roga control v1ac closed vector control electric motor with a national instruments scxi system. the...

Copyright Jeffers Emerging Technologies, LLC 2017-12-08

ROGA Control v1.0

User Manual Release 2

This document describes the data acquisition hardware and software for controlling the Baldor Drives VS1GV AC Closed Vector Control electric motor with a National Instruments SCXI system. The motor can be operated two different ways: Velocity and Feedback. Feedback mode uses the experimental data to determine the motor velocity in real time by interfacing the Proportional, Integral, and Derivative (PID) controller of the VS1GV.

ROGA System Diagram

Baldor Drives VS1GV

AC Closed Vector Control

Electric Motor

Personal Computer

Windows 32-bit

NI

DAQmx

9.3.0

LVRTE

2010

32-bit RO

GA

Co

ntr

ol

1.0

SC

XI:

16

00

(U

SB

1.0

, b3

2-b

it) SCXI:1124

Analog Out (2/6)

SCXI:1161

Digital Out (3/8)

SCXI:1102C Analog In (8)

SCXI:1520 Analog Bridge In (8)

SCXI:1325

Connect

SCXI:1300

Connect

SCXI:1314T

Connect

USB-6210

Analog In (2)

Clutch Flywheel

DRS61-AAA08912

Encoder

??? Load Cell

Teledyne ISCO 260D Syringe Pump

USB-RS232 Adapter

Temperature & Humidity

CROC Pressure Thermocouple (2)

Velocity

Torque

ON & OFF

Hard Drive

Control File

Data File

Personal Computer

Windows 7

64-bit

RO

GA

Fast

1.0

Copyright Jeffers Emerging Technologies, LLC 2017-12-08

Contents ROGA System Diagram .............................................................................................................................................................. 1

Documentation Errata ............................................................................................................................................................... 2

Mandatory Safety Check before Running an Experiment ......................................................................................................... 3

Using the Baldor Motor Manually ............................................................................................................................................. 4

ROGA Control V1.0 .................................................................................................................................................................... 5

ROGA Control Operation Theory and Control File ................................................................................................................ 6

Advanced Software Functions ............................................................................................................................................... 9

Calibrating and Assigning Data Channels .......................................................................................................................... 9

Process Control Mode .........................................................................................................................................................10

Syringe Pumps (CROC) ........................................................................................................................................................11

ROGA Fast ...............................................................................................................................................................................13

Appendix .................................................................................................................................................................................14

Wiring List............................................................................................................................................................................14

Software History ..................................................................................................................................................................14

Operation procedure (version 1.0, Date 7/27/2008) ..........................................................................................................15

Documentation Errata

3

Mandatory Safety Check before Running an Experiment

THIS STEP IS NECESSARY DUE TO THE FAILURE OF REMOTE COMMUNICATIONS ON THE BALDOR MOTOR CONTROLLER!

Motor Mode and Max RPM are for display only and must be manually matched to the actual motor controller when the software is started, Figure 1. See the section Using the Baldor Motor Manually for further detail. Click on the white boxes with black text to make selections and enter data. The User Type allows you to limit the graphical display and modifications of software settings while running experiments. Only the administrator can alter hardware configurations and a “Tester” can only operate the motor mode “Standard Run 2 Wire”. Click on the red “X” in the upper corner

CLICKING ON THESE SOFTWARE CONTROLS CAN CAUSE THE MOTOR TO MOVE AND DETERMINE THE SPEED IT MOVES!

The orange buttons with indicator lights that can be clicked are bright orange, Fig. 2(a). The buttons that are “greyed” cannot be used in the current mode, Fig. 2(b). The motor cannot be controlled when the button on the left says Motor Off. If this button is clicked it will turn green and display the words Motor On, Fig. 2(c). This enables the user to control the Motor Speed Volt., Fig. 2(d). The maximum value for this control is 10.0 and corresponds to requesting the motor to spin at the Max RPM, Fig. 2(e). These buttons change based on the Motor Mode selected: Standard Run 2‐Wire mode uses an analog voltage to control velocity and Process Control uses an additional Feedback signal.

Standard Run 2‐Wire Process Control

Motor Off/On Allows motor motion, when enabled the motor blower turns on.

Jog Forward Jog motor clockwise Table Select Selects motor settings table.

Jog Reverse Jog motor counter clockwise. Speed/Torque Control speed OR torque.

