dSPACE DS1103 dSPACE DS1103 Control Workstation Control Workstation

Tutorial Tutorial and and

DC Motor Speed DC Motor Speed Control Control

By: Annemarie ThomasBy: Annemarie Thomas

Advisor: Dr. Winfred AnakwaAdvisor: Dr. Winfred Anakwa

May 5, 2009 May 5, 2009

OutlineOutline

GoalsGoals Project Description/RequirementsProject Description/Requirements

Block Diagram, Functional Description, Block Diagram, Functional Description, RequirementsRequirements

EquipmentEquipment ImplementationImplementation Progress SummaryProgress Summary ReferencesReferences

GoalsGoals

Decrease the learning curve for the use of Decrease the learning curve for the use of the dSPACE DS1103 Workstation by the dSPACE DS1103 Workstation by future students by:future students by:

Writing a Tutorial for use of the new Writing a Tutorial for use of the new DS1103 Workstation.DS1103 Workstation.

Designing a controller to control the Designing a controller to control the speed of a DC motor.speed of a DC motor.

Implementing the controller design using Implementing the controller design using the DS1103 Workstation. the DS1103 Workstation.

Suggested DS1103 UsesSuggested DS1103 Uses

Motor ControlMotor Control RoboticsRobotics AutomotiveAutomotive Magnetic Suspension SystemsMagnetic Suspension Systems

Project DescriptionProject Description

Block DiagramBlock Diagram

DS1103

Motor System

ControlDesk(Desired Speed

Input)

Load Applied to Motor Shaft

By Brake

Optical Encoder

CLP1103 Connector

Panel

Description/Description/Requirements IRequirements I

ControlDesk software:ControlDesk software: Installed on PC.Installed on PC. Downloading, Monitoring, Changing Downloading, Monitoring, Changing

(Speed) Inputs.(Speed) Inputs. Controller:Controller:

OneOne or more designs. or more designs. Simulink and RTI blocks.Simulink and RTI blocks. PWM Output.PWM Output. Optical Encoder Input.Optical Encoder Input.

Description/Description/Requirements IIRequirements II

Motor System:Motor System: PWM Signal sent through Control Panel PWM Signal sent through Control Panel

and Additional Hardware before entering and Additional Hardware before entering motor.motor.

Optical Encoder:Optical Encoder: Optical Encoder Input directly to Optical Encoder Input directly to

Incremental Encoder Input of Control Incremental Encoder Input of Control Panel.Panel.

CLP1103 LED/Connector Panel:CLP1103 LED/Connector Panel: Connect Inputs/Outputs between DS1103 Connect Inputs/Outputs between DS1103

Board and Hardware.Board and Hardware.

Controller RequirementsController Requirements

DC motor speed controller DC motor speed controller designed/simulated using designed/simulated using Simulink and Simulink and dSPACE blocksets, Matlab-to-DSP dSPACE blocksets, Matlab-to-DSP interface libraries, the Real-Time interface libraries, the Real-Time Interface to Simulink, and Real-Time Interface to Simulink, and Real-Time Workshop.Workshop.

OvershootOvershoot less than or equal to less than or equal to 5%.5%. Rise timeRise time less than or equal to less than or equal to 110 ms. 110 ms. Minimize Steady-state Error.Minimize Steady-state Error.

Equipment: WorkstationEquipment: Workstation $14,000 dSPACE DS1103 system $14,000 dSPACE DS1103 system

consisting of:consisting of: DS1103 Board.DS1103 Board. Expansion Box.Expansion Box. CLP1103 PPC Connector and LED Panel.CLP1103 PPC Connector and LED Panel. ControlDesk Version 3.2.2/Other dSPACE ControlDesk Version 3.2.2/Other dSPACE

provided Software Applications. provided Software Applications. PC dedicated to the workstation PC dedicated to the workstation

containing other software applications containing other software applications required (Matlab/Simulink Version required (Matlab/Simulink Version R2008a and libraries). R2008a and libraries).

DS1103 WorkstationDS1103 Workstation

Equipment: OtherEquipment: Other Pittman GM9236C534-R2 Pittman GM9236C534-R2

DC Motor.DC Motor. Magtrol HB-420 Brake.Magtrol HB-420 Brake. TIP120 Transistor.TIP120 Transistor. IN4004 Diode.IN4004 Diode. SN7407 Hex Inverters.SN7407 Hex Inverters. Other electronic Other electronic

components, power supplies, components, power supplies, and measurement devices.and measurement devices.

