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May 13, 2016 - A. Najafpour, V. Ashrafian, J. TORQUE CONTROL OF A LOWER EXTREMITY EXOSKELETON ROBOT PROTOTYPE. The empirical results were compared with the results obtained from a PID. So, a robust control method should be used to regulate the braking torques. So, considering the Newton's laws, the variations in the velocity of locomotive v(t). Locomotive Company, and in particular, Eng. Fazli, for providing the test data.
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1 PID CONTROLLER DESIGN OF A SERVO SYSTEM USING PLC IMPLEMENTATION FOR CONTROL ENGINEERING EDUCATION NIK NUR SYAZLEN BINTI NIK AZMI UNIVERSITI TEKNOLOGI MALAYSIA
2 UNIVERSITI TEKNOLOGI MALAYSIA PSZ 19:16 (Pind. 1/07) DECLARATION OF THESIS / UNDERGRADUATE PROJECT REPORT AND COPYRIGHT Author s full name : NIK NUR SYAZLEN BINTI NIK AZMI Date of Birth : 2 ND NOVEMBER 1991 Title : PID CONTROLLER DESIGN OF A SERVO SYSTEM USING PLC IMPLEMENTATION FOR CONTROL ENGINEERING EDUCATION Academic Session : 2013/2014 I declare that this thesis is classified as: CONFIDENTIAL RESTRICTED OPEN ACCESS (Contains confidential information under the Official Secret Act 1972)* (Contains restricted information as specified by the organization where research was done)* I agree that my thesis to be published as online open access (full text) I acknowledged that Universiti Teknologi Malaysia reserves the right as follows: 1. The thesis is the property of Universiti Teknologi Malaysia 2. The Library of Universiti Teknologi Malaysia has the right to make copies for the purpose of research only. 3. The Library has the right to make copies of the thesis for academic exchange. Certified by: SIGNATURE NIK NUR SYAZLEN BINTI NIK AZMI ( ) SIGNATURE OF SUPERVISOR DR HERMAN BIN WAHID Date: 19 TH JUNE 2014 Date: 19 TH JUNE 2014 NOTES: * If the thesis is CONFIDENTAL or RESTRICTED, please attach with the letter from the organization with period and reasons for confidentiality or restriction.
3 I hereby declare that I have read this thesis and in my/our* opinion this thesis is sufficient in terms of scope and quality for the award of the degree of Bachelor (Instrumentation and Control) Signature :... Name of Supervisor : DR.HERMAN BIN WAHID Date : 19 TH JUNE 2014
4 PID CONTROLLER DESIGN OF A SERVO SYSTEM USING PLC IMPLEMENTATION FOR CONTROL ENGINEERING EDUCATION NIK NUR SYAZLEN BINTI NIK AZMI A thesis submitted in fulfillment of the requirements for the award of the degree of Bachelor of Engineering (Electrical - Instrumentation and Control) Faculty of Electrical Engineering Universiti Teknologi Malaysia JUNE 2014
5 ii DECLARATION I declare that this thesis entitled PID Controller Design of a Servo System Using PLC Implementation for Control Engineering Education is the result of my own project except as cited in the references. Signature :... Name of Candidate : NIK NUR SYAZLEN BINTI NIK AZMI Date : 19 TH JUNE 2014
6 iii Specially dedicated to Mama, Abah, siblings and friends for their love and sacrifice.
7 iv ACKNOWLEDGMENT Alhamdulillah praise be to Allah, the Merciful, the Benevolent for all His blessing and compassion. I was able to complete my final year project entitled PID Controller Design of a Servo System Using PLC Implementation for Control Engineering Education although I have to go through some difficulties along the way. First and foremost, I would like to express my gratitude to my supervisor Dr. Herman bin Wahid for his valuable comment, advice, utmost patience and dedication for guiding me in the completion of this project. I appreciate all his time and resources that he has provided in support of my project and education. Not to forget, my parents, sister and brothers who supported me throughout the year. Thanks for their concern, encouragement and understanding. Finally, thanks to those who have contributed directly or indirectly to the success of this project whom I have not mentioned their name specifically. Without them, this project would not successful.
8 v ABSTRACT DC motors have been widely used in electromechanical drives and automation processes due to the excellent dynamic performance. Many DC motor applications can be found such as rolling, mills, electric vehicles, passenger lifts and robotic manipulators, where a wide range of speed or position control is required. There are various control strategies available to drive the DC motor. In this project, the Proportional-Integral-Derivative (PID) controller approach will be used as the control paradigm in which the implementation will be done using the Programmable Logic Controller (PLC). A PLC is an industrial microprocessor-based control system that continuously monitors the state of input devices, makes decisions using a custom program, and controls the state of devices connected as outputs. A servo motor system that represents the industrial DC motor is used in this project. The aim of the project is to demonstrate the capability of the PLC as the main interface of the controller implementation for the purpose of control engineering education. The main focus of this project is to use a PID controller as a control algorithm which is integrated in the PLC to control the speed and position of servo motor at the desired levels. Generally, this project can be separated into four main parts which are PLC Setup, PLC Programming, PID Controller and plant to be controlled (a servo motor). OMRON SYSMAC PLC is used in this project. To operate the system, the PLC codes that are programmed by the user will be executed when the instruction is obey by the system situation and it will
9 vi send the signal output to operate some operation depending on the uploaded program.
