ELE 440 Fall 2010 Dr. Gao Design Assignment #3 Due Dec.

3, 2010

Overview:
You are to design and simulate a positioning control system for an industrial application. The system
consists of a digital controller, a DC motor drive (motor and power amplifier), and a load of 235 lbs that is to be
moved linearly by 12 inches in 0.3 second with an accuracy of 1% or better. A belt and pulley mechanism is used
to convert the motor ration to a linear motion. The design process involves:
1. Selection of components including: motor, power amplifier, the belt-and-pulley, the feedback devices
(position sensor and/or speed sensor)
2. Modeling of the plant
3. Control design and simulation
4. Implementation and tuning
The step 1 and 2 have been completed by Prof. Don and Jack Zeller with the results shown below. You are to
complete step 3. Hopefully, you will get a chance to do step 4 as part of your job later on. Here we address step 3.

System Parameters:
1) Electrical:
• Winding resistance and inductance: Ra=.4 om La= 8 mH (the transfer function of armature voltage to
current is (1/Ra)/((La/Ra)s+1) ;
• back emf constant:KE=1.49 v/(rad/sec),
• power amplifier gain:Kpa=80,
• current feedback gain: Kcf =.075 v/amp;
2) Mechanical:
• Torque constant: Kt=13.2 in-lb/amp;
• motor inertia Jm=.05 lb-in-sec2;
• Pulley radius Rp=1.25 in;
• load weight: W=235 lbs (including the assembly);
• total inertia Jt=Jm+Jl=.05 +(W/g)Rp2=1.0 lb-in-sec2.
With the maximum armature current set at 100 amp, the Maximum Torque = KtIa,max=13.2x100 = 1320 in-
lbs; the maximum angular acceleration = 1320/Jt=1320 rad/sec2, and the maximum linear acceleration =
1320*Rp=1650 in/sec2=4.27 g’s(1650/386). As it turned out, they are sufficient for this application.

Simulation Model:
1) Plant model: From the above discussion, the Simulink model of the plant is constructed as follows:
K cf 2

.0 7 5 to rq u e
d i stu rb a n c e

to ta l a n g u la r a n g u la r lin e a r lin e a r
a rm a tu re
a c c e la tio n v e l o c i try v e l o c i try p o si ti o n
v o lta g e to rq u e
Ia 1 1
80 2 .5 1 .0 1 .2 5 1
1 1 3 .2
s s
.0 2 s+ 1 X o ut
V [c ] P o w e r a m +p / - 1 6 0 V 1 /J t a c c to v e l Rp v e l to p o s
+ /-8 V A rm a t u re D y n a m i c s K t
c o n t ro l K pa
K e 2
si g n a l b a c k e m f e ffe c t
d X o u t/d t
1 .4 9

3
Ia

Figure 1 Plant
In Simulink, this can be defined as a single block subsystem: plant, as shown below. The
closed-loop control with a PID controller can now be simulated.
ELE 440 Fall 2010 Dr. Gao Design Assignment #3 Due Dec. 3, 2010

Xout Xout
PID V[c]

Xout
Step Position PID
dXout/dt

0 dXout/dt
torque disturbance
Ia
Constant
Plant Ia

Figure 2 Closing the loop with a PID controller

Control Design and Simulation: Part I

1) Design a PID controller so that the load is moved 12 inches in .3 second with no
overshoot;
2) Employ an industry-standard Trapezoidal Profile, defined as follows:

1
1 / 0 .3 12
s
Cl o ck
n o rm a l i z i n g I n t e g ra to r fi n a l S co p e
T ra p e zo i d ga in p o si t i o n

where the trapezoid is defined using the Simulink 1-D lookup table with the input
vector as [0 .1 .2 .3 .4] and the output vector as [0 1.5 1.5 0 0]. Repeat step 3) using
this profile. What changes do you see in motor voltage and current?
3) Introduce a small (e.g .01%) measurement noise in your simulation (white noise)
and observe if the system is still within the specs; gradually increase the level of
noise and determine the maximum level of noise this system can handle;
4) Determine how much constant torque disturbance this system can tolerate;
5) Introduce a sinusoidal torque disturbance with an amplitude equal to 10% of
maximum torque, find the highest disturbance frequency this system can handle;
6) Determine the largest tolerable transport delay in the output before the system
becomes unstable.
7) Draw the Nyquist diagram, analyze stability characteristics, and determine the gain
and phase margins of the PID loop. Discuss analytically the connection between the
phase margin and tolerable transport delay.
8) Determine how much inertia change the control system can handle before it
becomes unstable;
1
9) Now add a resonant mode, ( )2 + 2ζ s + 1 with ζ = .05 and ωn unknown, to the model
s
ωn ωn
between torque and acceleration as shown below. Determine the lowest resonant frequency the system
can handle.
ELE 440 Fall 2010 Dr. Gao Design Assignment #3 Due Dec. 3, 2010

K cf 2

.0 7 5 to rq u e angular
d i stu rb a n ce a cce l a ti o n

to ta l an gular linear l inear

a rm a tu re
ve l o ci try ve l o ci try p o si ti o n
vo l ta g e to rq u e
Ia 1 1 1
80 2 .5 1 .0 1 .2 5 1
1 1 3 .2
1 /(2 *p i*5 0 )^2 s 2
+2 *.0 5 /(2 *p i*5 0 )s+1
s s
.0 2 s+1 Xout
V [c] P o we r a m p +/-1 6 0 V 1 /Jt a cc to ve l Rp ve l to p o s
+/-8 V A rm a tu re Dyn a m ics Kt
co n tro l Kpa
Ke 2
re so n a n ce
sig n a l b a ck e m f e ffe ct
m ode d X o u t/d t
1 .4 9

Ia
ELE 440 Fall 2010 Dr. Gao Design Assignment #3 Due Dec. 3, 2010

Control Design and Simulation: Part II

Repeat Part I using the looping shaping method, compare it with the PID controller
performance benchmarked in part I; document the design process, the controller
obtained and the improvements, if any, in performance and energy consumption in
terms of percentage and put the results side by side in a table.

Control Design and Simulation: Part III (Optional, but recommended)

Repeat Part II using the Active Disturbance Rejection Control method. A motion control
example can be found at http://cact.csuohio.edu/index.php?
option=com_content&view=article&id=63&Itemid=78 under “Materials of ADRC motion control
example”. (I’m looking for a flash video showing how ADRC works for the problem in our design project).
To understand the general concept of ADRC, see http://cact.csuohio.edu/index.php?
option=com_docman&task=doc_download&gid=3&Itemid=54)

Preliminary Report:

1. Nov. 22nd: Submit a preliminary report on the frequency response analysis of your
previous PID design, including the open loop Bode and Nyquist plots, the GM and PM, and
the Bode magnitude plot of input disturbance attenuation (from the transfer from between
di and y).

2. Nov. 29th: Submit a preliminary report on the loop shaping design.

The format of preliminary report is informal.

Formal Final Report:

Write the report in the form of a technical paper, using the IEEE template. It should
include an abstract that summarizes your work; an introduction that provides the
background, motivation, and the formulation of the control problem (you may also want to
include some references here on motion control and its applications). Then comes the main
section of the paper, where you explain the modeling and model verification, the design
process, reasoning, and the solutions you obtained, using the simulation results as proof. In
the next section, discuss observations you made, unresolved problems, questions for
further investigation, etc, and summarize what you have learnt in the entire process
working on this problem during the semester. You may want to move some tedious
mathematical derivations, simulation programs, m-files, and some graphical results to an
appendix.