ImplementationImplementation

DS1103

Motor System

ControlDesk(Desired Speed

Input)

Load Applied to Motor Shaft

By Brake

Optical Encoder

CLP1103 Connector

Panel

Block DiagramBlock Diagram

ControlDeControlDesksk

Simulink ModelSimulink Model

Connector PanelConnector Panel

DS1103

Motor System

ControlDesk(Desired Speed

Input)

Load Applied to Motor Shaft

By Brake

Optical Encoder

CLP1103 Connector

Panel

PWM Output to MotorPWM Output to Motor Incremental Encoder InputIncremental Encoder Input

PWM Output IPWM Output I

pulses_ms_to_Hz

1000

Terminator 1

Terminator

RTI Data

RPM_to_Hz

50 .2996

RPM _in

0

Kz

.010417

K

5871 .7

Hz_to_pulses_ms

.001

Hz_to_RPM

.019881

Hz_DutyCycle

.00003

Ground

Gc

z +1.932751 z+0.9327512

z -1.39989 z+0.3998942

DS1103SL _DSP_PWM

PWM Channel 1

PWM Channel 2

PWM Channel 3

PWM Channel 4

DS1103 ENC_SETUP

ENCODERMASTER SETUP

DS1103 ENC_POS_C1

Enc position

Enc delta position

0_to_1

DutyCycle

pulses_ms_out

RPM_in pulses_ms_inHz

Hz RPM_out

Kz_out TF_outGain_outSum Duty

PWM Output

PWM Output IIPWM Output II

To MotorSystem(PWM Ch. 1)

Incremental Encoder Incremental Encoder Input IInput I

pulses_ms_to_Hz

1000

Terminator 1

Terminator

RTI Data

RPM_to_Hz

50 .2996

RPM _in

0

Kz

.010417

K

5871 .7

Hz_to_pulses_ms

.001

Hz_to_RPM

.019881

Hz_DutyCycle

.00003

Ground

Gc

z +1.932751 z+0.9327512

z -1.39989 z+0.3998942

DS1103SL_DSP_PWM

PWM Channel 1

PWM Channel 2

PWM Channel 3

PWM Channel 4

DS1103 ENC_SETUP

ENCODERMASTER SETUP

DS1103 ENC_POS_C1

Enc position

Enc delta position

0_to_1

DutyCycle

pulses_ms_out

RPM_in pulses_ms_inHz

Hz RPM_out

Kz_out TF_outGain_outSum Duty

Encoder Input

Incremental Encoder Incremental Encoder Input IIInput II

From Encoder

Motor System & BrakeMotor System & Brake

DS1103

Motor System

ControlDesk(Desired Speed

Input)

Load Applied to Motor Shaft

By Brake

Optical Encoder

CLP1103 Connector

Panel

Motor SystemMotor System

Hex Inverters (Buffer), NPN Darlington Transistor, and DiodeHex Inverters (Buffer), NPN Darlington Transistor, and Diode

-

+

Unit Step (238.57 RPM) Unit Step (238.57 RPM) InputInput

Ch 3: Motor CurrentCh 3: Motor Current Ch 4: Diode CurrentCh 4: Diode Current

Ch 1: Supply VoltageCh 1: Supply Voltage Ch 2: Voltage at Ch 2: Voltage at

CollectorCollector MATH: Motor VoltageMATH: Motor Voltage

Ch 1: PWMCh 1: PWM Ch 2: EncoderCh 2: Encoder

Motor ModelMotor Model

See “Current Motor Model” reference on Reference II slide.See “Current Motor Model” reference on Reference II slide.

Simulink Model

Transfer Function (Torque components Transfer Function (Torque components ignored):ignored):

178.1776

154.14

4699.19

78.177654.14

502852ssss

Motor Model ResponseMotor Model Response

Phase Margin = Phase Margin = 84°.84°.

ωωcc = 279 rad/s = 279 rad/s

-100

-50

0

50

Mag

nitu

de (

dB)

10-1

100

101

102

103

104

105

-180

-135

-90

-45

0

Pha

se (

deg)

Bode DiagramGm = Inf dB (at Inf rad/sec) , Pm = 84 deg (at 279 rad/sec)

Frequency (rad/sec)

ωc

BrakeBrake

Systems Stops at approximately:Systems Stops at approximately: 0.375 Nm -OR- 50 OzIn0.375 Nm -OR- 50 OzIn

Speed Input/Output ISpeed Input/Output I

DS1103

Motor System

ControlDesk(Desired Speed

Input)