10 vii ABSTRAK Motor DC telah digunakan secara meluas dalam pemacu elektromekanik dan proses automasi kerana prestasi dinamik yang cemerlang. Banyak aplikasi motor DC yang boleh didapati seperti mesin penggelek, kenderaan elektrik, lif penumpang, dan manipulator robot, di mana pelbagai kelajuan atau kedudukan kawalan diperlukan. Terdapat pelbagai strategi kawalan yang sedia ada untuk memandu motor DC. Dalam projek ini, pendekatan pengawal Berkadar-Pengamir-Pembeza (PID) akan digunakan sebagai paradigma kawalan di mana pelaksanaan akan dilakukan menggunakan Pengawal Logik Boleh Aturcara (PLC). PLC ialah satu sistem kawalan berasaskan mikropemproses industri yang sentiasa memantau keadaan peranti input, membuat keputusan menggunakan program yang ditetapkan oleh pengguna dan mengawal keadaan peranti yang bersambung sebagai hasil. Satu sistem motor servo yang mewakili DC motor perindustrian digunakan dalam projek ini. Tujuan projek ini adalah untuk menunjukkan keupayaan PLC sebagai peranti utama bagi perlaksanaan pengawal untuk tujuan pendidikan kejuruteraan kawalan. Fokus utama projek ini adalah untuk menggunakan pengawal PID sebagai algoritma kawalan yang bersepadu dalam PLC untuk mengawal kelajuan dan kedudukan servo motor di peringkat dikehendaki. Secara amnya, projek ini boleh dibahagikan kepada empat bahagian utama iaitu persediaan PLC, pengaturcaraan PLC, PID Pengawal dan sistem untuk dikawal (motor servo). OMRON SYSMAC PLC
11 viii digunakan dalam projek ini. Untuk mengendalikan sistem, kod PLC yang diprogramkan oleh pengguna akan dilaksanakan apabila sistem itu mengikuti arahan dan ia akan menghantar isyarat keluaran untuk mengendalikan beberapa operasi bergantung kepada program yang dimuat naik.
12 ix TABLE OF CONTENTS CHAPTER TITLE PAGE DECLARATION ii DEDICATION iii ACKNOWLEDGMENT iv ABSTRACT v ABSTRAK vii TABLE OF CONTENTS ix LIST OF FIGURES xii LIST OF TABLE xv LIST OF SYMBOLS / ABBREVIATIONS xvi LIST OF APPENDICES xvii 1 INTRODUCTION Overview of the Project Problem Statements of the Project Objectives of the Project Scopes of the Project Thesis Outline 5 2 LITERATURE REVIEW Introduction PID Controller 6
13 x Proportional Controller Proportional and Integral Controller Proportional and Derivative Controller Proportional, Integral and Derivative Controller Programmable Logic Control DC Servo Motor CE110 Servo Motor Trainer DC The Mathematical Modeling Servo Control System Actuator and Sensor Characteristic The Motor Transfer Function The Angular Speed Control The Angular Position Control CX-Programmer 22 3 METHODOLOGY Introduction PID Controller Design Mathematical Modeling of DC Servo Motor Motor Calibration Characteristic Speed Sensor Calibration Measurement of Time Constant Angular Position Transducer Calibration MATLAB Simulink Creating Simulink Diagram Programming PLC Using CX-Programmer Creating Ladder Diagram Hardware Development 36
14 xi 4 RESULTS AND DISCUSSION Introduction Servo System Modeling Motor Calibration Characteristic Speed Sensor Calibration Measurement of Time Constant Angular Position Transducer Calibration The System Transfer Function MATLAB Simulink Result Programming Result 46 5 CONCLUSION AND RECOMMENDATIONS Conclusion Problem Recommendation 52 6 PROJECT MANAGEMENT Introduction Project Schedule 53 REFERENCES 56 APPENDIX 58
15 xii LIST OF FIGURES NO. TITLE PAGE 2.1 Schematic of PID Controller Basic design of PLC CE110 Servo Trainer The servo control system with clutch engaged A servo control system The block diagram of a feedback control system The block diagram of feedback servo system The motor transfer function The block diagram of feedback control system for velocity control The block diagram of feedback control system for position control CX-Programmer software 23
16 xiii 3.1 Project methodology The connection for motor calibration The connection for speed sensor calibration The connection for time constant measurement The connection for angular position transducer calibration The new empty Simulink model Simulink Library Browser The connection between blocks The block parameter configuration PLC change configuration The new empty box on creating ladder diagram The function block that use to create ladder diagram The edit contact and edit comment configuration Overview of block diagram System set-up 37
17 xiv 4.1 Block diagram for speed control in MATLAB Simulink Output response for speed control Block diagram for cascade position control in MATLAB Simulink Output response for cascade position control Program before ON mode Program after ON mode and before upload the program to the PLC Condition PLC when program in ON mode and before upload the program to the PLC After upload the program to the PLC Condition PLC after upload the program 49
18 xv LIST OF TABLES NO. TITLE PAGE 2.1 Characteristic of, and if these value is increase Components and functions in PLC The motor calibration characteristic (Clutch Disengaged) The motor calibration characteristic (Clutch Engaged) The speed sensor calibration The angular position transducer calibration Summarize of tuning PID1 and PID Project Gantt chart for Semester One Project Gantt chart for Semester Two 55
19 xvi LIST OF SYMBOLS / ABBREVIATIONS PID - Proportional, Integral and Derivative Controller PI - Proportional and Integral Controller PD - Proportional and Derivative Controller PLC - Programmable Logic Control - Proportional gain - Integral gain - Derivative gain DC - direct current %OS percentage of overshoot settling time
