MCLECTURE14

Manufacturing Controls
FALL 2001 Lecture 14
11/2/2013
(C) 2001, Ernest L. Hall, University of Cincinnati
Syllabus

DATE TOPIC 1. Sep. 20 2. Sep. 25 3. Sep. 27 4. Oct. 2 5. Oct. 4 6. Oct. 9 7. Oct. 11 8. Oct. 16 9. Oct. 18 10. Oct. 23
Mechatronics Design Process System Modeling and Simulation Laplace Transforms and Transfer Functions Electrical Examples Mechanical Examples More Examples, Thermal and Fluid Examples, QUIZ 1 (Take Home) Sensors and Transducers Digital control, Advanced MATLAB Analog and Digital Sensing Ch. 3, Notes Actuating Devices, time and frequency response
NOTES Ch. 1 Ch. 2 Ch. 2 Ch.2, Notes Ch.2, Notes Ch. 3
Ch. 4
11. Oct. 25
12. Oct. 30 13. Nov. 1 14. Nov. 6 15. Nov. 8 16. Nov. 13 17. Nov. 15 18. Nov. 20 19. Nov. 22 20. Nov. 27 21. Nov. 29 22. Dec.
DC Motor Model,
Examples
Boolean Logic ,Programmable Logic Controllers
Ch. 4, Notes Ch. 5

Ch. 5, Notes Ch. 6 Ch. 7 Ch. 8 Ch. 9, Notes Ch. 9, Notes Ch. 9, Notes Comprehensive
Stability and Compensators, P, PI and PD PID Controllers QUIZ 2 (In Class - Open Book) Practical and Optimal Compensator Design Frequency Response Methods THANKSGIVING HOLIDAY Optimal Design of a Motion Control System QUIZ 3 (In Class - Closed Book) FINAL EXAM (In Class - Closed Book)
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Todays objective
To continue the introduction to systems theory by continuing the concept of stability response for digital control for PID compensation of a feedback control for the motorized arm. Compensator examples
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Digital Motion Control System Design Example
The motion control system of the AGV helps maneuver it to negotiate curves and drive around obstacles on the course. Designing a PID controller for the drive motor feedback system of Bearcat II Robot, the autonomous unmanned vehicle was therefore considered one important step for its success.
(C) 2001, Ernest L. Hall, University of Cincinnati 4
11/2/2013
System description
The wheels of the vehicle are driven independently by two Electrocraft brush-type DC servomotors. Encoders provide position feedback for the system. The two drive motor systems are operated in current loops in parallel using Galil MSA 12-80 amplifiers. The main controller card is the Galil DMC 1030 motion control board and is controlled through a computer.
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System Modeling

The position-controlled system comprises a position servomotor with (Electrocraft Brush type DC motor) an Encoder, a PID controller (Galil DMC 1030 motion control board) and an amplifier (Galil MSA 12-80).
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The block diagram of the system is shown below.

Clock 1 Computer Computer Sum s+1 s+1 Controller Controller 1 s+1 s+1 Zero-Order Zero-OrderHold Hold 1 DAC DAC 1 Amplifier Amplifier 1 s+1 s+1 Motor Motor XY XY Graph Graph
1 1 Encoder Encoder
Symbolic Block Diagram of the position controlled servo system

Figure 18. Block diagram of the position Controlled Server System
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Motor
Kt 0.3375 1330 M s 2 2 4 Js 2.54 10 s
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Amplifier
K a 1 .2
11/2/2013 (C) 2001, Ernest L. Hall, University of Cincinnati 9
DAC
10 Kd 0.0012 8192
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10
Encoder
K f 318
ZOH
2000 H s s 2000
Homework
Using the open loop transfer function and the Matlab functions, bode and margin, to determine the phase and gain margins of the compensated system. Does it meet the design criteria?
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13
Uncompensated Bode Plot

Bode Diagrams Gm=-51.2 dB (Wcg=4.1); Pm=-2.3 deg. (Wcp=78.8) 100 50
Phase (deg); Magnitude (dB)
0 -50 -100 200 100 0 -100 -200 -300 0 10

1 2 3 4
10
10
10
10
Frequency (rad/sec)
Fig 18. Bode diagram of motor control system before compensation
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14
Visio block diagram

K K p Kd A Kd (K p Kd ) C Ki 8 K ( z A) D( z ) Cz z z 1
T ( s ) Kp Ki / s Kd s H s
Compensator
2000 s 2000
ZOH
Kd
10 0.0012 8192
DAC
K a 1.2
Amp
M s
Kt 0.3375 1330 2 Js 2 2.54 104 s
Motor and Load
+
Step function
G(s) -
2000/ (s+2000)
0.0012
1.2
1330/s2
Encoder
318
Kf
4N [counts / rad ] 2
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15
Simplified block diagram

