Dynamometer for Testing Frequency Inverter Performance Andres Calle Otero, Alexander Sawyer, Christian Ratliff Team 1603 Sponsored by Lenze Advanced Power Electronics and Electric Drives Lab (APEDL) ECE Department and Center for Clean Energy Engineering 11/13/ /12/2015 Copyright © 2015 – Advanced Power Electronics & Electric Drives Lab (APEDL)

Outline Project Overview Solution GUI HMI/PLC Communication Deliverables Budget Schedule 2 11/12/2015 Copyright © 2015 – Advanced Power Electronics & Electric Drives Lab (APEDL)

Overview What is Lenze? What do they want? 3 11/12/2015 Copyright © 2015 – Advanced Power Electronics & Electric Drives Lab (APEDL)

Overview: Test Setup 4

Overview: Objectives 5 Primary: Secondary: Tertiary:

Overview: Desires 6

Solution: Ideal 7 HMI Visual Basic GUI with Modbus Communication Advantages Touchscreen Possibly all Lenze product No need for PLC More direct communication Use of Modbus reduces complexity Visual Basic is supported Disadvantages The use of the HMI adds complexity

Solution: Alternative 8 Computer GUI with DAQ and Analog/Digital Communication Advantages No need for Ethernet Switch Can use standard drive A/D ports Computer supports wide variety of GUI options External current sensing feasible DAQ Disadvantages More hardware is needed Less Lenze components and no HMI

Other Feasible Solutions 9 Computer GUI with PLC Control and Analog/Digital Communication Advantages No need for Ethernet Switch Can use standard drive A/D ports Computer supports wide variety of GUI options Disadvantages May need external signal conditioning components PLC needs more A/D inputs and outputs making it more costly

Other Feasible Solutions 10 Advantages Computer supports wide variety of GUI options Use of Modbus protocol throughout the design reduces design complexity Computer GUI with PLC Control and Modbus Communication Disadvantages Communication rate between the computer and drives is slower

Other Feasible Solutions 11 Advantages Computer supports wide variety of GUI options No need for PLC More direct communication Modbus reduces complexity Computer GUI with Modbus Communication Disadvantages More extensive communication programming on the computer

Other Feasible Solutions 12 Advantages Touchscreen Possibly all Lenze product Use of Modbus reduces complexity HMI GUI with PLC Control and Modbus Communication Disadvantages HMI does not support as may GUI options Communication rate between the HMI and drives is slower

GUI Programs 13 4/9/2014 Copyright © 2014 – Advanced Power Electronics & Electric Drives Lab (APEDL)

Visual Basic Pros Visual Basic 6.0 is free to download. Capable of object oriented programming. Free MODBUS toolkit. Links directly to MS Excel: beneficial for creating nice looking graphs. Can run on Windows CE. Lenze team can continue software support for free 14

Visual Basic Cons CANopen communication is not well supported. Our team does not have experience with this program. No longer supported by Microsoft 15

LabVIEW Pros Well supported by NI Free MODBUS library Our team has experience with this program. Possibility of HMI support NI DAQs are very easy to implement 16

LabVIEW Cons CANopen library cost $162 LabVIEW is no longer supported for Windows CE. Lenze team would need to purchase LabVIEW licenses to continue support of the program 17

LabVIEW GUI: Basic Tests 18

LabVIEW GUI: Basic Tests 19

LabVIEW GUI: Basic Tests 20

LabVIEW GUI: Periodic Tests 21

LabVIEW GUI: Periodic Tests 22

LabVIEW GUI: Periodic Tests 23

LabVIEW GUI: Real Time Tests 24

HMI Lenze HMIs are p500 and p300 Operating system is Windows CE Equipped for MODBUS communication Designed for PLC control. Potentially could control the drives directly from GUI program 25

PLC The PLC is a well supported control for the drives and can communicate with the Lenze HMI. Possibly redundant, and unneeded. Adds complexity, but may prove necessary if MODBUS or CAN does not work. 26

MODBUS Modbus only requires Ethernet ports Supported by free libraries. Well documented Lower communication rate. Dependent on Ethernet cable 27

