by: mark bright and mike donaldson. project summary system block diagram project goals 4 week...
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![Page 1: By: Mark Bright and Mike Donaldson. Project Summary System Block Diagram Project Goals 4 Week Progress ◦ Engine side ◦ Thermo side](https://reader038.vdocuments.us/reader038/viewer/2022103022/56649d3f5503460f94a18d78/html5/thumbnails/1.jpg)
By:Mark Bright
and Mike Donaldson
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Project Summary System Block Diagram Project Goals
4 Week Progress◦ Engine side◦ Thermo side
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For this project, an Engine Control Workstation will be designed to simulate the thermal environments found in cooling systems. The workstation will allow users to design, test and implement controllers via Matlab GUI to more precisely regulate the thermal dissipation of a motor-generator system with the goal of reducing energy use.
Code auto-generated within the same program with the processing of the data being done on a DSP board.
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Engine Control: Minimize C-code and execution
time
Learn Auto-code generation platform of Simulink/DSP interface
Design DSP/cooling system hardware interface
Design software for PWM generation and velocity calculation from rotary encoder.
Implement active thermal load for DC generator
Design closed-loop controllers for velocity and acceleration control.
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Thermal Control: Perform System Identification to
develop a model for the thermal portion of the workstation
Design Simulink/MATLAB GUI for controller parameter modification – will have data and graphs displayed
Design closed-loop controller for temperature regulation of cooling system.
Design energy management control system in Simulink to regulate voltage/current to each subsystem based on its energy usage.
Evaluate controller performance based on system accuracy, speed, and energy use.
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TMS320F2812 DSP Platform
Thermo Plant System
TMS320F2812 DSP Platform
Engine Control Workstation
PC(Plant/Engine Control)
PC(Thermo Control)
Energy Management/Control
MATLAB GUI Interface
- Command Velocity- Controller Parameters (P, PI, PID, ?)- Load
MATLAB GUI Display
- Plant Velocity- Motor Current- Steady-State-error- Transcient Response- PWM%- Controller Signal
MATLAB GUI Interface
- Set Point (Temp Coolant or Plant)- Pump Velocity- Fan Velocity
MATLAB GUI Display
- Flow Rate- Radiator Outlet temp- Radiator Inlet Temp- Plant Temp- PWM% ’s
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Thermo Plant System
PITTMAN GM9236C534-R2
DC MOTOR
ROTARY ENCODER
5.9 : 1
PITTMAN GM9236C534-R2
DC MOTOR
5.9 : 1
ROTARY ENCODER
Cooling Block Cooling BlockCooling Block CoolantCoolant
Coolant
Reservoir TNK-400
Pump PMP-400 Coolant
Radiator, HX-362
Fan Heat
Coolant
Co
ola
nt
Coolant
Co
ol a
nt
Radiator Inlet Temp
Radiator Outlet Temp
Plant Temp
ROTARY ENCODER ROTARY
ENCODER
Voltage
Voltage
Voltage
Load
Signal to be Controlled
Sensor Signals
JamecoSP - 320
PWR Supply
INS-FM16 Coolant Flow MeterCoolant
Flow Rate
Solenoid
Co
ola
nt
Coolant
Co
ola
nt
X
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Quadrature Encoder Reading
•Drag QEP Block from Simulink
•Code Below is Auto-Generated from Simulink
•Shown as Inner Shaft RPM in Code Composer
•DSP Port 8 - Pin 6 and 7
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Quadrature Encoder Reading
•Recorded as Inner Shaft RPM
•5.9:1 Gear Reduction is in GUI
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Proportional Control
Proportional Control was added K was tuned to .08 Ess = ± 75 RPM All data was sent to the GUI Main troubleshooting issues were data types
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Proportional, Integral Control
PI Control was added Integral Controller is (z/z-1)K was tuned to .0005Ess = ± 20RPMAll data was sent to the GUI
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Feed-Forward Testing
Gp = ______________ (s/146+1)(s/776+1)
______________
(s/146+1)
(s/1460+1)17.1FF=Gp =
17.1 -1
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Feed-Forward Testing
100 RPM Step Input Smaller time to first
Peak (Tp) by 20 mS Less Overshoot Ess=0
FF Compensation
PI Control Only
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Feed-Forward Controller in System
Performed Bilinear Transformation in MATLAB of s-plane TF Tuned Gain = 1/34.2 instead of 1/17.1 (inverse of plant)
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FF Simulation vs. Actual
Simulation: 596 RPM input FF Output is 17 RPM Impulse through 2mS
Actual: 596 RPM input System 605 RPM output FF Output is 17 RPM
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Engine Side GUI
User can input desired RPM
Outputs: RPM, Duty Cycle, FF Controller
Ess = ±20 RPM Updates in real
time Will add more as
the project continues
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GUI Design
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GUI Design
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Anti-aliasing filter
Moving Average Filter
X
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Conversion of ADC# to TEMP?
Excel Trendline
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Datatype conversions
Function auto-code generated
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Opto-Isolator
TIP120 choice
Design for 3A
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Use the same design for the Pump Increase Base current
Increase voltage from 12-volt regulator (more later)
Does any PWM work ? ◦ 300mHZ !
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12-Volt regulator enchanced
Motivation◦ TIP 120 Vce drop
880mv
◦ 13.5 volts max for pump/fan
* Linear/Switchmode Voltage Regulator Handbook
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LPF to DC the PWM
Ideal Op Amp theory
Voltage @ Input = Voltage @ Pump
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Set PWM’s via GUI slider
Slider value sent via ICHAN’s
OCHAN monitors PWM% for data logging
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Acknowledgement Nick Schmidt
◦ Case Assembly◦ Hardware Assembly
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Schedule
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Questions
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OCHAN’s allow for data to be outputted to:◦ GUI◦ Workspace
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P = Vce * Ie
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Thermo GUI
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Start, Type “guide” in MATLAB
GUI can be designed here with many components
Once designed, MATLAB auto-generates a .m file and .fig file
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Started with Professor Dempsey PWM Tutorial
Interfaced DSP Board, Simulink and PWM for Motor
Tutorial Contents: Simulink Model Auto-Gen .m file Auto-Gen .fig file Demo .m file DSP/Simulink Interface .m
file
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PWM Brush Type Servo Amplifer – Model 10A8DD
Protected for over-voltage and over-current
DC Supply Voltage: 20-80v
Peak Current: ±10A Maximum Continuous
Current: ±6A
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32-bit Processor 30 MHz Clock 16 A-D channels 12 PWM Digital I/O
Channels 128K on-chip Flash
memory 9 Ports total 3.3 v Supply Interface with TI C2000
Simulink System
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System ComponentsTotal Cost
Fan $ 10.99
Radiator $ 39.99
Cooling Block $ 54.99
Reservoir and Pump $ 116.99
Pump $ 77.99
Flow Meter $ 16.99
Coolant $ 14.99
Cold Cathode $ 10.99
Temp Sensors - (2) $ 19.99
30V Power Supply $ 142.00
TI TMS320F2812DSP Boards - (2) $ 938.00
120VAC Solenoid Valve $ 41.00
30.3V Pittman Motor - (2) $ 80.00
Misc - Wires, Tubing, Case $ 20.00
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