Final Post

The Final Year Project was a success. i would like to thank to my Advisor Sir Syamsul Adlan Bin Mahrim, and my core advisor  Sir Ismail Adam and Sir Nadaraj and also my friend, Shahnizam,  Zuhaili, Kamarul,Fazreen and to my senior. i hope this project can help others in anyway it would. The FYP demonstration is coming near. i hope everything will go well and hope the assessor go easy on me. it was a great journey in doing this project. thanks to all the reader who read this,

Video and Demostration of The Project

Make a Poster for project

Specification of the poster

•          Paper Size : A1

•          Recommended to use MS Power Point template provided

•          Print at your own cost

•          Free Design – no specific format

•          Must include the following content in poster :

1.       Objective

2.       Methodology

3.       Results

Example

• Poster for the project

Acknowledgment
-Sir Nadaraj a/l Maniappan
-Sir syamsul Adlan Bin Mahrim
-this person give alot of contribution and guiding me during my project
-Sir Raj is lecturer of Industrial Control in Electrical Department
-Sir Syamsul Adlan aka Sir Sam is lecturer in Telecomunication Department(my supervisor)

Labeling For Hardware and Software

Labeling for hardware and software

• Labeling of hardware and software in order to make it clear and easy to understand during explanation to examiner.

1. • motor
   • Signal output
   • Sensor
   • Dc motor

1. • PID
   • Set point (knob or desired value)
   • Justify waveform (PWM, SENSOR, OUTPUT, ACTUAL OUTPUT)
   • Output value (SPEED, FREQUENCY, DUTY CYCLE)

Conclusion For The System

• The objective of this project is to understand the PID controller and the tuning process for Industrial control system.  Labview Software is very powerful and one of SCADA system which can monitor and controlling the process.This project are develop the understanding in science and technology that provide a wide range scope of applications  of  high  performance  DC  motor   to drives  in  area  such  as  rolling  mills, chemical  process,  electric  trains,  robotic  manipulators  and  the  home  electric appliances require speed controllers  to perform  tasks. DC motors have speed control capabilities, which means  that  speed,  torque  and  even  direction  of  rotation  can  be changed at anytime to meet new condition.

• By design the block diagram, we can understand about the function of it controller, system plant, final control element, sensor and set point. The  goals  of  this  project  are  to  design  and  implement  speed measurement  for  the  DC  motor  using  LabView. Labview is the software that useful for engineering in industries of Malaysia.  So, this assessment practices us to be general with control system in industrial
  

• For the key finding, the PID controller in LabView used to compare the desire speed and actual speed. Then, it will send the signal to motor to make sure that it running in same speed as a desire speed.  The PID controller can be reduced the rise time since the motor start to running and follow the desire speed. It also eliminates the steady-state error by using integral controller and lastly it increase the stability of the system by using derivative control. The error is generated by disturbance that can make the speed of motor decreased because of the friction between slotted disc and optical encoder sensor. Finally, this project was successful constructed by using PID controller in LabView and to proved that this project is functioning is, the actual speed will follow the set point with having rise time, steady state error and stability.
  

• system in labview is much batter when compared with the microcontroller in DC motor controller and the disadvantages of the labiew is too expensive to have DAQ card. Therefore, only big company and industry used Labview software as their monitor and controlling process in system. For example,company like Texas Instrument(the biggest semi conductor company).

• We have some factors to be considered in our system, which is:

1)         PID cycle time

2)         Motor speed

3)         Encoder resolution

4)         PWM frequency

5)         Eliminates code tuning

6)         Maintains accurate PID timing

Analysis From Result

·         Discussion on result

             

• On the LABVIEW software, the set point of desire speed is set and controlled by the knob. The range of the speed motor that can be process in this system is in 1200-2400 RPM. Thus, this range of speed is in the operation of 0-100% duty cycle on PWM. The actual measurement speed from the sensor will runs through the set point value but it will take certain time to ensure the system error running in no steady state error. 

• The steady state error that controlled and corrected by PID algorithm is based on the operation with significant number of Kp, Ki and Kd. The manual tuning that been made for this project is Kp = 0.6, Ki = 0.05 and Kd = 0.04.  This number of gain has been set based on the manual tuning by try and error process and some calculation that have been done when the system is running.