20 xvii LIST OF APPENDICES NO. TITLE PAGE A The full program of the system 58
21 1 CHAPTER 1 INTRODUCTION 1.1 Overview of the Project Generally this project is about to design PID controller of a servo system by using PLC implementation for control engineering education. The focus of this project is to use a controller to control the speed and position of servo motor. Without controller, servo motor cannot operate smoothly. Thus, to control the speed and position of the servo motor to stop at the exact position and to maintain the speed, a controller could be used. There are many types of controller that can be use the control algorithm such as PID Controller, LQR Controller and State Feedback Controller. In this study, the PID Controller is used as the control approach. The other focus in this project is to setup the Programmable Logic Control (PLC) to match the setting of PC in computer which uses CX-Programmer as the programming software. CX-Programmer is software that will be used to write a program (ladder
22 2 diagram) for PLC in a computer. A program that is written in a computer should be transferred to the PLC unit before the system is run. 1.2 Problem Statements of the Project Normally in a huge and wide industry area, the speed and position control of servo motor is very difficult when it is done manually and several control strategies should be implemented, as it involves an interconnected and a multitasking system. There are many variables devices that need to be supervised and controlled continuously to make sure that the system will operate smoothly. In control engineering education, practically students are only exposed to use the servo motor system by using analogue technique, e.g. analogue PID and servo trainer is known as a simple DC motor that used by the students to run some laboratory experiments. Servo trainer is related to both position and speed control system. Basically, students are exposed to use this motor system by using analogue technique only (analogue control). The limitation using analogue technique sometimes give a difficulty to students while conduct it. Furthermore, it is not a standard control strategy in the industry, which normally uses digital control approach. So this project may assist the students in the control subject education and it can also expose student with digital implementation of the servo motor control since we use digital to analogue interface between PLC and servo trainer. A cascade control strategy
23 3 of the position control will be used in this project. For industrial, ladder diagram that will be designed could control the process efficiency and operate automatically and continuously. 1.3 Objectives of the Project There are three main objectives in this project which are: 1. To use PID controller as an algorithm in which it is integrated in the PLC. This system is just one example of the systems which is attempted to be controlled by PLC to give the overview about the capability of the PLC, hence it may also be applied to any other systems which are related to the servo system. 2. To design the PLC ladder logic diagram to be integrated with a servo system. This objective is to design the programming codes by using ladder diagram language for PLC in order to integrate it with a servo system. 3. To observe and demonstrate the capability of the PLC as a main interface of the controller. This objective is to observe while doing interface between servo and PLC, to understand how PLC and servo interact in the operations automatically.
24 4 1.4 Scope of the Project The scope of this project involves four main elements which have both software and hardware. There are: 1. Simulation of this project by using MATLAB Simulink. Simulink is a platform to model and design a system by using block diagram and transfer function of the motor. 2. Set-up the OMRON PLC and setting the PLC by using CX-Programmer software. The PLC model that will be used for this project is OMRON PLC and will be programmed by using CX-Programmer software. 3. Design and setting the configuration of the hardware. This scope configures all the hardware that are needed during the project. 4. Control and observe the speed and position of the servo. Once all software and hardware have been setup, the speed and position can be observed due to the implementation of the PID by using PLC and CX- Programmer
25 5 1.5 Thesis Outline This thesis consists of six chapters including this chapter. Chapter 1 explained the overview of the project, problem statements of the project, objectives of the project and scopes of the project. Chapter 2 contains a detailed of literature review as the main references towards the completion of this project. It includes the information about PID Controller, Programmable Logic Control (PLC), DC servo motor and CX-Programmer. Chapter 3 includes the project methodology. This will explain about the mathematical modelling of DC servo motor, PID controller design, PLC setting part, programming the PLC using CX-Programmer part and integration between PLC and hardware part. Chapter 4 discusses the result of the simulation by using MATLAB Simulink, the result for the system and also the problem that has been faced in this project. Chapter 5 discusses about the conclusion and recommendation of the project. Chapter 6 is the section in which the management of the project is summarized.