Acc/Dec Select Select Rise/Drop rate table. Process Mode Enable Enables motor motion.

Preset Speed Motor to Preset Speed 1 Jog Jog motor counter clockwise.

Clutch Engages clutch for sample rotation

Flywheel Display of test file. Not user controlled

Table 1: Baldor motor control signals.

(a)

(b)

(c)

(d)

(e)

Figure 2: Controlling motor motion with the software.

Figure 1: Matching software configuration to motor settings.

ROGA Control Manual Rev. 2

4

Using the Baldor Motor Manually

The Baldor Motor controller should be checked prior to any testing using the ROGA software. To check and/or set the motor “Input Settings” use the buttons to navigate the menus shown in Figure 3. The first check is the Motor Mode which is accessed through “Menu: Level 1 Block: Input Setup”. See Baldor Document #707VS‐411 for a complete list.

Figure 3: Checking the motor settings part 1.

The basic speed test uses “Operating Mode = Std Run 2‐Wire” and “Command Source = Analog Input1”. The maximum

RPM setting for the motor should also be verified. It can be accessed through “Menu: Level 1 Blocks: Motor Control”. Check the controller and enter the values in the software boxes using Figure 4.

Figure 4:Configuring a basic "Standard Run 2‐Wire" measurement.

The system should return to a default state each time is turned on. This state is “Command Source = None” and the

“Max RPM” at the last used setting. If you attempt to run a test the motor will not spin.

Step 1: Menu button Step 3: Enter Button

Step 2: Arrow Button

ROGA Control Manual Ver. 2

5

ROGA Control V1.0

Data acquisition speed and the unit are set with software controls in the upper left of the window, Figure 6. The Mode can be: Paused, Acquire Units, Acquire Voltages Slow, Acquire Voltage Fast, and Test. Data speed and display speed are set by the controls Sample Rate (Hz) and Data Rate (Hz). The data is shown on the Motor Tab Display.

Figure 5: Acquiring data in units

The software will record and display 1000 frames of data, equivalent to (1000/Data Rate (Hz)) seconds, which can be saved to a file. The amount of time data is recorded is increased by lowering the Data Rate (Hz). The number of data points recorded is calculated as Sample Rate (Hz) X (1000/Data Rate (Hz)). Use low sample rates for eddy current measurements and general research to limit memory usage. Use standard settings for installing a rock sample and measuring the eddy currents (in microns) and the normal load (in pounds) are shown in Figure 7.

Figure 6:Data displays can be changed, and the trend data depends on the units selected: scaled or voltage.

To save data the user must stop acquisition by setting Mode to “Paused” and then switch to the Compare Tab. The user should then click on the File menu and select Save. You will then be prompted to select a file name.

Motor

Data

Mode Time

Display Menus

Data Displays

View Tabs

Time (sec) = =10sec

Data (Points) =10 (sec)×5kHz =50000

Time (sec) = =50sec

Data (Points) =50 (sec) ×500(Hz) =25000


6

ROGA Control Operation Theory and Control File

ROGA Control uses one software timed 1 kHz analog output (either the velocity or torque signal in cover page Figure 1) and three digital control signals to operate the entire mechanical apparatus. The Control File function tab is used to create and set experiment parameters, Figure 7. The black line on the graph shows the analog voltage output from the NI hardware that the Baldor motor controller turns into either velocity or torque. The red, green, and blue lines are the states of the blower, flywheel, and clutch during the test. Figure 10 displays a basic 9 second velocity experiment and data collection with three “TEST STEPS”.

Part 1: Pre-test baseline data collection for 3 seconds (Mode 9) The blower and motor are enabled (turned ON) with a 5 Volt digital signal (electronic noise) The clutch is enabled (turned ON) with a 5 Volt digital signal (possible motion or slipping) The flywheel is disabled (turned OFF) with a 0 Volt digital signal The motor is not moving (0 RPM) with a 0 Volt analog signal

Part 2: Test data collection for 3 seconds The motor starts spinning at maximum velocity (600 RPM) with a 10 Volt analog signal for 3 seconds

All other control signals stay the same Part 3: Spin-down data collection for 3 seconds

The motor drive signal ends and motion *slows* with a 0 Volt analog signal All other control signals stay the same At the end of this 9 second test all control signals go to 0 Volts and data is saved.

Figure 7:ROGA starting screen of Control File display of analog voltage (black line) and three digital control voltages.

