20 V peak to peak, 100 Hz sine wave using digital

interface and output. Verify with oscilloscope.

Input Wave

Output Wave



Critical Parameters

2. 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

step

yM OS ss pt

−

=



Critical Parameters

– Use a Simulink Integrator Controller

• Verify: -Tachogenerator voltage 1.5 V ± 5%

Step1

s

Integrator

5

Gain

0. 5

Constant

Ana log

Output

Ana log Output

Measurement Computing

PCI-DAS1602-16 [auto]

Analog

Input

Ana log Input



Add1Ad d

10 11 12 13 14 15 16 17 18 19 20

0

0.5

1

1.5

time [sec]

TachometerVo

ltage[V]

Results for Integrator Controller

SIMULATION

RESULTTachogenerator

Voltage from

Motor

Power Amplifier

on Motor



Critical Parameters

– Use a Simulink PI Controller

• Verify: -Tachogenerator voltage 1.5 V ± 5%

-Transient Results within ± 5%

s+6.5

s

Transfer Fcn

Step 2. 5

Ga in

0. 5

Constant

Ana log

Output

Analog Output

Measurement Comput ing


Ana log

Input

Analog Input



Add1Ad d

10 11 12 13 14 15 16 17 18 19 200

0.5

1

1.5

time [sec]

TachometerVoltage[V]

Results for Integrator Controller

SIMULATION

RESULT

Tachogeneartor

Voltage from

Motor

Power Amplifier

on Motor



Critical Parameters

– Use a Simulink One Pole Controller

• Verify: -Tachogenerator Voltage within ± 5%

Theoretical Steady State Error

-Transient Results within ± 5%

1

s+5

Transfer Fcn

Step 20

Gain

0. 5

Constant

Analog

Output

Analog Output



Analog

Input

Analog Input



Add1Ad d

10 11 12 13 14 15 16 17 18 19 20-0.2

0

0.2

0.4

0.6

0.8

1

1.2ResultsforOnePoleController

SIMULATION

RESULT

Tachogenerator

Voltage Output

from Motor

Power Amplifier

on Motor



Critical Parameters

3. 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

1

Gain

Analog

Output

Analog Output



Analog

Input

Analog Input1



Ana log

Input

Analog Input



Ad d

0 1 2 3 4 5 6 7 8 9 10-10

-5

0

5

time[sec]

P

o s i t i o n V o l t a g e s [ V ]

FeedbackPositionResults(Motor Initiallyat 270degreesandmovedto90degrees)

Output Shaft Voltage

Input Shaft Voltage

Input Shaft

Voltage from

Motor

Output Shaft

Voltage from

Motor



Critical Parameters

4. 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

s+6.5

s

Transfer Fcn

Step 2. 5

Ga in

0. 5

Constant

Ana log

Output

Analog Output



Ana log

Input

Ana log I npu t



Add1Ad d

PCB LAYOUT

Simulink Diagram TestPoints

PCI

Connectors

Motor

Connector



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



Major Design Challenges

• Understanding and using Real Time Workshopusing xPC Target Toolbox and Real Time

Windows Target Toolbox

–Read manuals on both toolboxes and performed tutorials

• Noise when reading sensor data from theservo DC motor board

–Traced to Feedback switching power supply

–Noise eliminated when using HP power supply currently in lab

Interface Design



Interface Design

-Interface connections needed

Motor Board

5 Analog Sensors

1 Analog Input

6 Digital Outputs

PCI DAQ Card

6 Analog Inputs

1 Analog Output

6 Digital Inputs

Interface Board



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



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



Final Design

-Interface board is redesigned with the previousconnections but with different test point locations and additional pads in case extracircuitry is desired

-Larger holes will be designed into the interfaceboard to be able to put a Plexiglas cover