26 6 CHAPTER 2 LITERATURE REVIEW 2.1 Introduction This chapter focuses on the literature review of the components and devices in this project. The components and devices that will discuss in this chapter are: 1. PID Controller 2. Programmable Logic Control (PLC) 3. DC servo motor 4. CX-Programmer 2.2 PID Controller
27 Proportional Controller A proportional controller is a kind of linear feedback control system and widely used in first order process. The reason why proportional controller widely used because it is the simplest controller than others and it is used mainly to decrease the steady state error of the system [1]. As a proportional controller, increase, the rise time and steady-state error of the system will decrease Proportional and Integral Controller As we have known, proportional controller can decrease the steady state error, but actually the proportional gain does not completely exterminate the steady-state error. So, to exterminate the steady state error that resulting from proportional controller, proportional and integral controller could be used. Proportional and integral controller is mainly used to remove the steady state error without affecting transient response [1]. As a proportional integral controller, increase, the rise time will decrease and increases both the overshoot and the settling time Proportional and Derivative Controller A proportional and derivative is used to recover transient response and increase stability of the system. The derivative is taken from the output of the output response of
28 8 the system variable instead of the error signal in order to avoid effects of the sudden change in the value of error signal [1]. As a proportional derivative controller, increase, both the overshoot and the settling time will be decreases Proportional, Integral and Derivative Controller The term of proportional, integral and derivative mention that we design an active PD controller followed by an active PI controller. PID controller can improve both steady-state error and transient response at the same time without change the original transient response [1]. As specification, the proportional gain value ( ) will cause decreasing the rise time, but never exterminate the steady-state error. The integral gain ( ) will cause in exterminating the steady-state error, but it may make the transient response become inferior. The derivative gain value ( ) will causes in increasing the stability of the system, reducing the overshoot, and improving the transient response. So, when all of the, and are combined, the stability will be maintained [1]. Input Plant Output Feedback Figure 2.1: Schematic of PID controller
29 9 The value of will cause the changes in output response. Each of these gain value have their own characteristic. So, the table below shows the summarization of characteristic of PID gain. Table 2.1: Characteristic of Kp, Ki and Kd if these value is increase Closed Loop Response Rise Time Overshoot Settling Time Steady-State Error Decrease Increase Small Change Decrease Decrease Increase Increase Eliminate Small Change Decrease Decrease Small Change 2.3 Programmable Logic Control The first PLC was intended and developed by Modicon as a relay re-placer for General Motor and Landis. Dick Morley invented the first PLC, model 084, in 1969 and the first profitable effective PLC, the 184, was announced in 1973 which was designed by Michael Greenberg. However the Modicon brand was sold in1977 to Gould Electronics, and later acquired by German Company AEG and then by Schneider Electric, the recent vendor [2]. A PLC is an industrial microprocessor-based control system that continuously monitors the state of input devices, makes results using a custom program and controls the state of devices linked as outputs [2]. Although PLC are relatively bulky compared
30 10 to a microcontroller, they remain the most commonly-used industrial data acquisition and control devices in manufacturing and electromechanical automation [2]. Programmable controllers have been achievement admiration on the factory floor and will probably remain major for some time to come. It offers several benefits over a conventional relay type of control [2]. In addition to cost savings, PLC provides many other advantages including the consistency, more flexibility, faster response time, easier to troubleshoot and capability in communication. Figure 2.2: Basic design of PLC By referring to the programmable logic controller, PLC design as shown in Figure 2.2 above, the function of each components are [2]:
31 11 Components Input Module Output Module Central Control Unit Table 2.2: Components and functions in PLC Function Convert incoming into signal which can be processed by PLC and pass it to central control unit. Perform a reverse task of input module. It converts the PLC signal suitable for the actuators. Process the signal according to the program stored in memory. It also provides intelligence to command and given the activities of the entire PLC system. PLC Program The desired program of sequence of operation and control which is entered by programmer. 2.4 DC Servo Motor DC motors have been widely used in electromechanical drives and automation processes due to the excellent dynamic performance and a wide range of accurate speed and position control [3]. Many DC motor applications can be found in industries such as rolling mills, electric trains, electric vehicles, electric cranes, passenger lifts, large mine pit head winding gears and robotic manipulators, where a wide range of speed and position control is required. DC motors are easy to drive, fully controllable and readily available in all sizes and structures. In manipulators, to follow a predetermined speed or position track under variable load, DC motors are used [3]. In this project, a specific model of the servo system is used which will be applied in educational control engineering. Thus, CE110 servo trainer will be used as DC servo motor. The CE110 servo trainer is one of a unique range of products designed explicitly
32 12 for the study and practical enquiry into basic and advanced control engineering principles that includes the study of static and dynamic system using either analogue or digital technique CE110 Servo Motor Trainer The CE110 servo trainer apparatus relates to DC servo speed and position control system using typical industrial technique. It used as a flexible tool for the practical introduction into the design, operation and application of controllers in general. Two additional identical inertia discs which may be added to the flywheel, the CE110 is supplied [3]. Access to the flywheel to achieve the inertia variations is via an interlock hinged cover at the rear of the unit [3]. The servo motor trainer is user safety assured because it authorizes that no power to the motor is reachable should the cover be open. Figure 2.3: CE110 Servo Trainer
33 The Mathematical Modeling of Servo Motor The mathematical modelling for the DC servo motor is required in order to get the transfer function that represents the characteristics of the system. The transfer function of the DC servo motor should be determined first before designing the controller using the Simulink diagram Servo Control System In control system, we must know in mechanical term how the system behaves without control before we can conduct it. This is called as system modeling and it is an important part of our work in control systems analysis. The simple form of servo system is made of an electric motor with an output shaft that has an inertial load J on it, and friction in the bearings of the motor and load (represented by the constant b). There will be an electric drive circuit where in input voltage V(t) is transformed by the motor into a torque T(t) in the motor output shaft. A torque balance can be written between the input torque from the motor and the torque required to accelerate the load and overcome friction by using systems modelling ideas for mechanical systems. Initially consider the servo system with the clutch disengaged. In this case configuration the system is a speed control process, which can be represented as shown in Figure 2.4.