Part 1 Part 2 Part 3


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NOTE: The core functionality of the software is based on the limitation that the SCXI-1124 analog outputs do not have

internal memory for storing a “waveform”. The memory and “clock” is maintained by ROGA Control in computer memory,

Figure 8, that is accessed at random intervals subject to Windows operating system, LabVIEW execution, and data

collection transfer over the single USB 1.0 connection. The MAXIMUM rate is 1 kHz, but the actual rate is much less

because there is no guarantee the software will output every data point in this array. The possible delays could easily be

0.1 seconds. This is accounted for by shifting data with the counter but causes many problems. For example, the software

could output 0, 1, or all the data points shown in the figure at the time indicated by the test design. Each test run will have

a different result. At this time resolution it may be insignificant, but it introduces uncertainty.

Figure 8: Internal memory and the possible output timing due to computer multi-tasking

Test Steps edited by a right‐click and the keyboard. Each row is a step with a MODE, LENGTH, START VALUE, and END

VALUE. The MODE is a decimal number where each bit defines the control signals for various system devices shown in

Table 3. Control Bit 1 is assigned to “Jog” but not implemented.

This control information is displayed graphically on the Control File view tab. There three different tests available:

Velocity, Power, and Quake. A “Quake” test example is shown in Figure 10. WARNING: a “Quake” test uses the flywheel

and requires it to be engaged manually prior to the test.

Bit Decimal Device Description

0 1 Blower/Motor Enables motor operation.

2 4 Flywheel Disengages flywheel.

3 8 Clutch Toggles status of clutch.

4 16 Hydraulic Pump Activates hydraulic system.


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Figure 11: Control file examples of the different test types.


9

Advanced Software Functions

Calibrating and Assigning Data Channels

The software enables real‐time voltage data to be scaled to units such as distance, force, or pressure. This uses the National Instruments Measurement and Automation Explorer (MAX) program, shown in Figure 11, and the function tabs Analog & Counter, TC & Bridge, and Save File.

Figure 12: NI Measurement and Automation Explorer (MAX) custom scale option.

Scale Menu

Scale Name

Linear Scale Scaled Value

Input Volt Value

Signal Name = Scale Name

Analog Channel

Voltage Range


10

Process Control Mode

Process Control Mode can control the motor velocity or torque with feedback to a standard PID algorithm. See Baldor

Document #707VS‐411 Figure 5‐4 for a description of the PID block diagram. The user must set eight (8) parameters on

the Baldor controller, Table 2. In addition to the eight parameters the “Multiple Parameter Sets” function of the controller

must be completed to allow dynamic switching (not implemented). These settings are accessed through the

Baldor menu as either a Level 1 block (Operating Mode) or a Level 2 block (all others).

Figure 9: Process control feedback for power control.

Operating Mode P1401 Process Control Description

Command Source None (0)

Process Type P2601 Reverse Acting (1) Error = Set ‐ Feed

Figure 13: Selecting different data trends and two files for display.

Signal List

Save List

Edit Controls

Function Tab = Save File

Calculated Operation Point ( Volts )

Control Set Point ( Volts )

Error ( Volts )

Torque ( Volts )


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Set Adjust Lim P2602 100% Limit of setpoint correction

Feedback P2603 Analog In2 (4) Signal from J1‐3

Setpoint P2604 Analog In1 (3) Signal from J1‐4

P (proportional) P2607 10.0 Gain or speed of change

I (Integral) P2608 1.0 Long‐term offset correction

Integral Clamp P2609 0.3% Long‐term correction limit

D (Derivative) P2610 0.01 Fast acting changes

Proc Filter

Proc Offset

Proc Gain Table 2: Process control Baldor motor settings 11/10/2011.

Figure 10:Process control diagram and software controls.

Syringe Pumps (CROC)

The ROGA software can control up to three Teledyne Isco 260D syringe pumps. Communication is with a 25‐pin serial

connection and requires the correct adapters and port configuration. The software uses a dynamically linked library

(.dll) with a custom communication protocol (DASNET). The ROGA window display is shown in Figure 14.

Feedback (Volts) = (MotorVelcity (Volts)+ 0)×0.001 +

(SampleTorque (Volts)+ 0)×1e7


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Figure 14: Syringe pump control view in ROGA software.

Function Option 1 Option 2 Description

Control Mode Constant Flow Constant Pressure

Run Mode Stop Run Refill

Setpoint 0‐?? 0‐?? Table 4: Software functions implemented for pump control.


