1. By: Mark Bright and Mike Donaldson Advisor: Dr. Gary Dempsey

2.  Project Goal  System Applications  Thermal Plant Overview  Engine Side  Thermal Side

3. The goal of our Engine Control Workstation is to simulate thermal environments that are found in liquid-based cooling systems. With this system we created several different control methods via MATLAB and Simulink working together to control both the engine and thermal transient and steady state responses.

4. Car Application PC Application The overall goal of this project is to protect the motor with varying loads with minimum energy usage

5. Engine Side Circuitry Thermal Side Circuitry

6. Engine DSP Board Thermal DSP Board

7. Generator Thermistor Flowmeter Pump Pittman Motor Cooling Blocks

15. Thermal Comparison Pittman Motor  Tmax = 311 deg F  Thermal impedance 75.9 deg F/watt  (2.9 A)^2 * (3.91 ohm) = 36 watts  36W * (75.9 deg F/watt) = 2732 deg F

16. Engine Side Goals Engine Control:  Minimize C-code and execution time  Learn Auto-Code generation platform of Simulink/DSP interface  Design software for PWM generation and velocity calculation from rotary encoder.  Design closed-loop controllers for velocity and acceleration control.

17.  32 bit Processor  150 MHz Clock  16 A/D Channels  12 PWM Digital I/O Channels  128K on-chip Flash Memory  9 Ports Total  3.3v Supply  Interfaced to PC by serial port  Inputs and output go through level- shifter IC (5v to 3.3v / 3.3v to 5v)

18. User Interaction: Set RPM and Gain System DesignSimulink Model MATLAB GUI Code Composer Auto Code Generated C Code TI 2812 DSP Board PWM Output to Drive Motor

19.  Both encoder channels from the Pittman motor are offset from each other  Pulses are wired into the DSP board Port 8 – pins 6 and 7  2 counts can be obtained per period for each channel – 4 times as many counts  Allows for Steady State Error of ± 5 RPM  Simulink codes this as inner shaft RPM, which must be converted to outer shaft RPM – 5.9:1 gear ratio  Drag QEP Block into Simulink diagram to implement

20.  Data sent to GUI is set here  Model is used to generate Code Composer C code  P, PI, and FF Control Implemented

21.  Data sent to GUI is set here  Model is used to generate Code Composer C code  P, PI, and FF Control Implemented

22.  Data sent to GUI is set here  Model is used to generate Code Composer C code  P, PI, and FF Control Implemented

23.  Data sent to GUI is set here  Model is used to generate Code Composer C code  P, PI, and FF Control Implemented

24.  Data sent to GUI is set here  Model is used to generate Code Composer C code  P, PI, and FF Control Implemented

25.  Data sent to GUI is set here  Model is used to generate Code Composer C code  P, PI, and FF Control Implemented Desired RPM Actual RPM Controller Output PWM Duty Cycle

26.  Simulation model started where the 2008 mini project left off  Bilinear Transform converted analog controllers to digital controllers  P, PI, and FF Control Implemented

27. Gp = ______________ (s/146+1)(s/776+1) ______________ (s/146+1) (s/1460+1)17.1 FF=Gp = 17.1

28. Simulation:  596 RPM input  FF Output is 17 RPM  Impulse duration was 2mS Actual:  596 RPM input  FF Output is 17 RPM  As expected from simulation

29.  100 RPM Step Input  FF Control decreases response time by 20 mS  Less overshoot  Smaller time to first peak FF Compensation PI Control Only RPM vs Time (ms) plot

30.  Start, Type “guide” in MATLAB  GUI can be designed here with many components  Once designed, MATLAB creates an.m file and.fig file MATLAB GUI Design

31.  GUI created in MATLAB and interfaced to Simulink Model  Plots Motor RPM, PWM Duty Cycle, Transient Response, and both PI and Feed Forward Controller Output  User can input desired RPM: 0 to 834 RPM  Optimal controller gains loaded at startup, but user can control both the gain and type of control  GUI updates in real time

32. numMsgsOchan1 = r.msgcount('ochan1'); if (numMsgsOchan1) speed = r.readmsg('ochan1', 'int32'); end numMsgsOchan2 = r.msgcount('ochan2'); if (numMsgsOchan2) pid = r.readmsg('ochan2', 'int32'); end numMsgsOchan3 = r.msgcount('ochan3'); if (numMsgsOchan3) RPM = r.readmsg('ochan3', 'int32'); end numMsgsOchan4 = r.msgcount('ochan4'); if (numMsgsOchan4) PI_Out = r.readmsg('ochan4', 'int32'); end numMsgsOchan5 = r.msgcount('ochan5'); if (numMsgsOchan5) FFOut = r.readmsg('ochan5', 'int32'); end