34 14 Figure 2.4: The servo control system with clutch disengaged The system model is determined by relating the torque supplied by the motor to that required driving the load generator, the flywheel and fractional losses. This can be express as, = Load Torque + Frictional Torque + Inertial Torque (1) where, Load Torque = torque which is proportional to the load control voltage, ( ) Frictional Torque = torque which is proportional to the shaft speed, Inertial Torque = determined by the flywheel inertia and the shaft acceleration Thus, = + b + I (2) where, = gain constant of load/generator b = friction coefficient of rotating components I = inertia of flywheel
35 15 The motor electrical circuit is governed by equation, V(t) = Ri + L + (3) where, V(t) = motor input voltage L = armature inductance I = armature current = motor back emf The back emf and the motor torque can be written in terms of the motor constant, thus =.(4) = I (5) Combining equations, by taking Laplace transform and eliminating variable yields the transfer function relating the output speed (s) to the input V(s) and the load voltage (s). (s) = ( )( ) V(s) - ( ) ( )( ) (s) (6) The transfer function simplifies if inductance L of the armature circuit is assumed to be small compared with the inertia of flywheel. This gives the order transfer function,
36 16 (s) = v(s) - (s) (7) where, time constant, T is given by; T = (8) = (9) = (10) Frequently, we will consider the situation when the servo control system only has an inertial load. In this case ( ) = 0 and equation simplifies to, (s) = ( ) V(s) (11) With the clutch engaged, the gearbox and output position shaft are connected to the main shaft as Figure 2.5.
37 17 Figure 2.5: A servo control system The output shaft position 0 is related to the main shaft velocity by, (s) = ( ) (12) where, the constant 30 is associated with 30:1 reduction speed through the gearbox. The addition of gearbox load also change the gain and time constant Actuator and Sensor Characteristic When servo control system is used as feedback control system the motor speed, is controlled by adjusting the applied voltage to the motor drive amplifier, V(t). the shaft speed and angular position are sensed by transducers, which produce output
38 18 voltages. (voltage from speed sensor) and proportional to the shaft velocity and shaft position respectively. (voltage from position sensor) are the shaft velocity and shaft position respectively. V(t) Drive motor amplifier Servo-control system module Gearbox Position Sensor Speed Sensor Figure 2.6: The block diagram of feedback control system If, and are the motor, speed sensor and position sensor constants respectively, then = (13) = (14) = (15) Combining equation (11), (13) and (14), the standard system transfer function is ( )= ( ) ( ) (16)
39 19 where, =, is the steady state gain of the transfer function from the input voltage V(s) and sensed shaft speed. The relation between shaft speed sensed and shaft position sensed is: ( ) = ( ) (17) where, = The overall system transfer function is the combination of the system transfer function for angular velocity and angular position as shown in figure below. Figure 2.7: The block diagram of feedback servo system The overall motor transfer function is: ( ) ( ) (18)
40 The Motor Transfer Function From Experiment The time constant and the steady state gain could be obtained from the transient and steady state responses graph relating the speed with the applied voltage as shown in Figure 2.8. Figure 2.8: The motor transfer function
41 The Angular Speed Control Figure 2.9 below shows the block diagram of a feedback control for angular velocity control. Potentiometer Servo amplifier Motor Speed Measurement Figure 2.9: The block diagram of feedback control system for velocity control The Angular Position Control control. Figure 2.10 shows the block diagram of a feedback control for angular position
42 22 Potentiometer Sum Servoamplifier Motor Gear and Screw Load Measurement Potentiometer Figure 2.10: The block diagram of feedback control system for position control 2.5 CX-Programmer CX-Programmer is a software to write the program for OMRON PLC. It provides facilities for the support of PLC devices and address information and for communication with OMRON PLC and their supported network types [4]. CX- Programmer operates on IBM compatible personal computers with Pentium or better central processors, including Pentium II. It runs in a Microsoft Windows environment (Microsoft Windows 95, 98, Millennium or 2000 and NT4.0 with Service Pack 5 or later) [4]. The software use is shown in Figure 2.4 below.