Load Applied to Motor Shaft

By Brake

Optical Encoder

CLP1103 Connector

Panel

Speed Input/Output IISpeed Input/Output II

pulses_ms_to_Hz

1000

Terminator 1

Terminator

RTI Data

RPM_to_Hz

50 .2996

RPM _in

0

Kz

.010417

K

5871 .7

Hz_to_pulses_ms

.001

Hz_to_RPM

.019881

Hz_DutyCycle

.00003

Ground

Gc

z +1.932751 z+0.9327512

z -1.39989 z+0.3998942

DS1103SL_DSP_PWM

PWM Channel 1

PWM Channel 2

PWM Channel 3

PWM Channel 4

DS1103 ENC_SETUP

ENCODERMASTER SETUP

DS1103 ENC_POS_C1

Enc position

Enc delta position

0_to_1

DutyCycle

pulses_ms_out

RPM_in pulses_ms_inHz

Hz RPM_out

Kz_out TF_outGain_outSum Duty

pulses_ms_to_Hz

1000

Terminator 1

Terminator

RTI Data

RPM_to_Hz

50 .2996

RPM _in

0

Kz

.010417

K

5871 .7

Hz_to_pulses_ms

.001

Hz_to_RPM

.019881

Hz_DutyCycle

.00003

Ground

Gc

z +1.932751 z+0.9327512

z -1.39989 z+0.3998942

DS1103SL_DSP_PWM

PWM Channel 1

PWM Channel 2

PWM Channel 3

PWM Channel 4

DS1103 ENC_SETUP

ENCODERMASTER SETUP

DS1103 ENC_POS_C1

Enc position

Enc delta position

0_to_1

DutyCycle

pulses_ms_out

RPM_in pulses_ms_inHz

Hz RPM_out

Kz_out TF_outGain_outSum Duty

Controller IController I

DS1103

Motor System

ControlDesk(Desired Speed

Input)

Load Applied to Motor Shaft

By Brake

Optical Encoder

CLP1103 Connector

Panel

Controller IIController II

Controller IIIController III

Controller VController V

OvershootOvershoot less than or equal to less than or equal to 5%. 5%.

Rise timeRise time less than or equal to less than or equal to 110 110 ms. ms.

Minimize Steady-state error.Minimize Steady-state error.

Controller VIController VI Analog Controller designed and pre-warping and bilinear Analog Controller designed and pre-warping and bilinear

methods used to convert to a Digital Controller.methods used to convert to a Digital Controller. 12kHz Sampling Frequency12kHz Sampling Frequency

931.1

9976.01)482282.0(0631.72

6.857

8.28

)000040278.0(

)482282.0(0631.72

zz

zz

ss

s

931.0931.1

9976.00024.0)482282(.0631.72

2

2

zz

zz

Additional Gain adjustments have been made in MATLAB calculations and Simulink Models.

-150

-100

-50

0

50

Mag

nitu

de (

dB)

100

101

102

103

104

105

-270

-225

-180

-135

-90

Pha

se (

deg)

Bode DiagramGm = 24.2 dB (at 1.22e+003 rad/sec) , Pm = 69.5 deg (at 157 rad/sec)

Frequency (rad/sec)

MATLAB: MATLAB: Motor Model and Motor Model and

ControllerController Actual:Actual:

Phase Margin = 69.5º.Phase Margin = 69.5º. ωωcc = 157 rad/s. = 157 rad/s.

Designed for:Designed for: Phase Margin = Phase Margin =

69.01º.69.01º.

(5 % O.S.)(5 % O.S.) ωωcc = 157.08 rad/s. = 157.08 rad/s.

(20 ms Rise Time)(20 ms Rise Time)ωc

MATLAB: Step ResponseMATLAB: Step Response

Overshoot = 6%Overshoot = 6% Rise Time = 8.33 msRise Time = 8.33 ms

0 200 400 600 800 1000 1200 1400 1600 1800 20000

0.2

0.4

0.6

0.8

1

1.2

1.4

System: sysTime (sec): 165Amplitude: 1

System: sysTime (sec): 249Amplitude: 1.06

System: sysTime (sec): 125Amplitude: 0.901

System: sysTime (sec): 25Amplitude: 0.104

Step Response

Samples (sec)

Am

plitu

de

Simulink: Model ISimulink: Model I

MATLAB controller with added Gain of 7 BlockMATLAB controller with added Gain of 7 Block

Simulink: Model IISimulink: Model II

Simulink: Step ResponseSimulink: Step Response

238.57 RPM = 1 pulse_in238.57 RPM = 1 pulse_in Overshoot = 5%Overshoot = 5% Rise Time = 110 msRise Time = 110 ms

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 10

0.2

0.4

0.6

0.8

1

1.2

1.4

X: 0.2237Y: 1.05X: 0.1608

Y: 1.001

X: 0.1242Y: 0.9009

X: 0.01342Y: 0.1003

System Response ISystem Response I

Actual System: ControlDeskActual System: ControlDesk

(Possible Time Delay, Rise (Possible Time Delay, Rise Time < 108 ms)Time < 108 ms)

Simulink SimulationSimulink Simulation

(200 RPM Input, 2.14 second Step Time)(200 RPM Input, 2.14 second Step Time)