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ROGA Fast

ROGA Fast controls 4 PCI data acquisition devices


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Appendix

Wiring List

Signal Name 3/29/2012 6/22/2017

Analog Voltages

Motor Velocity SC1Mod3/ai0

Motor Torque SC1Mod3/ai1

Eddy 1

Eddy 2

Eddy 3

Eddy 4

Encoder Voltage SC1Mod3/ai15

Temperature SC1Mod3/ai10

Humidity SC1Mod3/ai9

Bridge Inputs

Axial Load SC1Mod4/ai3

Torque SC1Mod4/ai1

Strain 11

Strain 12

Strain 13

Pressure CROC

Strain 21

Thermocouple 1 SC1Mod3/ai23

Thermocouple 2 SC1Mod3/ai26

Control File Format

The control file is a minimum of 13 lines. Line 1 contains user information. Line 2 contains required information:

operator, diameter measurement type, inner diameter, outer diameter, and TEST TYPE & FEEDBACK FREQUENCY. Other

information in line two is populated by the software. Line 5 is the sampling frequency in kilohertz (kHz). Line 6 is the

Motor Max RPM. Line 11 is the time after the test to collect data. Line 12 is the sampling frequency in kHz for the time

after test. Line 13 is the first test step. Additional file lines define test steps with 4 columns.

Software History

File LabVIEW Version Date Author(s)

ROGA2 7.1 1/15/2009 ZR

ROGA3 7.1 1/16/2009 ZR

ROGA Analysis 7.1 2/22/2009 ZR

ROGA Counter 7.1 2/25/2009 ZR


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Load Cells 6/2/2009 ZR

Quake 1 8/12/2009

Encoder 10/12/2009

Eddy 8.6 11/9/2009

Eddy 1 7/12/2010 ZR

Quake 10 201 JJ

ROGA 2010 2010 2/16/2011 JJ

Eddy 2 Strain Gage 8.6 5/29/2011 ZR, JJ

ROGA 11 2010 10/2/2011

Operation procedure (version 1.0, Date 7/27/2008)

The order of operation for a typical experiment:

A. Sample/cell preparations (on bench) a. Deformation cell preparations

i. Clean both parts of the cell ii. Check the conditions of the seals

iii. Selecting/emplacing the rings that will push the powder b. Sample preparation

i. Drying powder under 105 ii. Sieving/weighing powder

iii. Setting the powder inside the cell iv. Manual rotation (check if rotates freely)

B. Cell setup in apparatus a. Install/connect load cells for the planned experimental conditions

i. Set cell so the torque sensors will be in contact with torque arms ii. Use oil pump switch to lower ram to almost contact with cell

b. Connectors according to the planned experiment i. Pore pressure piping

1. Check gas pressure in accumulator/intensifier ii. SCXI connections:

1. IR probe (supplied with conditioner) 2. Strain gages (four rosettes) 3. Eddy current connectors (four sensors supplied w/conditioner) 4. IR switch (if installed) (to stop rotation if the temperature is too high)

iii. Cooling water 1. Connect piping 2. Start circulating

iv. Camera (if installed) C. Programming the test procedure

a. Initialize all parameters in SCXI (from PLC) b. Data saving (on PC):

i. Clear memory from un-necessary program/data ii. Setup a virtual ram on the PC (as large as needed)

iii. Open a file for the test


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c. Enter test conditions/info for the record (operator, powder info, axial load, cell type/size, pore pressure etc.)

d. SET the following test parameters: i. Axial load

ii. Pore pressure level iii. Ultimate velocity iv. Options of loading history:

1. ramp (slow loading) a. Set rise time from rest to full velocity b. Duration of run

2. fast step a. set time for pre-spinning of the motor b. Flywheel:

i. Disengage clutch ii. Conditions (RPM for disengagement)

3. Complex history (several velocity ramps (or steps) and flats) v. Type of data to be collected as a stream of digital data from the SCXI/PLC (including frequency):

1. Time 2. Motor velocity (from motor encoder) 3. Cell velocity (from encoder on rotating half of cell) 4. Pore pressure 5. Axial load 6. Torque load (two sensors) 7. Strain gages (four rosette) 8. Vertical displacement (four sensors of eddy currents) 9. Temperature (IR sensor)

D. Pre-run initialization of control/monitoring systems: a. Check emergency controllers:

i. STOP button ii. IR switch for automatic stop if a critical temperature is exceeded

b. Check communication in the network and between instruments (e.g., by running a virtual test): i. Motor drive

ii. PLC + display iii. SCXI iv. PC.

c. Check connectivity between all sensors and SCXI (resistivity) d. Transfer test program from PC to PLC. After initiation, the PC will not control the motor drive or system.