43 23 Figure 2.11: CX-Programmer software CX-Programmer software use Ladder Diagram language to communicate information to PLC. Ladder Diagram is a graphical depiction of a process with rungs of logic, similar to the relay ladder logic schemes that were replaced by PLC. Ladder diagram language is the most commonly used PLC language and is designed to mimic relay logic.
44 24 CHAPTER 3 METHODOLOGY 3.1 Introduction In this chapter, the method to do this project will be explained thoroughly. There are three main parts that need to be considered for completing this project. First step is to design PID controller by tuning the, and gains. The second part is to design a ladder logic diagram for PLC by using CX-Programmer which is integrated with the servo system. The last part of this project is to develop of hardware. Figure 3.1 shows the research methodology of this project. The first step of the project is to collect and read the journals that are related to the project title. Then, after understanding the related approach from the journal, the researcher started to identify the problem statement and scope of the project. Then, when all the problem statement, objectives and scope had been classified, understanding of the mathematical modelling part was started so that it was easy to design PID controller by using MATLAB. After the design process, programming the PLC was started, which was designing a ladder
45 25 logic diagram in order to integrate with servo system. Then, this continued with the development of the hardware which uses a servo motor as an output of the process. LITERATURE REVIEW IDENTIFYING PROBLEM STATEMENT & SCOPE OF THE PROJECT UNDERSTANDING MATHEMATHICAL MODEL DESIGNING THE PID PROGRAMMING THE PLC USING CX-PROGRAMMER HARDWARE DEVELOPMENT CONCLUSION Figure 3.1: Project methodology 3.2 PID Controller Design Mathematical Modeling of DC Servo Motor From overview of the project, I use DC motor to control speed and position of motor. The type of DC servo motor used is CE110 servo trainer. The servomotor has to be modelled first to understand the principle of how does it work. The purpose is to
46 26 obtain the relationship between speed and position of the motor and how does it responds when controller is applied to the motor Motor Calibration Characteristic The setting for the equipment is shown in Figure 3.2 Figure 3.2: The connection for motor calibration The initial setting was clutch disengaged for CE110 and potentiometer reading is 0V for the CE120. The potentiometer voltage was slowly increased by turning the potentiometer control to clockwise. The potentiometer voltage reading for this speed is
47 27 known as the Dead-Zone value. The potentiometer then was increased to 1V and the reading of the motor speed was recorded. After that, the potentiometer voltage was increased another 1V until 10V and the reading was recorded. The same steps were repeated for negative value of the potentiometer and also for clutch engaged. All the reading was recorded Speed Sensor Calibration The setting for the equipment is shown in Figure 3.3 Figure 3.3: The connection for speed sensor calibration
48 28 The initial setting was clutch disengaged for CE110 and potentiometer reading is 0V for the CE120. The potentiometer voltage then was slowly increased until the speed sensor reads 1V and the reading of the speed motor was recorded. The process was repeated until 9V. The same steps were repeated for negative value of the potentiometer voltage. All the reading was recorded Measurement of Time Constant The setting for the equipment is shown in Figure 3.4 Figure 3.4: The connection for time constant measurement
49 29 The initial setting was clutch disengaged for CE110 and for the CE120, the function generator LEVEL at zero position, and OFFSET was adjusted until the voltage reads 0V. The function generator was set to a square wave with a frequency of 0.05Hz and LEVEL at 2.5V. The potentiometer voltage output was also set to 2.5V. The output square wave signal was observed using the oscilloscope. The time constant is the 63% of final value of the output Angular Position Transducer Calibration The setting for the equipment is shown in Figure 3.5 Figure 3.5: The connection for angular position transducer calibration
50 30 The initial setting was clutch engaged for CE110 and reference position dial set to zero. The potentiometer was then slowly increased until the motor output shaft gives the specified angles. These angles are between -150 to 150 with increment 30 for each reading. The voltage reading of position sensor output for every angle was recorded MATLAB Simulink MATLAB Simulink was used to create a block diagram which will represent the DC servo control system and PID controller. It uses a graphical user interface (GUI) to interact with blocks that represent subsystems. It also can position the blocks, resize the blocks, label the blocks, specify block parameters and interconnect blocks to form complete systems from which simulations can be run Creating Simulink Diagram To create a Simulink diagram, first Simulink model icon at the top of the window was clicked and a new empty Simulink model will appeared to create new diagram of block diagram. Then, the Simulink Library Browser icon was clicked and all list of block diagram was appeared.
