Transcript ppt

Andy Lian (EE)
Gabriel Miranda (EE)
Andrew Perez (EE)
Chris McManus (EE)
Drew Pearson (EE)
April 25, 2011


Design motor control system for the Solar
Jackets solar racing vehicle
Continuing work from previous group
 Fall 2010

System responsibilities:
 Electric motor operation
 Central communication between vehicle
subsystems

Dynamic control of air gap motor

Functional cruise control using SBC
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Regenerative braking
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Load testing
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Communication with vehicle subsystems
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Load testing setup conducted with
motor/generator setup
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Air gap control via relay system and switch
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Cruise control

Throttle control

Communications
 RS-485
▪ MPPT
▪ Battery Management
 RS-232
▪ Motor Controller
 USB
▪ HMI
 Digital I/O
▪ Window Lift Motor
▪ Cruise Control & Air Gap
Switches
 A/D Converter
▪ 10-Turn Potentiometer

Communications
 RS-485
▪ MPPT
▪ Battery Management
 RS-232
▪ Motor Controller
 USB
▪ HMI
 Digital I/O
▪ Window Lift Motor
▪ Cruise Control & Air Gap
Switches
 A/D Converter
▪ 10-Turn Potentiometer

Communications
 RS-485
▪ MPPT
▪ Battery Management
 RS-232
▪ Motor Controller
 USB
▪ HMI
 Digital I/O
▪ Window Lift Motor
▪ Cruise Control & Air Gap
Switches
 A/D Converter
▪ 10-Turn Potentiometer

Communications
 RS-485
▪ MPPT
▪ Battery Management
 RS-232
▪ Motor Controller
 USB
▪ HMI
 Digital I/O
▪ Window Lift Motor
▪ Cruise Control & Air Gap
Switches
 A/D Converter
▪ 10-Turn Potentiometer

Communications
 RS-485
▪ MPPT
▪ Battery Management
 RS-232
▪ Motor Controller
 USB
▪ HMI
 Digital I/O
▪ Window Lift Motor
▪ Cruise Control & Air Gap
Switches
 A/D Converter
▪ 10-Turn Potentiometer

Communications
 RS-485
▪ MPPT
▪ Battery Management
 RS-232
▪ Motor Controller
 USB
▪ HMI
 Digital I/O
▪ Window Lift Motor
▪ Cruise Control & Air Gap
Switches
 A/D Converter
▪ 10-Turn Potentiometer

Ethernet
 Telnet
▪ Login
 FTP
▪ File Transfer
 Default IP Config
▪ 192.168.0.50
▪ 255.255.255.0
▪ 192.168.0.255
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motord
 Motor control daemon
 Handles state variable generation, cruise control, air
gap control, & log file generation

mcon
 Allows discrete user control of motor controller
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mmon
 Allows monitoring of state variables through terminal

capture
 Continuously captures state variable data and saves it
to specified CSV file

Features
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Runs on startup
Serial timeout and recovery
Log file generation
Cruise control
Air gap control
State variable generation as separate file accessible
by other programs
 RS-485 communication is handled separately by a
stand alone program still under development
▪ Pavel has been heading up this effort
▪ These programs communicate using the state variable file

Features
 Discrete user control
 Serial line flushing
 Verbose debug mode
▪ Directly monitor message
and response registers

Features
 Continuously monitors
state variables
 Displays on terminal
 Non-intrusive
 Simple

Features
 Continuously monitors
state variables
 Stores data in CSV file
 Easy import into Excel
 Example program call
▪ capture /var/capture.csv
Controller prevents
change from serial to
discrete or vice-versa
while coasting
 Solution:

Serial
 Keep controller in serial
mode
 Use SBC to read
controller values
Discrete
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
FIRST Robotics
Window Lift
Motor
Custom Mounting
Gear
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Currently only one speed, fast
Possibility of a slow speed
 Add extra relay to turn a resistor on/off
▪ Gives option of both a fast and a slow speed
 Add resistor to existing circuit
▪ One speed, slow
 Need to ensure torque is adequate

Actual motor operating speed to be verified
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Relay controlled

Directional
switch on control
box sends signal
to SBC
 SBC controls
relays
Air Gap Adjustment
Switch

Input 12V

Input 12V

SBC Controls

Input 12V
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SBC Controls
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On/Off Relay

Input 12V
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SBC Controls

On/Off Relay
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Forward/
Reverse Relay
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Input 12V
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SBC Controls
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On/Off Relay
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Forward/
Reverse Relay
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Output to
Motor
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10 Turn potentiometer
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In-line with air gap
screw

Measure voltage on
wiper to determine air
gap’s position
Motor-generator
setup with resistor
box
• Provided variable
loading to verify:
•
• General motor
functionality
• Cruise control
capability
• Control in throttle
mode

Motor control setup

Generator
 Added to provide load for motor
 Connected to motor via flange

Resistor Box
 Connected to generator
 Decrease resistance to increase load on motor
 Allowed simulation of drive cycles

Normal operation of motor under variable
load was successful
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Operation of cruise control under variable
load was effectively verified
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Throttle control mode was tested and
debugged

Data was gathered and various load profiles
were created
Phase Current vs Time
Phase Current (A)
6
5

4
3
2
Phase current
remains constant
1
 Proportional to
0
0
20
40
60
80
100
torque
Time (s)
Speed vs Time
120
Speed (Hz)
100

80
60
40
20
0
0
20
40
60
Time (s)
80
100
As load increases
speed decreases
Phase Current vs Time
Phase Current (A)
30
25
20

Phase current
varies

As load changes
speed remains
constant
15
10
5
0
0
20
40
60
80
100
120
140
Time (s)
Speed vs Time
120
Speed (Hz)
100
80
60
 In cruise control
40
20
0
0
20
40
60
80
Time (s)
100
120
140

Use of pot to judge closeness to air gap
extremes (ADC)

Testing of air gap adjustment system after
mounting onto gear

Communication with other subsystems

Test refurbished motor
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Mounting motor onto vehicle
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Motor functionality
 Cruise (speed) control
 Manual (throttle) control
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Cruise control
 Maintain set speed under variable load
 Disengages when braking
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Air gap adjustment via SBC
Event logging