Students: Andrew Fouts Kurtis Liggett. Advisor: Dr. Dempsey

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1 Students: Andrew Fouts Kurtis Liggett Advisor: Dr. Dempsey

2 Presentation Overview Project Summary Observer-based control Previous Work Project Goals System Block Diagram Functional Requirements Preliminary Results Engine Subsystem Thermal Subsystem Schedule & Equipment 2

3 Project Summary Engine cooling control workstation Several control methods Proportional control PI control A different advanced method Observer-based control CAN bus communication 3

4 Project Workstation 4

5 Power Electronics 5

6 Observers in Controls Overview Advantages Reduced number of sensors Increase stability Disadvantages Added complexity Computational Resources Response to plant changes George Ellis. Observers in Control Systems, Academic Press,

7 Previous Work Nick Schmidt Chris Mattus Hardware design Mike Donaldson and Mark Bright Thermal cooling redesign Dr. Dempsey Advanced software not used 7

8 Overall Project Goals Learn software packages for auto-code generation and real-time control via Simulink/DSP interface Design energy management control system in Simulink environment to regulate voltage/current to each subsystem Evaluate controller performance based on system accuracy, speed, and energy use Determine the limitations of the Simulink/DSP interface in terms of real-time execution and program memory 8

9 Engine Subsystem Goals Understand DSP/motor hardware interface Design software for PWM generation and velocity calculation from rotary encoder Design closed-loop controllers for velocity control using observer-based system Design observer-based system to acquire low noise current and velocity signal with minimal phase lag Design energy management software to limit engine power output based on Thermal DSP data via CAN bus interface and motor power calculation based on observer outputs of velocity and current Provide engine data to Thermal DSP via CAN bus 9

10 Thermal Subsystem Goals Understand DSP/cooling system hardware interface Obtain a mathematical model of the cooling system Design closed-loop controllers for temperature regulation of cooling system using observer-based system and energy management software for control of pump and fan Provide temperature data to Engine DSP via CAN bus interface 10

11 System Block Diagram Engine model/cooling system Engine PWM Velocity Current Pump/Fan PWM Sensor Temperatures Engine control (TMS320F2812 DSP board) CAN bus communication Thermal control (TMS320F2812 DSP board) Windows PC #1 Windows PC #2 Code Composer Code Composer User Input User Input 11

12 Functional Requirements Engine control system: Steady-state error = ± 5 RPM Percent overshoot 10% Rise time 30 ms Settling time 100 ms Phase margin = 45 Thermal control system: Steady-state error = ±2 Celsius Percent overshoot 25% Rise time 2 seconds Settling time 10 seconds Phase margin = 45 12

13 Preliminary Work - Engine Block diagram Pittman motor model Simulink models Control System Toolbox models ezdsp DSP Board

14 Preliminary Work - Engine Block Diagram In1 Out1 bits_in v olts 5/3.3 In1 v olts v olts internal shaf t v elocity rad/sec motor_rpm motor_rpm Input Control Laws PWM level shifter H-bridge Pittman Motor Model H To Workspace1 Unity Feedback

15 Preliminary Work - Engine Pittman Motor Model To Workspace2 current To Workspace3 torque load load 1 volts 1 La.s+Ra EE side Kt Kt 1 J.s ME side 1 internal shaft velocity B Kv Kv T_f Tf B

16 Preliminary Work - Engine Simulink System Model t Clock To Workspace cmd_rpm Error Tuned_Error pwm_signal Motor_Voltage cmd_rpm Error Tuned pwm signal Motor Voltage Input z z-1 Discrete Transfer Fcn Ki Ki bits_in PWM v olts 5/3.3 level shifter In1 v olts H-bridge volts internal shaft velocity Pittman Motor Model rad/sec H motor_rpm motor_rpm To Workspace1 Kp Kp Scope

17 Preliminary Work - Engine Control System Toolbox Must account for time delay Frequency domain design Compare Simulink model and Control System Toolbox results Design using Control System Toolbox