51 31 Figure 3.6: The new empty Simulink model Figure 3.7: Simulink Library Browser
52 32 After that, the appropriate blocks from Simulink Library Browser was chosen by click and drag the block to the new empty Simulink model. The connection between blocks is done by just click at the end of a block and drags the arrow to another block as shown in Figure 3.8. Figure 3.8: The connection between blocks The parameter of each block was set by double-clicking at the particular block and the Function Block Parameter block will appear. Then, we could adjust the parameter as desired. For example, we could set the Step Input block to 3V as shown in Figure 3.9 below.
53 33 Figure 3.9: The block parameters configuration 3.3 Programming PLC Using CX-Programmer CX-Programmer was used to create a ladder diagram and program the PLC. The ladder logic program is written offline and then downloaded to the PLC via RS 232 port (Serial Port). The program can then be monitored and debugged while the PLC is still in communication with PC.
54 Creating Ladder Diagram To create a new ladder diagram, first new icon at the top of the window was clicked and a new of configuration change PLC will appeared. Then, the device type and network type was selected based on the type of PLC used as shown in Figure Figure 3.10: PLC change configuration After that, the new empty program will appear to create new block function of ladder diagram.
55 35 Figure 3.11: The new empty box on creating ladder diagram After new empty work program was appeared, the appropriate function block was chosen by click at the above toolbox that shown in the Figure The entire of ladder diagram was created sequential to make a full program. Figure 3.12: The function block that use to create ladder diagram
56 36 The name of each block was set by double-clicking at the particular block and the Edit Contact and Edit Comment block will appear. Then, we could change and set the input and output that used at the Edit Contact and the name as desired at the Edit Comment program. For example, we could set the output to and name it as alight as shown in Figure 3.13 below. Figure 3.13: The edit contact and edit comment configuration 3.4 Hardware Development In this project, the system is set-up between PC, PLC and servo. For the testing of the system, servo and trainer are used. The system was set-up as shown in Figure 3.15.
57 37 Figure 3.14: Overview of the block diagram Upload Program Input to the drive motor Process value Figure 3.15: System set-up In this system, PLC was used to control the whole operation of the system according to the instruction given by the programmer or user. It was the main part which is given the figure of the electrical controller in that mechanical system. Without PLC, the system is just a mechanical system which is not in operation. The OMRON SYSMAC model PLC was used for this project.
58 38 CHAPTER 4 RESULTS AND DISCUSSION 4.1 Introduction This project involves hardware and software for support the operation. Mostly, the focus is given to program the PLC by using CX-Programmer. 4.2 Servo System Modeling The experiments of servo motor medeling were conducted as stated in the previous chapter. The purpose of these experiments is to get the CE110 DC Servo Motor Trainer transfer function. The result of the experiment was recorded in table form.
59 Motor Calibration Characteristic From the experiment conducted, the results are as in the Table 4.1 (Clutch Disengaged) and Table 4.2 (Clutch Engaged). Table 4.1: The motor calibration characteristic (Clutch Disengaged) Motor Drive Voltage (V) (Positive) Motor Speed (rpm) Motor Drive Voltage (V) (Negative) Motor Speed (rpm) Dead-zone = Dead-zone =
60 40 Table 4.2: The Motor Calibration Characteristic (Clutch Engaged) Motor Drive Voltage (V) (Positive) Motor Speed (rpm) Motor Drive Voltage (V) (Negative) Motor Speed (rpm) Dead-zone = Dead-zone = From Table 4.1, the motor constant, was obtained as shown below; = ( ) ( ) ( ) = rev/vsec
61 Speed Sensor Calibration From the experiment conducted, the result is as in the Table 4.3 below. Motor Speed (rpm) (Positive) Table 4.3: The speed sensor calibration Speed Sensor Input (V) Motor Speed (rpm) (Negative) Speed Sensor Input (V) From Table 4.3, the speed sensor constant, was obtained as shown below; = ( ) ( ) = 0.3 V/(rev/sec) Measurement of Time Constant Using oscilloscope, the waveform of the output was obtained. The time constant was founded around 0.55 seconds. Thus, T = 0.55seconds
62 Angular Position Transducer Calibration From the experiment conducted, the result is as in the Table 4.4 below. Table 4.4: The angular position transducer calibration Indicated Angle ( ) Position Sensor Output (V) From Table 4.3, the speed sensor constant, was obtained as shown below; = ( ) ( ) = V/
63 The System Transfer Function Since this is the speed response experiment, the motor transfer function is the relation between the input voltage and the output speed. Referring to the equation 16, the transfer function is given as; ( )= ( ) ( ) (16) = = (3.303) (0.3) = = is the steady state gain of the transfer function from the input voltage, V(s) and sensed shaft speed. Initially, the value of is equal to However, since the calibration was done using CE120 controller, there are some gain effect. Thus, the system transfer function was again calibrated for the gain adjustment using direct control to the MATLAB Software and the result is that the system gain is equal to Thus, the system transfer function is: = ( )
64 MATLAB Simulink Result Figure 4.1 shows the block diagram for speed control in MATLAB Simulink. In this section, the values of PID gains were recorded after tuning the PID block to get the best performance in the transient and steady state response. Figure 4.1: Block diagram for speed control in MATLAB Simulink After tuning was taken in several times, the best transfer response was chosen due to the minimum percentage of overshoot and settling time.
