DC Motor Control Project Group A ALEXANDER M FUNK LAM D NGUYEN JAKEISHA D THOMPSON PAULETTE J VERNON ERIC G ZAISER 12/03/01

Introduction Motor Design Motor Construction Problems Control Design Control Problems Final Results Conclusion

Project Overview Design, construct, and control a dc homemade motor, commutation system, control system, and a speed measurement device such that the machine assembly rotates at selected speeds Create a detailed web-page to outline the development process

Specifications The outer diameter of the rotor: 1.5 and 4.5 inches. The length of the rotor housing: 2 and 6 inches. A commutator must be built. Standard magnets must be used Supply jacks must be supplied for an unknown resistance

Schedule

Motor Design Four Pole Motor Simplex Lap Winding 45 windings 26 gauge Copper Wire Steel Stator – 3.5“ inner diameter and 4” outer diameter 16 magnets(1” by ½“ by ¼“) acting as 4 poles JB Weld to place magnets Steel rotor-2” diameter 25 1/8” thick, 2.5” outer diameter discs; ” diameter holes

Motor Design 4 brushes alternating at 90° 3/8” Shaft Polyurethane lamination

DC Permanent Magnet Motor

4 Pole Simplex Lap Winding

1.5 inch inner diameter copper pipe 12 segments required for four pole operation Vinyl insulation from the shaft Brush contact 12 segments (2 x 0.78 inches ) Epoxy to fill in slots Commutator

Motor Construction Problems Uneven commutator bars Drilling through copper for hooks Commutator bars popping off Misalignment of magnets in the stator Fitting the bearings onto the shaft Sliding of shaft as motor was spinning Friction in commutator from lack of epoxy

The Final Product

Control Basic Hardware Setup Initial Research Regarding Motors Limited Theoretical Modeling “Control Theory” group shifted to “Test & Fix” Group

Control Implementation Encoder Open Loop/Bonus day PID implementation Tweaking/Tuning Competition

Control System in Simulink

Control Problems Encoder-related Mounting Cable Motor-related Friction Drift/alignment Simulink-related Disappearing feedback

Final Results Bonus Day :300 rpm 10 points Competition Day: 1 st Place Average Steady State Error of +/ RPM Transient score of.4165

Transient Response

Conclusion Motor design was outstanding Steady state control was outstanding Control system was outstanding Group A is Great!!