Automated Industrial Wind Tunnel Network Control with LabVIEW Matt Draear Advisor: Dr. Malinowski 1
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
Old Hardware Overview 3
New National Instruments Hardware 4
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
National Instruments crio 9074 6
Analog Input NI - 9205 7
Thermocouple Input NI - 9211 8
Digital Output NI - 9472 9
Motor Controller NI - 9505 10
FPGA Interface http://www.mit.bme.hu/system/files/oktatas/targyak/7258/criodevgudfull.pdf 11
Downloading LabVIEW Code to FPGA http://www.mit.bme.hu/system/files/oktatas/targyak/7258/criodevgudfull.pdf 12
LabVIEW Project with FPGA / Real Time Controller / IO 13
FPGA Front Panel 14
FPGA LabVIEW Code Hardware I/O Actuator PID Control Loop Actuator Control PWM Wind Speed PID Control Loop Damper Control PWM 15
FPGA LabVIEW Code Hardware I/O 16
Hardware I/O Interface With FPGA 17
FPGA LabVIEW Code Actuator PID Control Loop 18
Actuator PID Control Loop 19
Linear Actuator Distance Versus Setpoint 70 60 50 40 30 Setpoint Position 20 10 0 Actuator Extension (mm) 0 0.12 0.24 0.36 0.48 0.6 0.72 0.84 0.96 1.08 1.2 1.32 1.44 1.56 1.68 1.8 1.92 2.04 2.16 Time (s) 20
FPGA LabVIEW Code Actuator Control PWM 21
Actuator Control PWM Generation 22
FPGA LabVIEW Code Wind Speed PID Control Loop 23
Wind Speed PID Control Loop 24
Wind Speed Versus Setpoint Time (Seconds) 25 Wind Speed (Mile Per Hour)
FPGA LabVIEW Code Damper Control PWM 26
Damper Control PWM Generation 27
FPGA LabVIEW Code Hardware I/O Actuator PID Control Loop Actuator Control PWM Wind Speed PID Control Loop Damper Control PWM 28
Real Time Target LabVIEW Code 29
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
Real Time Target LabVIEW Code Startup Code 31
Startup Code WindTunnelConfigSettings.CSV Enable(1)/Disable(0) Lower Limit (mm) Upper Limit (mm) Actuator #1 1 70 160 Actuator #2 1 0 199 Actuator #3 0 0 199 32
Real Time Target LabVIEW Code Inputs From FPGA Output To FPGA 33
FPGA I/O Inputs From FPGA Outputs To FPGA 34
Real Time Target LabVIEW Code Measurement Conversions 35
2.5 Lift Force Sensor Voltage to Ibs 2 Lift Force Ibs 1.5 1 y = 20.555x + 0.0314 0.5 0 0 0.02 0.04 0.06 0.08 0.1 0.12 Sensor Output Voltage Drag Force Sensor Voltage to Ibs 1.5 1 Drag Force Ibs 0.5 y = 9.2584x + 0.0033 0-0.15-0.1-0.05 0 0.05 0.1 0.15-0.5-1 -1.5 Sensor Output Voltage 36
Ambient Air Pressure Sensor Voltage to Pa 120000 Absolute Air Pressure Pa 100000 80000 60000 40000 20000 0 y = 6009.7x + 79473 0 1 2 3 4 5 6 Sensor Output Voltage Wind Tunnel Air Pressure Sensor Voltage to Pa Relative Air Pressure Pa 8000 7000 6000 5000 4000 3000 2000 1000 y = 689.48x 0 0 2 4 6 8 10 12 Sensor Output Voltage 37
Measurement Conversions 38
Measurement Conversion Sub VIs SensorConvRT.VI WindSpeedCalcRT.VI 39
Real Time Target LabVIEW Code Automated Test Control 40
Automated Test Control 41
Automated Test Control 42
Automated Test Control 43
Real Time Target LabVIEW Code Graph and Data Acquisition 44
Graphing and Data Acquisition 45
WindSpeedTest.CSV Step Wind #1 Actuator #2 Actuator #3 Actuator Step Time (s) Speed Position (mm) Position (mm) Position (mm) 0 20 50 120 90 0 1 15 50 90 90 0 2 15 50 150 90 0 3 20 70 120 90 0 4 15 70 90 90 0 5 15 70 150 90 0 6 20 60 120 90 0 7 15 60 90 90 0 8 15 60 150 90 0 9 15 80 120 90 0 10 15 90 120 90 0 46
Data Acquisition Sub VIs FilePathRT.VI FileSetupRT.VI 47
Real Time Target LabVIEW Code Test Time Counter 48
Test Time Counter 49
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
Test Results and Debugging 51
Plot From Test Data Recorded to Spreadsheet 160 140 120 100 80 60 40 20 0 Time (s) 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150-20 -40 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
Sources [1] Ben Morrison and Mike Firman. Web Enabled Wind Tunnel System, Senior Project, Electrical and Computer Engineering Department, Bradley University, March 2010, http://cegt201.bradley.edu/projects/proj2010/webwind/ [2] Nick Detrempe and Daniel Monahan. Automated Industrial Wind Tunnel Controller, Senior Project, Electrical and Computer Engineering Department, Bradley University, April 2012, http://cegt201.bradley.edu/projects/proj2012/aiwt/ [3] NI CompactRIO, National Instruments, [Online] 2012, http://www.ni.com/compactrio 53
NI 9505 Wiring Diagram 54
NI 9472 Wiring Diagram 55
NI 9205 Wiring Diagram 56
NI 9211 Wiring Digram 57