•   The results show that the motor can run by controlling the desire speed of the setpoint. The system can running accurately from the set point speed with no steady state error after a certain seconds. By injecting the output process from the PID controller to the PWM by controlling the duty cycle of the PWM, the motor will run with desire speed based on the voltage needed that equivalent to the desire set point speed that has been calculated by PID algorithm based on the current steady state error that occurred to the system.

• However, there been a bit of non proportional measurement of 10% duty cycle with 20% duty cycle. The frequency output for 10% duty cycle is 45.94 Hz while 20% duty cycle produces 200.50 Hz. This attenuation of measurement is caused by the friction that consider as mechanical disturbance and this disturbance will produce error to the readings. It will occur to the system when the motor is running low speed because the force of rotation is low to encounter the friction force. Hence, the system will not produce an accurate output when running at low speed

Result Of The Project

 Result of the project

·         

Graph of Motor

  10% duty cycle of PWM

20% duty cycle of PWM

35% duty cycle of PWM

50% duty cycle of PWM

60% duty cycle of PWM

75% duty cycle of PWM

90% duty cycle of PWM

100% duty cycle of PWM

A Complete Design of the Labview Software

• Complete design for labview circuit

there are several formula need to be done in the labview sofware

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• Complete front panel for Labview which this front panel will be able to monitor and controlling the process of the system.

Determine Controller in closed loop System in Labview

·  PID

• The PID acts as the controller of the system. The steady state (Ess) error gives response to PID to correct the error. A PID controller calculates an "error" value as the difference between a measured process variable (actual value) and a desired set point. The controller attempts to minimize the error by adjusting the process control inputs.

• The PID controller calculation (algorithm) involves three separate constant parameters, and is accordingly sometimes called three term control: the proportional, integral and derivative values, denoted P, I, and D.

• Proportional Gain kp produces an output value that is proportional to the current error value. This kp will adjusting the time response which reducing the rise time (Tr). However, high proportional gain kp will results the system become unstable which is increasing overshoot of the system.

• Integral Gain ki produces a contribution to both the magnitude of the error and the duration of the error. The Integral Gain ki accelerates the movement of the process towards set point and eliminates the steady state error that occurs to the controller. However, it also can cause the present value to overshoot the setpoint value of the system.

• Derivative Gain kd slows the rate of change of the controller output. kd used to reduce the magnitude of the overshoot produced by the proportional and integral component and improve the combined controller-process stability. However, the derivative term slows the transient response of the controller.

• For the stability of this DC motor speed control system process, the gain of Kp, Ki and Kd is tuned by using manual tuning method. This method is first by setting set ki and kd values to zero. Increase the kp until the output of the loop oscillates, then kp should be set to approximately half of that value for a "quarter amplitude decay" type response. Then increase ki until any offset is corrected in sufficient time for the process. However, too much ki will cause instability. Finally, increase kd, if required, until the loop is acceptably quick to reach its reference after a load disturbance. However, too much kd will cause excessive response and overshoot. A fast PID loop tuning usually overshoots slightly to reach the setpoint more quickly.

• In this process control, the output of the PID controller (algorithm) gives the range of output 0-100 duty cycle for the input of the PWM

· MOTOR

• Refer to the graph above; the speed of the motor is proportional to the duty cycle. In this system, the range speed of the motor is 0-2600 RPM and the voltage supply to the motor is 0-5V depends on the duty cycle (0-100%) of the PWM.

• The Motor Voltage (Vm) that supplied to the motor from the PWM and MOSFET give variable speed to the motor depending on the variable voltage supplied.

• The desire speed that set at the setpoint input for example 2000 RPM needs at a range of 4.2V. Thus the PWM must inject at least 80% - 90% duty cycle to supply the motor input for producing 2000 RPM.

Output From Sensor(osiloscope)

Output from sensor

Result Test Sensor (RE08A kit)

No	Volt	Frequency (Hz)	RPM
1	0.5Volt	184.5Hz	1383.75
2	1.0Volt	191.9Hz	1432.5
3	1.5Volt	287.9Hz	2159.25
4	2.0Volt	557.4Hz	4180.5
5	2.5Volt	617.8Hz	4633.5
6	3.0Volt	790.5Hz	5928.75
7	3.5Volt	946.4Hz	7098
8	4.0Volt	1.154kHz	8655
9	4.5Volt	1.269kHz	9517.5
10	5.0Volt	1.446kHz	1084.5

Interfacing Between Hardware and Software

Do connection between function generator and hardware. Where the trainer will provide 5V supply to the hardware

Do a connection between function generation, hardware and DAQ.

