d SPACE DS 1103 Control Workstation Tutorial and

d. SPACE DS 1103 Control Workstation Tutorial and DC Motor Speed Control By: Annemarie Thomas Advisor: Dr. Winfred Anakwa May 5, 2009

Outline Goals n Project Description/Requirements n n Block Diagram, Functional Description, Requirements Equipment n Implementation n Progress Summary n References n

Goals Decrease the learning curve for the use of the d. SPACE DS 1103 Workstation by future students by: n n n Writing a Tutorial for use of the new DS 1103 Workstation. Designing a controller to control the speed of a DC motor. Implementing the controller design using the DS 1103 Workstation.

Suggested DS 1103 Uses Motor Control n Robotics n Automotive n Magnetic Suspension Systems n

Project Description Block Diagram

Description/Requirements I n Control. Desk software: Installed on PC. n Downloading, Monitoring, Changing (Speed) Inputs. n n Controller: One or more designs. n Simulink and RTI blocks. n PWM Output. n Optical Encoder Input. n

Description/Requirements II n Motor System: n n Optical Encoder: n n PWM Signal sent through Control Panel and Additional Hardware before entering motor. Optical Encoder Input directly to Incremental Encoder Input of Control Panel. CLP 1103 LED/Connector Panel: n Connect Inputs/Outputs between DS 1103 Board and Hardware.

Controller Requirements n DC motor speed controller designed/simulated using Simulink and d. SPACE blocksets, Matlabto-DSP interface libraries, the Real-Time Interface to Simulink, and Real-Time Workshop. n Overshoot less than or equal to 5%. Rise time less than or equal to 110 ms. Minimize Steady-state Error. n n

Equipment: Workstation n $14, 000 d. SPACE DS 1103 system consisting of: DS 1103 Board. n Expansion Box. n CLP 1103 PPC Connector and LED Panel. n Control. Desk Version 3. 2. 2/Other d. SPACE provided Software Applications. n n PC dedicated to the workstation containing other software applications required (Matlab/Simulink Version R 2008 a and

DS 1103 Workstation

Equipment: Other Pittman GM 9236 C 534 -R 2 DC Motor. n Magtrol HB-420 Brake. n TIP 120 Transistor. n IN 4004 Diode. n SN 7407 Hex Inverters. n Other electronic components, power supplies, and measurement devices. n

Implementation Block Diagram Control. Desk Simulink Model

Connector Panel n n PWM Output to Motor Incremental Encoder Input

PWM Output I PWM Output

PWM Output II To Motor System (PWM Ch. 1)

Incremental Encoder Input I Encoder Input

Incremental Encoder Input II From Encoder

Motor System & Brake

Motor System + - Hex Inverters (Buffer), NPN Darlington Transistor, and Diode

Unit Step (238. 57 RPM) Input n n n Ch 1: Supply Voltage Ch 2: Voltage at Collector MATH: Motor Voltage n n Ch 1: PWM Ch 2: Encoder Ch 3: Motor Current Ch 4: Diode Current

Motor Model Simulink Model See “Current Motor Model” reference on Reference II slide. Transfer Function (Torque components ignored):

Motor Model Response ωc n Phase Margin = 84°. n ωc = 279 rad/s

Brake n Systems Stops at approximately: n 0. 375 Nm -OR- 50 Oz. In

Speed Input/Output I

Speed Input/Output II

Controller I

Controller II

Controller III

Controller V n Overshoot less than or equal to 5%. n Rise time less than or equal to 110 ms. n Minimize Steady-state error.

Controller VI n n Analog Controller designed and pre-warping and bilinear methods used to convert to a Digital Controller. 12 k. Hz Sampling Frequency Additional Gain adjustments have been made in MATLAB calculations and Simulink Models.

MATLAB: Motor Model and Controller n n ωc Actual: n Phase Margin = 69. 5º. n ωc = 157 rad/s. Designed for: n Phase Margin = 69. 01º. (5 % O. S. ) n ωc = 157. 08 rad/s. (20 ms Rise Time)

MATLAB: Step Response Overshoot = 6% n Rise Time = 8. 33 ms n

Simulink: Model I MATLAB controller with added Gain of 7 Block

Simulink: Model II

Simulink: Step Response 238. 57 RPM = 1 pulse_in n Overshoot = 5% n Rise Time = 110 ms n

System Response I (200 RPM Input, 2. 14 second Step Time) Actual System: Control. Desk (Possible Time Delay, Rise Time < 108 ms) Simulink Simulation

System Response II Simulink/Actual System (RPM Output Only, Rise Time appears similar) Actual: Frequency-to. Voltage Converter (No Visible Overshoot)

Project Status: Timeline Week Goal Task Completed 1 January 27 Write tutorial introduction January 22 2 February 3 Verify motor parameters Not Complete Simulate motor model in MATLAB February 10 Design/Simulate controller in MATLAB March 10 Design/Simulate controller in Simulink April 9 February 24 Make required adjustments to model and download to DS 1103 March 12 6 March 3 Design/Build/Test hardware for motor subsystem February 12 7 March 10 Design/Build/Test hardware for optical encoder system February 17 8 - 10 March 31 Make required adjustments to controller model to work with motor and hardware and download to DS 1103 March 12 11 - 13 April 21 Improve controller or Design/Build/Test additional controllers April 23 14 April 28 Work on presentation/final report/tutorial In Progress 15 May 5 Presentation May 5 16 May 11 Final Report Due In Progress 3 4 -5 February 10

Project Status A Controller has been designed and implemented using the DS 1103 Board. n The Controller functions correctly but may not meet the rise time specification. n The tutorial is still being put together but will be completed. n The motor/brake model was verified/developed in a previous project. n

References I n Guides/Manuals: Control. Desk Experiment Guide For Control. Desk 3. 2, Germany: d. SPACE Gmb. H, 2008, Release 6. 1. n d. SPACE System First Work Steps For DS 1103, DS 1104, DS 1005, DS 1006, and Micro Auto Box, Germany: d. SPACE Gmb. H, 2007, Release 6. 0. n DS 1103 PPC Controller Board Hardware Installation and Configuration, Germany: d. SPACE Gmb. H, 2007, Release 6. 0. n Real-Time Interface (RTI and RTI-MP) Implementation Guide, Germany: d. SPACE Gmb. H, n

References II n d. SPACE Product Descriptions: “DS 1103 PPC Controller Board”, Germany: d. SPACE, July 2008. n “Connector and LED Panels, ” Catalog 2008, Germany: d. SPACE Gmb. H, 2008, p. 302. n n Current Motor Model: n Sabbisetti, Amulya Sabbisetti. "Discrete Time Gain Scheduled Adaptive Control of DC Motor Speed", Masters Project Report, Bradley University ECE Department, December 2008.

Acknowledgments n Mr. Nick Schmidt: n n Motor/Brake System Construction Mr. Mattus: Initial Setup of DS 1103 Workstation n Construction of Slave I/O and Encoder Connectors n n Larry Kendrick of Caterpillar: n Funds for purchase of DS 1103 system.