By:Mark Bright

and Mike Donaldson

Project Goal Applications of our system System Block Diagram Thermal Plant Overiew

Current Progress◦ Engine Side (Mark)◦ Thermal Side (Mike)

The goal of our Engine Control Workstation is to simulate thermal environments that are found in liquid-based cooling systems.

With this simulation we are creating several different control methods via MATLAB and Simulink that all work together to control both the engine and thermal transient responses.

Both of which combine to reduce system energy usage

Applications of our system

Car Application PC Application

Cooling Block

Thermistor

Flowmeter

Pump

Motor

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

X

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

What is it?◦ Two Square Waves 90º

out of phase

How does this improve accuracy?◦ Four times as many

pulse counts

Allows for ±5 RPM Error Max

Used in DSP Port 8 – Pins 6 and 7

Drag QEP Block from Simulink Code Below is Auto-Generated

from Simulink Show as Inner Shaft RPM in

Code Composer Show as Out Shaft RPM in GUI

Proportional, Integral Control

PI Control was added Integral Controller is (z/z-1)K was tuned to .0005Ess = ± 20RPMAll data is sent to the GUI

Performed Bilinear Transformation in MATLAB

Bilinear Transform converts an analog controller to a digital controller

Tuned Gain = 1/34.2 instead of 1/17.1 (inverse of plant)

100 RPM Step Input

Smaller time to first Peak (Tp) by 20 mS

Less Overshoot

Ess=0

FF Compensation

PI Control Only

User can input desired RPM

Outputs: RPM, Duty Cycle, Transient Response

Updates in real time

Will add more as the project continues

Variable Resistance

Anti-aliasing filter

X

Conversion of A/D Value to Temperature

Excel Trendline

Moving Average Filter

Datatype conversions

Function auto-code generated

Interface from digital to analog

Average Voltage seen by the device

Opto-Isolator

TIP120 choice

Design for 3A

Increase Base current

Increase voltage from 12-volt regulator (more later)

Does any PWM work ? ◦ 300mHZ !

LPF to DC the PWM

Ideal Op Amp theory

Voltage @ Input = Voltage @ Pump

Nick Schmidt◦ Case Assembly◦ Hardware Assembly

Motivation◦ TIP 120 Vce drop

880mv

◦ 13.5 volts max for pump/fan

* Linear/Switchmode Voltage Regulator Handbook

OCHAN’s allow for data to be outputted to:◦ GUI◦ Workspace

P = Vce * Ie

Start, Type “guide” in MATLAB

GUI can be designed here with many components

Once designed, MATLAB auto-generates a .m file and .fig file

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

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

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