CANopen Faster communication rate Requires a CANopen reader card or dongle Libraries cost money Less supported than MODBUS in most cases 28

Analog/Digital Requires the use of a data acquisition module (DAQ) Fast communication Will integrate well with additional external sensors such as per phase current sensors. Requires less software development 29

Torque Estimation 30

Deliverables 31 Minimum Deliverables Computer A/D Control of i500 and EVS 9329 Drives Torque Estimation from Drive Sampled Data Speed from Resolver Data (Servo Motor) Real Time Load Manipulation Output.csv data for external processing Target Deliverables HMI/MODBUS Control of i500 and EVS 9329 Drives Torque Estimation from Drive Sampled Data Compare Commanded Torque from Servo Speed from Resolver Data (Servo Motor) Real Time Load Manipulation User Defined Load Profile Inputs Output.csv data for external processing Embedded Figure Generation

Budget - Ideal 32 ItemCostQuantitySub-TotalVendor P500 HMITBD1 CFI Power Cable $12.252$24.50Grainger CAT 5 Cable $7.802$15.60Amazon Twist-Locks $34.002$68.00Hubbell USB Cable $4.991 Amazon Total$113.09

Budget – A/D Circuit & DAQ 33 ItemCostQuantitySub-TotalVendor NI DAQ$ NI USB Cable$4.991 Amazon Resistors Kit$7.992$15.98Mouser Op-Amps$0.7010$7.00Mouser Vector Board$6.464$25.84Mouser Wire$0.2910$2.90Mouser Total$ Total: $ % for shipping and taxes Total:$ % for shipping and taxes Will be considerably higher with HMI.

Schedule Overview 34 DateMilestone 11/5/2015Complete Research 11/8/2015Present proposal to Lenze 11/6/2015Design Proposal 11/12/2015Design Review 11/20/2015Decide design route 11/14/2015Thanksgiving break begins 11/28/2015Thanksgiving break ends 12/4/2015Gather all necessary Components 12/11/2015Complete test setup 12/20/2015Winter Break Begins Legend Completed Design Milestones UCONN submissions DateMilestone 1/19/2016Spring Semester Begins 3/1/2016Complete first draft of Design 3/10/2016Present design to Lenze 3/12/2016Midterm Design Review 4/15/2016Finish Final Design 4/25/2016Finish Paperwork 5/1/2016Project Submission

Questions? 35

References [1]F. Assurance, A. Converter, F. Assurance, D. #200421, D. sensor, B. converter, 1. CS5503-AP DIP Low-Cost, 1. #090421, 1. #200421, 5. #090421, 5. ROLLING DIGITAL MAP MEASURING READER TOOL SCALE READING TOOL TRACER CONVERTER, 5. # and L. module, 'Popular Free Measurement Converter-Buy Cheap Free Measurement Converter lots from China Free Measurement Converter suppliers on Aliexpress.com', Aliexpress.com, [Online]. Available: [Accessed: 13- Nov- 2015]. [2] Lenze.com, 'Controls - Lenze in the Americas. As easy as that.', [Online]. Available: us/products/controls/. [Accessed: 13- Nov- 2015]. [3] Msdn.microsoft.com, 'Visual Basic', [Online]. Available: [Accessed: 13- Nov- 2015]. [4] Ni.com, 'LabVIEW System Design Software - National Instruments', [Online]. Available: [Accessed: 13- Nov- 2015]. [5] Modbus.org, 'The Modbus Organization', [Online]. Available: [Accessed: 13- Nov- 2015]. [6] Canopen-solutions.com, 'CANopen – Vector's Comprehensive Tool Chain', [Online]. Available: [Accessed: 13- Nov- 2015]. [7] MESSAOUDI,, Mustapha, Habib KRAIEM,, Mouna BEN HAMED, Lassaad SBITA, and Mohamed Naceur ABDELKRIM. "A Robust Sensorless Direct Torque Control of Induction Motor Based on MRAS and Extended Kalman Filter." Leonardo Journal of Sciences 12 (2008): Web. 12 Oct