0 0.5 1 1.5 2 2.5 3 3.5 40

50

100

150

200

250

0 0.5 1 1.5 2 2.5 3 3.5 40

50

100

150

200

250

X: 2.141Y: 0

X: 2.422Y: 0

X: 3.424Y: 178.9

X: 3.636Y: 238.6

X: 2.53Y: 200

System Response IISystem Response II

Simulink/Actual SystemSimulink/Actual System

(RPM Output Only, Rise Time (RPM Output Only, Rise Time appears similar)appears similar)

Actual: Frequency-to-Voltage Converter Actual: Frequency-to-Voltage Converter

(No Visible Overshoot)(No Visible Overshoot)

0 0.5 1 1.5 2 2.5 3 3.5 40

50

100

150

200

250

Project Status: TimelineProject Status: TimelineWeek Goal Task Completed

11 January 27 Write tutorial introduction January 22

22 February 3 Verify motor parameters Not Complete

33 February 10

Simulate motor model in MATLAB February 10

Design/Simulate controller in MATLAB March 10

Design/Simulate controller in Simulink April 9

4 - 54 - 5 February 24 Make required adjustments to model and download to DS1103 March 12

66 March 3 Design/Build/Test hardware for motor subsystem February 12

77 March 10 Design/Build/Test hardware for optical encoder system February 17

8 - 108 - 10 March 31Make required adjustments to controller model to work with motor

and hardware and download to DS1103March 12

11 - 1311 - 13 April 21 Improve controller or Design/Build/Test additional controllers April 23

1414 April 28 Work on presentation/final report/tutorial In Progress

1515 May 5 Presentation May 5

1616 May 11 Final Report Due In Progress

Project StatusProject Status

A Controller has been designed and A Controller has been designed and implemented using the DS1103 Board.implemented using the DS1103 Board.

The Controller functions correctly but The Controller functions correctly but may not meet the rise time specification.may not meet the rise time specification.

The tutorial is still being put together The tutorial is still being put together but will be completed.but will be completed.

The motor/brake model was The motor/brake model was verified/developed in a previous project.verified/developed in a previous project.

References IReferences I

Guides/Manuals:Guides/Manuals: ControlDesk Experiment Guide For ControlDesk ControlDesk Experiment Guide For ControlDesk

3.23.2, Germany: dSPACE GmbH, 2008, Release 6.1., Germany: dSPACE GmbH, 2008, Release 6.1. dSPACE System First Work Steps For DS1103, dSPACE System First Work Steps For DS1103,

DS1104, DS1005, DS1006, and Micro Auto BoxDS1104, DS1005, DS1006, and Micro Auto Box, , Germany: dSPACE GmbH, 2007, Release 6.0.Germany: dSPACE GmbH, 2007, Release 6.0.

DS1103 PPC Controller Board Hardware DS1103 PPC Controller Board Hardware Installation and ConfigurationInstallation and Configuration, Germany: dSPACE , Germany: dSPACE GmbH, 2007, Release 6.0. GmbH, 2007, Release 6.0.

Real-Time Interface (RTI and RTI-MP) Real-Time Interface (RTI and RTI-MP) Implementation GuideImplementation Guide, Germany: dSPACE GmbH, , Germany: dSPACE GmbH, 2008, Release 6.1.2008, Release 6.1.

References IIReferences II

dSPACE Product Descriptions:dSPACE Product Descriptions: ““DS1103 PPC Controller Board”, Germany: DS1103 PPC Controller Board”, Germany:

dSPACE, July 2008.dSPACE, July 2008. ““Connector and LED Panels,” Connector and LED Panels,” Catalog 2008Catalog 2008, ,

Germany: dSPACE GmbH, 2008, p. 302.Germany: dSPACE GmbH, 2008, p. 302.

Current Motor Model:Current Motor Model: Sabbisetti, Amulya Sabbisetti. "Discrete Sabbisetti, Amulya Sabbisetti. "Discrete

Time Gain Scheduled Adaptive Control of Time Gain Scheduled Adaptive Control of DC Motor Speed", Masters Project Report, DC Motor Speed", Masters Project Report, Bradley University ECE Department, Bradley University ECE Department, December 2008. December 2008.

AcknowledgmentsAcknowledgments

Mr. Nick Schmidt:Mr. Nick Schmidt: Motor/Brake System ConstructionMotor/Brake System Construction

Mr. Mattus: Mr. Mattus: Initial Setup of DS1103 Workstation Initial Setup of DS1103 Workstation Construction of Slave I/O and Encoder Construction of Slave I/O and Encoder

ConnectorsConnectors

Larry Kendrick of Caterpillar: Larry Kendrick of Caterpillar: Funds for purchase of DS1103 system.Funds for purchase of DS1103 system.