Automated Industrial Wind Tunnel Network Control with LabVIEW. Matt Draear

Transcription

1 Automated Industrial Wind Tunnel Network Control with LabVIEW Matt Draear Advisor: Dr. Malinowski 1

2 Presentation Outline Overview of Old Hardware Overview of New Hardware Details of New Hardware FPGA LabVIEW Code Real-Time Controller LabVIEW Code Wind Tunnel Test Results 2

3 Old Hardware Overview 3

4 New National Instruments Hardware 4

5 System Diagram With New Hardware Computer Remote LabView Operator Interface Internet Router Ethernet National Instruments crio NI 9472 NI 9205 Real NI 9211 Time FPGA Cont. NI 9505 NI 9505 NI 9505 Wind Tunnel Relay Fan On/Off Relay Damper Direction Relay Damper On/Off Actuator #1 Feedback Actuator #2 Feedback Actuator #3 Feedback Wind Tunnel Air Pressure Ambient Air Pressure Drag Force Lift Force Future Thermocouple #1 Future Thermocouple #2 Actuator #1 Motor Actuator #2 Motor Actuator #3 Motor Ethernet Webcams 5

6 National Instruments crio

7 Analog Input NI

8 Thermocouple Input NI

9 Digital Output NI

10 Motor Controller NI

11 FPGA Interface 11

12 Downloading LabVIEW Code to FPGA 12

13 LabVIEW Project with FPGA / Real Time Controller / IO 13

14 FPGA Front Panel 14

15 FPGA LabVIEW Code Hardware I/O Actuator PID Control Loop Actuator Control PWM Wind Speed PID Control Loop Damper Control PWM 15

16 FPGA LabVIEW Code Hardware I/O 16

17 Hardware I/O Interface With FPGA 17

18 FPGA LabVIEW Code Actuator PID Control Loop 18

19 Actuator PID Control Loop 19

20 Linear Actuator Distance Versus Setpoint Setpoint Position Actuator Extension (mm) Time (s) 20

21 FPGA LabVIEW Code Actuator Control PWM 21

22 Actuator Control PWM Generation 22

23 FPGA LabVIEW Code Wind Speed PID Control Loop 23

24 Wind Speed PID Control Loop 24

25 Wind Speed Versus Setpoint Time (Seconds) 25 Wind Speed (Mile Per Hour)

26 FPGA LabVIEW Code Damper Control PWM 26

27 Damper Control PWM Generation 27

28 FPGA LabVIEW Code Hardware I/O Actuator PID Control Loop Actuator Control PWM Wind Speed PID Control Loop Damper Control PWM 28

29 Real Time Target LabVIEW Code 29

30 Real Time Target LabVIEW Code Startup Code Inputs From FPGA Measurement Conversions Output To FPGA Automated Test Control Graph and Data Acquisition Test Time Counter 30

31 Real Time Target LabVIEW Code Startup Code 31

32 Startup Code WindTunnelConfigSettings.CSV Enable(1)/Disable(0) Lower Limit (mm) Upper Limit (mm) Actuator # Actuator # Actuator #

33 Real Time Target LabVIEW Code Inputs From FPGA Output To FPGA 33

34 FPGA I/O Inputs From FPGA Outputs To FPGA 34

35 Real Time Target LabVIEW Code Measurement Conversions 35

36 2.5 Lift Force Sensor Voltage to Ibs 2 Lift Force Ibs y = x Sensor Output Voltage Drag Force Sensor Voltage to Ibs Drag Force Ibs 0.5 y = x Sensor Output Voltage 36

37 Ambient Air Pressure Sensor Voltage to Pa Absolute Air Pressure Pa y = x Sensor Output Voltage Wind Tunnel Air Pressure Sensor Voltage to Pa Relative Air Pressure Pa y = x Sensor Output Voltage 37

38 Measurement Conversions 38

39 Measurement Conversion Sub VIs SensorConvRT.VI WindSpeedCalcRT.VI 39

40 Real Time Target LabVIEW Code Automated Test Control 40

41 Automated Test Control 41

42 Automated Test Control 42

43 Automated Test Control 43

44 Real Time Target LabVIEW Code Graph and Data Acquisition 44

45 Graphing and Data Acquisition 45

46 WindSpeedTest.CSV Step Wind #1 Actuator #2 Actuator #3 Actuator Step Time (s) Speed Position (mm) Position (mm) Position (mm)

47 Data Acquisition Sub VIs FilePathRT.VI FileSetupRT.VI 47

48 Real Time Target LabVIEW Code Test Time Counter 48

49 Test Time Counter 49

50 Real Time Target LabVIEW Code Startup Code Inputs From FPGA Measurement Conversions Output To FPGA Automated Test Control Graph and Data Acquisition Test Time Counter 50

51 Test Results and Debugging 51

52 Plot From Test Data Recorded to Spreadsheet Time (s) Wind Speed Set Point (MPH) Wind Speed (MPH) Linear Actuator #1 Setpoint (mm) Linear Actuator #1 Position (mm) Drag Force Ibs x10 Lift Force Ibs x10 52

53 Sources [1] Ben Morrison and Mike Firman. Web Enabled Wind Tunnel System, Senior Project, Electrical and Computer Engineering Department, Bradley University, March 2010, [2] Nick Detrempe and Daniel Monahan. Automated Industrial Wind Tunnel Controller, Senior Project, Electrical and Computer Engineering Department, Bradley University, April 2012, [3] NI CompactRIO, National Instruments, [Online] 2012, 53

54 NI 9505 Wiring Diagram 54

55 NI 9472 Wiring Diagram 55

56 NI 9205 Wiring Diagram 56

57 NI 9211 Wiring Digram 57