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

PCI CardPCI Card

Interface

Board

Interface

Board

Motor

Board

Motor

Board

Computer

PCI Card

Interface

Board

Motor

Board

Two Computer SolutionOne Computer Solution



Testing Results•

Integrator Results

Control Algorithm OS (%) % Error OS Tr (sec) % Error Tr Tp (sec) % Error Tp

Integrator Cont roller (Analog) 38.10 6.46 0.68 7.94 1.09 4.78

Integrator Controller (RTW ) 39.60 2.77 0.65 3.17 1.06 1.89

Integrator Controller (xPC) 39.48 3.07 0.64 1.59 1.06 1.89

Integrator Controller (S imulat ion) 40.20 1.30 0.66 4.76 1.09 4.59

Integrator Cont roller (Theoret ical) 40.73 --- 0.63 --- 1.04 ---

10 11 12 13 14 15 16 17 18 19 20-1.5

-1

-0.5

0

0.5

1

1.5

2

time[sec]

T a c h o m e t e r V o l t a g e [ V ]

Resultsfor Integrator Controller (ResultsShiftedfor ViewingPurposes)

AnalogControl BoardResult

SimulationControl Result

Digital Control MATLABReal TimeWindowsResult

Digital Control MATLABxPCTarget Result

step

yM OS

ss pt −

=



Testing Results•

PI Controller Results

Control Algorithm OS (%) % Error OS Tr (sec) % Error Tr Tp (sec) % Error Tp

PI Controller (Analog) 24.30 3.57 0.27 3.85 0.46 2.68

PI Controller (RTW) 25.80 2.38 0.27 3.85 0.47 3.79

PI Controller (xPC) 25.35 0.60 0.26 0.00 0.46 2.68

PI Controller (Simulation) 25.20 --- 0.26 --- 0.45 ---

10 10.5 11 11.5 12 12.5 13 13.5 14 14.5 15-1.5

-1

-0.5

0

0.5

1

1.5

2

time[sec]

T a c h o m e

t e r V o l t a g e [ V ]

Resultsfor PI Controller (ResultsShiftedfor ViewingPurposes)





step

yM OS

ss pt −

=

Testing Results



Testing Results

•

One Pole Controller Results

C o n tro l A lg o ri th m O S (%)% Erro r O STr (sec) % Error r

O ne P o le C ont ro lle r (A n a log ) 27 .0 3 8 .68 0.3 5 4.48

O ne P o le C ont ro lle r (R TW ) 28.0 1 5 .37 0.3 5 4.48

O ne P o le C ont ro lle r (x P C ) 28.1 0 5 .07 0.3 5 4.48

One P o le Cont ro lle r (S im u la t ion)27 .0 3 8 .68 0.3 5 4.48

One P o le Cont ro l le r (Theore t ica l )29 .6 0 --- 0 .3 4 ---

Tp (se c)% Error Tp Vss (V ) % Er ro r Vss

O ne P o le Cont ro lle r (A n a log ) 0 .55 5 .83 1.21 50 3.61

O ne P o le C ont ro lle r (R TW ) 0.54 4 .85 1.21 86 3.92

O ne P o le C ont ro lle r (x P C ) 0 .54 4 .85 1.21 58 3.68

One P o le Cont ro lle r (S im u la t ion)0 .54 4 .85 1.17 28 0.01

One P o le Cont ro l le r (Theore t ica l )0 .52 --- 1 .17 27 ---

10 11 12 13 14 15 16 17 18 19 20-1.5

-1

-0.5

0

0.5

1

1.5

Time[sec]


Resultsfor OnePoleController (ResultsShiftedfor ViewingPurposes)





step

yM OS

ss pt −

=

Testing Results



Testing Results

•Two Pole, One Zero Controller Results

Sampling Time [sec] 0.0250 0.0375 0.0500 0.1000 0.2000

Simulation OS [%] 15.000 19.900 24.600 39.800 --

Single Computer [% Error] 3.000 2.010 2.439 3.015

Two Computer [%Error] 0.667 1.508 1.626 3.769

Simulation Tr [sec] 0.429 0.430 0.413 0.410 --


Two Computer [% Error] 3.263 1.163 0.606 7.317

Simulation Tp [sec] 0.600 0.610 0.625 0.650 --


Two Computer [% Error] 0.000 0.000 0.000 0.000

0 2 4 6 8 10 12 14 16 18 20-0.2

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

Time[s]