18 Preliminary Work - Engine Simulink Step Response Control System Toolbox Step Response 1 Velocity Plot 1 Closed-Loop Step Response Velocity (RPM) time (sec) Amplitude Time (sec)

19 Preliminary Work - Engine DSP Board PWM, Quadrature Encoder, and A/D Tutorials Mini-project implementation Proportional control PI control

20 Preliminary Work - Thermal Thermistor-temperature calculation Proportional/Proportional-integral controller (1 st iteration) System identification Proportional-integral controller (2 nd iteration) 20

21 Preliminary Work - Thermal Thermistor-temperature calculation Required linearization of thermistor vs. temperature Thermistor Chart Resistance (Ohms) Linear (Resistance (Ohms)) y = x

22 Preliminary Work - Thermal Thermistor resistance to temperature conversion C281 x A VoltsIn TempOut EngineBlock 1 VoltsPer A1 VoltsToTemp ADC A2 ADC 1 VoltsIn 3.3 RefVolts 1 u Math Function Const Const 2 1 TempOut

23 Preliminary Work - Thermal Proportional/Proportional-integral controller (1 st iteration) Kp = 50; Ki =.0001 Early problems with windup C281 x W2 SetTemperature.0001 Ki Kp z z-1 Discrete Transfer Fcn Using limit 1 Using limit PWM PWM CalcPWM 7 F2812 ezdsp (From Thermistor/ADC) EngineVolts 23

24 Preliminary Work - Thermal System identification Pump PWM from 50% to 90% Temperature change too small to measure; used small amplification circuit & recorded on scope 24

25 Preliminary Work - Thermal System identification Pump step graph example Vt Trigger 20 per. Mov. Avg. (Vt) 20 per. Mov. Avg. (Trigger)

26 Preliminary Work - Thermal System identification pump system model Created using data from pump step graphs & control theory t Clock To Workspace Post-controller Scope PWM Scope Pump Voltage Scope temperature To Workspace1 Error Scope Step Temp Error.02 Kp 5/3.3 DSP Limit PWM Limit Level Shifter 2.69 Circuit Gain Delay (.1477 /2.16 )/2.69 s s+.204 Pump /Thermistors Temperature Temp Scope Ki z z-1 Discrete Transfer Fcn Temperature 26

27 Preliminary Work - Thermal Proportional-integral controller (2 nd iteration) Kp = 0.02; Ki = Windup problem still prevalent; implemented antiwindup system PWMBeforeSat 5 0 W1 C281 x /3.3 Input Output FanPWM W2 PWM SetTemperature Kp Pump range adjust PWM U' Using limit U Level Shifter CalcPWM OutputPWM z Ki z-1 Integrator IntegratorPWM 6 Ka 50 1/z Unit Delay EngineBlock 1 F2812 ezdsp Temp 1 A/D 1 A0 C281 x 2 RadiatorInlet 3 RadiatorOutlet Temp 2 A/D 2 Temp 3 A/D 3 A/D to Temp A1 A2 ADC ADC 27

28 Spring Semester Schedule Week Thermal Control System Engine Control System 1 P/PI Control PI Control 2 P/PI Control Feed-Forward Control 3 Alt. Advanced Control Feed-Forward Control 4 Observer-based Control Observer-based Control 5 Observer-based Control Observer-based Control 6 Observer-based Control Observer-based Control 7 Energy management & power calculations Engine governor & power dissipation calculations 8 Energy management & power calculations Engine governor & power dissipation calculations 9 CAN Bus CAN Bus 10 CAN Bus CAN Bus 11 Performance Evaluations Performance Evaluations 12 Performance Evaluations Performance Evaluations 13 Final Report & Presentation Final Report & Presentation 14 Final Report & Presentation Final Report & Presentation 28

29 Equipment Pittman motors (2) Motor Heat Sinks H-bridge 30 volt, 315 watt switching power supply ezdsp F2812 TI DSP boards(2) Control and interfacing circuitry Fan Radiator Cooling block Reservoir and pump Flow meter Coolant Code Cathode Temperature Sensors (4) Tubing, clamps 29

30 Questions 30

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