33. if ((numMsgsOchan1 ~=0) && (numMsgsOchan2 ~= 0) && (numMsgsOchan3 ~= 0) && (numMsgsOchan4 ~= 0) && (numMsgsOchan5 ~= 0)) axes(handles.axes3); plot(handles.axes3,x_axis1, RPM); title(handles.axes3,'Measured speed of the Motor'); xlabel(handles.axes3,'t (s)'); ylabel(handles.axes3,'Speed (RPM)'); grid(handles.axes3,'on'); axis(handles.axes3,[0 5 1 850]); axes(handles.axes4); cycle = double(pid); plot(handles.axes4,x_axis1, cycle); title(handles.axes4,'Duty Cycle of the PWM Waveform'); xlabel(handles.axes4,'t (s)'); ylabel(handles.axes4,'Duty Cycle (%) '); grid(handles.axes4,'on'); axis(handles.axes4,[0 5 1 100]);

34.  Acceleration Control ◦ Adjustable Feed Forward control with different types of input commands: combos of ramps, steps, and parabolic. Load changes can simulate hills and different road conditions.  CAN Bus Interface ◦ Use the DSP board’s CAN bus to send data between the boards. This would allow for a main GUI to control both sides of the system.  Data Logging Feature ◦ Allow for a user to tune controllers and compare results. Could implement a new EE431 / 432 homework or design project around the system.  Set Control Points for Thermal and Engine Response ◦ Set desired temperature for a change in the coolant as well as a engine RPM governor based on load conditions

36. Hardware Interfacing

37.  Variable Resistance  Anti-aliasing filter

38.  Use PWM to drive Pump/Fan  Interface from digital to analog  Average Voltage seen by the device

39.  Opto-Isolator  TIP120 choice  Design for 3A Opto-Isolator

40.  LPF to ‘DC’ the PWM  Ideal Op Amp theory  Voltage @ Input = Voltage @ Pump Opto-Isolator

41. DSP/Simulink Data-Logging

42.  Conversion of A/D Value to Temperature  Excel Trendline Simulink Data-Logging

43.  Conversion of A/D Value to Temperature  Excel Trendline Simulink Data-Logging

44.  Conversion of A/D Value to Temperature  Excel Trendline Simulink Data-Logging

45.  Conversion of A/D Value to Temperature  Excel Trendline Simulink Data-Logging

46. Simulink Data-Logging cont.  Datatype conversions  Function auto-code generated

47. Simulink Data-Logging cont.  Datatype conversions  Function auto-code generated

48. Logging The Data

49. Model vs. Actual

50. Final Simulink Model

51. Thermal Model

52. Noise Addition

53. Anti-Aliasing Hardware

54. Software Conversion

55. Energy Management

56. Power Consumption

57. Heat Addition

58. Final Simulink Auto-Code Block

67. Controller Types  Bang – Bang  Improved Bang Bang  P Control  PI Control

68. Bang – Bang Control 300 Watts/ Min

69. Improved Bang-Bang Control 211 Watts / Min

70. P Control 62 Watts / Min

71. PI Control 143 Watts / Min

72. Thermal Efficiency (Degrees F/Watts) Pump PWM% Fan PWM%

73. Further Thermal Development  Supervisory Control  Further improvement by utilizing Pump and Fan cooling efficiencies  Faster PID Control  Use of more temperature sensors  Use of CAN bus

74.  Nick Schmidt ◦ Case Assembly ◦ Hardware Assembly  Dr. Dempsey ◦ Case Assembly ◦ Hardware Assembly

76. P Control – Crossover Freq  Plant Wc is at 899 rad/sec  P Control System Wc was at 164 rad/sec  Gain =.08  Phase Margin with P control: ◦ 115 Gp = __________________ (s/146+1)(s/776+1) 17.1

78.  Gp(s) =K * 1/(Tc(s)+1) * e^-(s)Td  Pump/Plant ◦ K = (-.8 degrees F / 6.4 V) ◦ Tc = 20 ◦ Td = 6  Fan/Plant ◦ K = (-9.6 degrees F / 13V) ◦ Tc = 12 ◦ Td = 15

79.  P-Pump ◦ Wc =.148 radians PM = 105 GM =22.1dB  P-Fan ◦ Wc = ? PM = undefined GM =29.4dB  PI-Pump ◦ Wc =.39 radians PM = -139 GM =16.1dB  P-Pump ◦ Wc =.0966 radians PM = -48 GM =-15.92dB

80. Reading the data  OCHAN’s allow for data to be outputted to: ◦ GUI ◦ Workspace

81. H-Bridge Servo Amplifier  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

82. Active Load

83. Conversions (A/D to Temp, PWM% to Watts

84. Energy Management

85. Heat Addition

86. Power

87. Thermal

88. Noise

89. Software Conversion

90. Opto-Isolator 4N25

91. LMC6482 Op-Amp

92. TIP 120 Power Amp

93. MC7801 12-Volt regulator

94. SN74.. Level-shifter

96. Flowmeter Graph