Produce signal from sensor

Output signal from sensor which produce pulse will send to the oscilloscope when the motor start rotate

Simulate PWM Using Labview Softwere

PWM

• Pulse Width Modulation (PWM) used in this process to control the speed of the motor by varying the duty cycle of the PWM. In this system, 0% duty cycle produce 0V of output voltage which means the PWM is in fully-off state while 100% duty cycle produces 5V of output voltage which means the PWM is in fully-on state.
  

• The variable output voltage which denoted here as Controlled Voltage (Vc) is used for variable input voltage to the motor which give variable speed to the motor which depends on the input voltage.

Pulse width modulation ( Final Control Element)

• Pulse width modulation (PWM) is a technique to control the DC motor speed which is a series of digital pulses is used to control an analog circuit. The length and frequency of these pulses determines the total power delivered to the circuit.  The digital pulse train that makes up a PWM signal has a fixed frequency and varies the pulse width to alter the average power of the signal. The ratio of the pulse width to the period is referred to as the duty cycle of the signal.  Figure below is the waveform of PWM in 40% until 100% of duty cycle.

Labview program

LABVIEW SOFTWARE (one of SCADA system which can monitor and controlling)

Design a circuit and program in labview

Features need to be added on the labview software:

• SET POINT (knob which control the voltage)
• DAQ ASSIST 1(acquired and transmit signal from output sensor)
• DAQ ASSIST 2 (generate voltage from DAQ card to the hardware)
• SIMULATE SIGNAL (PWM)
• WAVEFORM SENSOR
• WAVEFORM PWM
• CALCULATION
• PID (Compare and calculating the error continuously)
• CONSTANT(create value for PWM duty cycle)
• MEAN BLOCK (get the average result in order to get precise value)
• WIRING AND CONNECTION

Installation of Hardware

Step 1

Street board has been used for installing the mosfet circuit.

 

Step 2

Mosfet circuit is attached to the prospect

Step 3

Installation of dc motor 6V and Iron 88 stainless steel is used to hold the motor.

Step 4
Wiring installation for signal output from the sensor

Step 5

Sensor RE08A included with slotted disc is connected together with motor

Step 6

Complete circuit Hardware

Interface Between The DC Motor and Sensor RE08A

• Optical encoder (Speed Sensor)

Speed sensor is used to measure the speed of the DC motor. This sensor is placed at the rotation of the shaft. The connection of this sensor is shown in Figure below.

• There are plenty of speed sensors that available at the current market. For this project, Rotary Encoder Kit RE08A has been chosen because easy to use, easy to understand. This kit is made to sense the rotation of the DC motor by generating the pulses. These pulses can be translated into the speed of the DC motor by applying a simple mathematical formula which will be added into the programming part. The pulses generated by this RE08A are shown in Figure below and the formula to calculate the speed is shown in Equation below

• Figure above shows that +5 pin is connected to the +5V source. The Gnd pin is connected to the ground. The Signal pin which gives the pulses as output is connected to the counter pin at DAQ through interrupt approach. 
  

• These pulses represent the rotation of the DC motor. We have to count these pulses in one minute to get the speed in rpm. The LabView will measure the time period of the pulse signal. Then, we use the mathematical method to find frequency. 

• Frequency is multiply with 60 because 60 is assume as a 60 second or 1 minute. Then, Divide by 8 because one full rotation has 8 blades.

• Figure below shows the interface between the DC motor and the RE08A. Slotted disc has been installed at the end of DC motor shaft. The wire from DC motor is connected to the power source. In order to control the speed, an adjustable resistor has been connected to the power source which is seeks to adjust the desired speed. The value of speed will appear at the computer screen

Interface between the DC motor and RE08A

    Installation of sensor

• 
  There are 3 terminal of sensor which is 5V, ground, and signal.5V terminal is generated by function generator in the lab and the ground of sensor is connected to the DAQ ground terminal. Signal that produce from this sensor is connected to the DAQ assist means that DAQ required signal from sensor.