By:Mark Bright

and Mike Donaldson

Project Summary System Block Diagram Project Goals

4 Week Progress◦ Engine side◦ Thermo side

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.

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.

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.

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

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

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

Quadrature Encoder Reading

•Recorded as Inner Shaft RPM

•5.9:1 Gear Reduction is in GUI

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

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

Feed-Forward Testing

Gp = ______________ (s/146+1)(s/776+1)

______________

(s/146+1)

(s/1460+1)17.1FF=Gp =

17.1 -1

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

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)

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

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

GUI Design

GUI Design

Anti-aliasing filter

Moving Average Filter

X

Conversion of ADC# to TEMP?

Excel Trendline

Datatype conversions

Function auto-code generated

Opto-Isolator

TIP120 choice

Design for 3A

Use the same design for the Pump Increase Base current

Increase voltage from 12-volt regulator (more later)

Does any PWM work ? ◦ 300mHZ !

12-Volt regulator enchanced

Motivation◦ TIP 120 Vce drop

880mv

◦ 13.5 volts max for pump/fan

* Linear/Switchmode Voltage Regulator Handbook

LPF to DC the PWM

Ideal Op Amp theory

Voltage @ Input = Voltage @ Pump

Set PWM’s via GUI slider

Slider value sent via ICHAN’s

OCHAN monitors PWM% for data logging

Acknowledgement Nick Schmidt

◦ Case Assembly◦ Hardware Assembly

Schedule

Questions

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

P = Vce * Ie

Thermo GUI

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

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

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