E. Pre-run testing of the mechanical system a. Disengage clutch b. Engage OR disengage flywheel according to the planned experiment c. Start recoding on PC d. Run the motor up the final planned velocity (~20 sec) e. Stop motor f. Check recoded data on PC g. Delete recoded data h. Open new file

F. Run steps: a. Axial load

i. Increase up to the pore-pressure value.


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ii. If no pore pressure increase axial load to final value b. Pore pressure

i. Increase under control (slowly, depending on grain size) to final value. ii. Wait 2-3 minutes to check if no leaks (pore pressure drop/fluid volume change)

c. Increase axial load to its final value (skip if no pore pressure) d. Disengage clutch e. Loading sample (options according to planned history):

i. Option 1: Ramp (slow acceleration) 1. Engage clutch 2. Disengage flywheel 3. Start rotating motor at constant accelerating velocity according to planned experiment 4. Once reach the final velocity, run for the planned duration while the drive controls the

velocity 5. Stop motor (brake?)

ii. Option 2: Fast step 1. Disengage clutch 2. Engage flywheel 3. Start rotating motor to the final velocity 4. Once reach the final velocity:

a. Engage clutch b. After 2-3 sec (to be determined by experience of the operator) disengage the

flywheel 5. Run for the planned duration 6. Stop motor (brake?)

f. Stop recording g. Save data to hard disk h. Reduce axial load to pore pressure value i. Zero the pore pressure j. Zero the axial load k. Stop cooling water. l. Take off cell.


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Procedure #101 Operating/Tunning the H2 motor drive 09/26/08

Manual: VS1GV AC Vector-765.pdf in C:\Documents and Settings\ZR\My Documents\ROGA\Operations_Manuals

Software:

1. Double-click “MMC” shortcut on desktop; it opens to C:\Documents and Settings\ZR\My

Documents\ROGA\Operations_Manuals\1st.mmc

2. From MMC window click “Launch WorkBench” to load 'H2 Drive (node 1) on USB.wbx' which is located in C:\Documents and Settings\ZR\My Documents\ROGA\Operations_Manuals

3. Double-click “SCXI” shortcut on desktop; it opens the controller of the SCXI box 4. Start LabView and open programs (in C:\Documents and Settings\ZR\My

Documents\ROGA\Operation_LabView_programs): 1. Run_analog_control_card_1124.vi 2. Run_relay_control_card_1161.vi 3. Run_Logging.vi

Pre-Running:

1. Connect the Command box to 110 V (if not connected) 2. Check if the USB cables are connected to the H2 drive AND the SCXI 3. Start the high-power box (push upward the red handle) 4. Turn the SCXI on 5. IMPORTANT: In the MMC window, the button of the Host>USB>H2... should be green. If in red:

1. Pull-push the USB plug of the H2 on the computer (sometimes it works) 2. If not: Disconnect the high-power (pull-down the red handle) 3. Wait until the on-drive control box is turned-off 4. Restart the high-power box (push upward the red handle)

6. If the button of the Host>USB>H2... (in the MMC window) is still red, restart the computer

Tunning the H2 drive:

1. Five windows should be opened (see above): 1. MMC 2. Mint WorkBench1 3. Run_analog_control_card_1124.vi 4. Run_relay_control_card_1161.vi 5. Run_Logging.vi

2. The “Mint WorkBench” window displays the parameters of the last run that become the active run. If another set of parameters is needed (from an earlier run or tunning), goto File>Open file and select the *.ptx file with the need drive parameters.

3. The drive can be tunned with two groups of parameters (Fig. 1, 2 below): 1. Ramp Rates that control the acceleration/deceleration time (P1101, 1104, 1107, 1110) 2. Motor Control that controls the shape of the ramp, primarily by P1634, 1635, 1636.

4. Examples: 1. Figs. 1, 2 show the data for the sharp steps in Fig. 3. The later is screen print of the three LabView windows. 2. By switching P1635 from 80.0 in Fig. 3, to 20.0 (the default) we get Fig. 4.


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