T a c h o g e n e r a t o r V o l t a g e [ V ]

RTWTarget StepResponsefor Different SamplingTimeswithZOHEquivalent DiscreteController

0.0375SamplingTime

0 2 4 6 8 10 12 14 16 18 20-3

-2

-1

0

1

2

3

4

Time[s]

T a c h o g e n e r a

t o r V o l t a g e [ V ]

RTWTarget StepResponsefor Different SamplingTimeswithZOHEquivalent DiscreteController

0.2SamplingTime



Testing Results

•Position Control

Results

0 1 2 3 4 5 6 7 8 9 10-10

-5

0

5

time[sec]

P o s i t i o n V o l t a g e s [ V ]

FeedbackPositionResults(Motor Initiallyat 270degreesandmovedto90degrees)

Output Shaft Voltage

Input Shaft Voltage

0 1 2 3 4 5 6 7 8 9 10-10

-5

0

5

AnalogBoardFeedbackPositionResults(Motor Initiallyat 270degreesandmovedto90degrees)

time[sec]

P o s i t i o n V o l t a g e s [ V ] Output Shaft Voltage

Input Shaft Voltage

Output Shaft

Input Shaft



Testing Results

• Power Supply Noise Results

10 11 12 13 14 15 16 17 18 19 20-0.2

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

time[sec]


Plot of Tachometer Voltagevs. Timefor Different Power Supplies(Shiftedfor ViewingPurposes)

HPE3631APower Supply

Feedback01-100Power Supply



Testing Results

• Fuzzy PI Controller Implementation PerformanceComparison

Sampling

Frequency

Single Computer

Experiment: Processor

Percentage

Two Computer

Experiment: Task

Execution Time

1 kHz 4% 49 μs

2 kHz 7% 50 μs

4 kHz 14% 53 μs

8 kHz 29%--Stopped Running 51 μs

10 kHzStopped Running

Immediately54 μs



Conclusions

-Both designs successful

-Both can be used in Current Control Systems Design Lab

-Two Computer Setup can be used in multiple applications

Computer Computer RS-232

PCI CardPCI Card

InterfaceBoard

InterfaceBoard

Motor

Board

Motor

Board

Computer

PCI Card

InterfaceBoard

Motor

Board

Two Computer SolutionOne Computer Solution



Thank You

Dr. Phillips

Dr. Mathew

Ken Snyder Jim Stefano

Jacob Slezak



Questions

?



Item Itemized Cost Qty. Total

Interface PCB (3 min. order) $17.00 1 $17.0050 Pin Connector $1.47 2 $2.94

34 Pin Connector $1.14 1 $1.14

PCI-DAS1602/16 $715.50 1 $715.50

C100FF-2 (50 Pin Ribbon Cable) $44.10 1 $44.10

Total Cost Per Station $780.68

Complete Lab Station $780.68 8 $6,245.44

Single Computer Setup BOM

Two Computer Setup BOM

Item Itemized Cost Qty. Total

Interface PCB (3 min. order) $17.00 2 $34.00



PCI-DAS1602/16 $715.50 2 $1,431.00

C100FF-2 (50 Pin Ribbon Cable) $44.10 2 $88.20

RS-232 Cable $8.00 1 $8.00

xPC Target License (One Year for

Entire Lab) $600.00

Total Cost Per Pair $1,569.36

Total Cost for Lab (Hardware) $1,569.36 4 $6,277.44

Total Cost for Lab with Software $6,877.44



Production Plan

Week 1 Week 2 Week 3 Week 4 Week 5 Week 6

Order PCI Card fromMeasurement Computing

Receive PCI Cards

Install PCI Cards into PC's

Order PCB Boards

Receive PCB Boards

Populate PCB Boards

Test Setups

controls lab 6508 cdr

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