1. By: Mark Bright and Mike Donaldson

2.  Project Summary  System Block Diagram  Project Goals  4 Week Progress ◦ Engine side ◦ Thermo side

3. 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.

4. Project Goals 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.

5. Project Goals 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.

7. X

8. 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

9. Recorded as Inner Shaft RPM 5.9:1 Gear Reduction is in GUI

10.  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

11. Proportional, Integral Control  PI Control was added  Integral Controller is (z/z-1)  K was tuned to.0005  Ess = ± 20RPM  All data was sent to the GUI

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

13.  100 RPM Step Input  Smaller time to first Peak (Tp) by 20 mS  Less Overshoot  Ess=0 FF Compensation PI Control Only

14.  Performed Bilinear Transformation in MATLAB of s-plane TF  Tuned Gain = 1/34.2 instead of 1/17.1 (inverse of plant)

15. 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

16.  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

20.  Anti-aliasing filter  Moving Average Filter X

21.  Conversion of ADC# to TEMP?  Excel Trendline

23.  Datatype conversions  Function auto-code generated

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

25. Use the same design for the Pump  Increase Base current  Increase voltage from 12-volt regulator (more later)  Does any PWM work ? ◦ 300mHZ !

26. 12-Volt regulator enchanced  Motivation ◦ TIP 120 Vce drop 880mv ◦ 13.5 volts max for pump/fan * Linear/Switchmode Voltage Regulator Handbook

27.  LPF to DC the PWM  Ideal Op Amp theory  Voltage @ Input = Voltage @ Pump

28.  Set PWM’s via GUI slider  Slider value sent via ICHAN’s  OCHAN monitors PWM% for data logging

30.  Nick Schmidt ◦ Case Assembly ◦ Hardware Assembly

32. Questions

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

39. P = Vce * Ie

46. Thermo GUI

47.  Start, Type “guide” in MATLAB  GUI can be designed here with many components  Once designed, MATLAB auto- generates a.m file and.fig file

48.  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

49.  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

50.  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

51. System Components Total 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 TMS320F2812 DSP Boards - (2) $ 938.00 120VAC Solenoid Valve $ 41.00 30.3V Pittman Motor - (2) $ 80.00 Misc - Wires, Tubing, Case $ 20.00