K K p Kd A Kd (K p Kd ) C Ki 8 K ( z A) D( z ) Cz z z 1
T ( s ) Kp Ki / s Kd s H s
Compensator
Combined system transfer function
2000 s 2000
ZOH
Kd
10 0.0012 8192
DAC
K a 1.2
Amp
M s
Kt 0.3375 1330 2 Js 2 2.54 104 s
Motor and Load
+
Step function
G(s) -
3830/(s3+2000s2)
Encoder
318
Kf
4N [counts / rad ] 2
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16
Compensated open loop transfer function -GH

% Verfying the open loop transfer function numz=[0,318*2000]; denz=[1,2000]; numdac=[0.0012]; numamp=[1.2]; nummotor=[0,0,1330]; denmotor=[1,0,0]; numenc=[318]; numoloop=conv(numz,numdac); numoloop=conv(numoloop,numamp); numoloop=conv(numoloop,nummotor); denoloop=conv(denz,denmotor); sysol=tf(numoloop,denoloop); numsysol=conv(numoloop,[.25,42]); syscmp=tf(numsysol,denoloop) %Open loop transfer function syscloop=feedback(syscmp,318)
11/2/2013
17
Bode plot using margin

Bode Diagrams Gm=-401.23 dB (at 0 rad/sec), Pm=44.089 deg. (at 198.5 rad/sec)
100 50
0 -50 -100 -120
-140
-160
-180 0 10
10
10
10
10
Frequency (rad/sec)
Homework solution

PD Compensator G(s)=.25s+42 Phase margin close to design objective of 45 degrees at crossover frequency of 200 rad/sec.
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19
Another compensator example
DC motor is used to drive a robot arm horizontally.

z y
Mg
Figure 12. A single joint robot arm driven by an armature-controlled DC motor horizontally
System Analysis with Compensator

Now with the system parameters known, the open loop transfer function can be computed as follows: Num=[1217940]; Den=[1,2000,0,0]; Sys=tf(Num,Den);
3830 * 318 1217940 G (s) H (s) 2 2 s ( s 2000 ) s ( s 2000 )
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21
Absolute stability - pzmap

Form closed loop transfer function Num=[1217940]; Den=[1,2000,0,0]; EDU sys=tf(Num,Den) Transfer function: 1.218e006 -------------s^3 + 2000 s^2 sys2=feedback(sys,1) Transfer function: 1.218e006 -------------------------s^3 + 2000 s^2 + 1.218e006 pzmap(sys2)
Pole-zero map
25 20 15 10
Imag Axis
5 0 -5 -10 -15 -20 -25 -2500
-2000
-1500
-1000
-500
500
Real Axis
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22
Bode plot of open loop transfer function

Margin(sys) Has Gain margin of 0 dB tather than 10 dB Phase margin of 0 degrees rather than 40 degrees Relatively unstable system
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Bode Diagrams Gm = 0 dB, Pm = 0 (unstable closed loop)
50 0
-50 -100 -150 -180 -200 -220 -240 -260 1 10
10
10
10
Frequency (rad/sec)
23
Try a root-locus plot
C(s) R(s) + E(s) E(s) Gc(s)=K F(s) G(s)
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Closed loop transfer function
Examine pole locations, roots of the characteristic equation as K is varied from 0 to infinity If poles move into rhp there is a problem Range of K values for stability may be found
C ( s) KG ( s) R( s) 1 KG ( s)
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25
For our example
rlocus(olsys) shows poles located in rhp

2000 1500 1000 500
Imag Axis
0 -500 -1000 -1500 -2000 -2500
-2000
-1500
-1000 Real Axis
-500
500
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26
Try a compensator
Let us first try a compensator that has zeros at the origin to cancel out the poles at the origin. As a first step we will also try poles at s=-50 and s=150 to try to stabilize the closed loop system.
G s
s 50 s 150
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New OLTF - Program

% Verfying the open loop transfer function numz=[0,318*2000]; denz=[1,2000]; numdac=[0.0012]; numamp=[1.2]; nummotor=[0,0,1330]; denmotor=[1,0,0]; numenc=[318]; numoloop=conv(numz,numdac); numoloop=conv(numoloop,numamp); numoloop=conv(numoloop,nummotor); denoloop=conv(denz,denmotor); sysol=tf(numoloop,denoloop); numsysol=conv(numoloop,[.25,42]); syscmp=tf(numsysol,denoloop) %Open loop transfer function syscloop=feedback(syscmp,318) %New pole cancellation compensator numg=[1,0,0]; deng=conv([1,50],[1,150]); numcomp=conv(numsysol,numg); dencomp=conv(denoloop,deng); sysgcomp=tf(numcomp,dencomp)
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New open loop transfer function - simplified

Transfer function: 3.045e005 s + 5.116e007 ----------------------------------------s^3 + 2200 s^2 + 407500 s + 1.5e007
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Compute closed loop transfer function

Num=[3.045e005, 5.116e007]; Den=[ 1,2200,407500,1.5e007]; sys=tf(Num,Den); Sys2=feedback(sys,1)
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Closed loop transfer function of compensated system

Transfer function:
304500 s + 5.116e007 ------------------------------------s^3 + 2200 s^2 + 712000 s + 6.616e007
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Pole zero map- test for absolute stability
pzmap(Sys2)
Pole-zero map
50 40 30 20
Imag Axis
10 0 -10 -20 -30 -40 -50 -2000
-1500
-1000
-500
500
Real Axis
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Step response
A definite improvement
Step Response
From: U(1) 0.8
0.7
0.6
0.5
Amplitude
To: Y(1)
0.4
0.3
0.2
0.1
0 0 0.005 0.01 0.015 0.02 0.025 0.03
Time (sec.)
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Frequency response - Bode

margin(Sys2) Gail margin Phase margin Relatively stable
Bode Diagrams Gm = Inf, Pm = Inf

0
-20
-40
-60 0 -50 -100 -150 -200 1 10
10
10
10
Frequency (rad/sec)
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Summary

Compensator design is a multi-criteria problem Stability
Absolute stability Marginal stability Relative stability
Time response

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Rise time Overshoot Steady state error

(C) 2001, Ernest L. Hall, University of Cincinnati 35
Any questions?
11/2/2013
36

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Manufacturing Controls

FALL 2001 Lecture 14

(C) 2001, Ernest L. Hall, University of Cincinnati

NOTES Ch. 1 Ch. 2 Ch. 2 Ch.2, Notes Ch.2, Notes Ch. 3

Ch. 4, Notes Ch. 5

(C) 2001, Ernest L. Hall, University of Cincinnati

(C) 2001, Ernest L. Hall, University of Cincinnati

Digital Motion Control System Design Example

(C) 2001, Ernest L. Hall, University of Cincinnati

(C) 2001, Ernest L. Hall, University of Cincinnati

The block diagram of the system is shown below.

Symbolic Block Diagram of the position controlled servo system

(C) 2001, Ernest L. Hall, University of Cincinnati

Kt 0.3375 1330 M s 2 2 4 Js 2.54 10 s

(C) 2001, Ernest L. Hall, University of Cincinnati

(C) 2001, Ernest L. Hall, University of Cincinnati

(C) 2001, Ernest L. Hall, University of Cincinnati

Uncompensated Bode Plot

Phase (deg); Magnitude (dB)

0 -50 -100 200 100 0 -100 -200 -300 0 10

Fig 18. Bode diagram of motor control system before compensation

(C) 2001, Ernest L. Hall, University of Cincinnati

Visio block diagram

Kt 0.3375 1330 2 Js 2 2.54 104 s

Motor and Load

(C) 2001, Ernest L. Hall, University of Cincinnati

Simplified block diagram

Combined system transfer function

Kt 0.3375 1330 2 Js 2 2.54 104 s

Motor and Load

(C) 2001, Ernest L. Hall, University of Cincinnati

Compensated open loop transfer function -GH

(C) 2001, Ernest L. Hall, University of Cincinnati

Bode plot using margin

Phase (deg); Magnitude (dB)

0 -50 -100 -120

(C) 2001, Ernest L. Hall, University of Cincinnati

Another compensator example

DC motor is used to drive a robot arm horizontally.

System Analysis with Compensator

3830 * 318 1217940 G (s) H (s) 2 2 s ( s 2000 ) s ( s 2000 )

(C) 2001, Ernest L. Hall, University of Cincinnati

Absolute stability - pzmap

5 0 -5 -10 -15 -20 -25 -2500

(C) 2001, Ernest L. Hall, University of Cincinnati

Bode plot of open loop transfer function

Phase (deg); Magnitude (dB)

-50 -100 -150 -180 -200 -220 -240 -260 1 10

(C) 2001, Ernest L. Hall, University of Cincinnati

Try a root-locus plot

C(s) R(s) + E(s) E(s) Gc(s)=K F(s) G(s)

(C) 2001, Ernest L. Hall, University of Cincinnati

Closed loop transfer function

(C) 2001, Ernest L. Hall, University of Cincinnati

For our example

rlocus(olsys) shows poles located in rhp

0 -500 -1000 -1500 -2000 -2500

-1000 Real Axis

(C) 2001, Ernest L. Hall, University of Cincinnati

(C) 2001, Ernest L. Hall, University of Cincinnati

New OLTF - Program

(C) 2001, Ernest L. Hall, University of Cincinnati