65 45 Figure 4.2: Output response for speed control Figure 4.2 shows the block diagram for cascade position control in MATLAB Simulink. In this section, same as the speed control, the values of PID gains were recorded after tuning the PID block to get the best performance in the output of the response, however for the cascade block diagram, speed control is a secondary loop and position loop act as a primary loop of the system. Figure 4.3: Block diagram for cascade position control in MATLAB Simulink
66 46 After tuning was taken in several times, the best transfer response was chosen due to the minimum percentage of overshoot and settling time. Figure 4.4: Output response for cascade position control Table 4.5: Summarize of tuning PID1 and PID2 %OS PID s PID s 4.4 Programming Result For the CX-Programmer ladder diagram, the operation state is shown by the green highlighting colour. It can provide the monitoring operation without connecting the PLC with the system hardware to observe the operation. We can easily simulate the program by using the indicator output in OMRON PLC before connecting it to the system hardware.
67 47 Based on Figure 4.5, it shows that the condition of the final program before the program in ON mode (online mode). Figure 4.5: Program before ON mode The condition of the program after ON mode and before upload the program to PLC is similar. At this stage, the program at every rung was highlighted with green colour but it is not covered all to the output at every sequent of rung. Figure 4.6 and 4.7 shows the condition of program at CX-Programmer and PLC in ON mode and before upload the program to PLC
68 48 Figure 4.6: Program after ON mode and before upload the program to PLC Figure 4.7: Condition PLC when program in ON mode and before upload the program After the program upload to the PLC, the final output shows the green colour, means that the program successfully delivered to the output. In this case, it shows that the servo motor start to operate when user give an input as shown in Figure 4.8 and 4.9.
69 49 Figure 4.8: After upload the program to PLC Figure 4.9: Condition PLC after upload the program
70 50 CHAPTER 5 CONCLUSION AND RECOMMENDATIONS 5.1 Conclusion Programmable Logic Control is the important and popular system that been applied in industry field. PLC system has a lot of benefit which can help human to control system easier and faster for the complex system. Thus, with this system control, any process can work smoothly. This PLC system has a lot of potential which can be explored to make it more sophisticated in the future. From the objectives of the project, we can see that both knowledge and skills are needed in order to complete this task. For this project, PID controller has been successful act as a algorithm which is integrated in the PLC. All PLC have their expansion unit to use PID block function in CX-Programmer. With the specification range of the value PID, we can change the value of proportional, integral and derivative depending on the desired value for the system. Besides that, by using ladder diagram language, fully programming codes for PLC has been successful written in order to
71 51 integrate it with a servo system. Based on coding in CX-Programmer, the result shows that the servo motor can operate successfully while PLC in run mode. So, both objective of the project was successfully achieved and the knowledge of using PID in PLC could be used for enhancing the learning method of control engineering education. The objectives of this project also give a lot knowledge which is involved in PLC control system. Indirectly, from this project, the students are just not learning in how to control the system, but also can learn about programming the PLC in order to running the system. The students also can get creativity skills in programming the PLC so that it will run with their own way of operation. 5.2 Problem Although the project can functional as expected based on the programming of ladder diagram, there is one problem faced during to set up the hardware. After the coding of the program was successfully completed, the servo motor cannot be directly controllled by PLC and PC. From PLC actually it need D/A converter to convert between the digital signal (i.e. in PC and PLC) to analogue signal (i.e. in servo motor). This I/O converter is not currently available at the control laboratory. This problem has only been noticed after programming part was fully completed and a new purchase for that component is necessary.
72 Recommendation For the future work, there are some recommendations that are suggested here. This project is about to design PID controller of a servo system by using PLC implementation for control engineering education. However, in this project the servo motor cannot be demonstrated in fully working condition during exhibition. Therefore, for the future work, the hardware implementation of this system can be developed completely. Besides that, this project also can be expanded with the interfacing between PLC, hardware and GUI system so that it is easy to control in central location only. Since PLC and GUI is very synonym in industrial, so undergraduate students can also learn it in details in control engineering education.
73 53 CHAPTER 6 PROJECT MANAGEMENT 6.1 Introduction Project management is an important part to achieve all project goals, in this case, the objectives of the study. Project management is divided into project planning, organizing and controlling the resources within a time interval. In this project, there are some constraints and limitations that need to be overcome, which are scopes of the project, time of the project, budget of the project and human resource to perform the project activity. 6.2 Project Schedule Gantt charts for semester one and two are shown in Table 6.1 and 6.2 respectively. From the Table 6.1, all the activity during semester one has been started
74 54 after discussing with the supervisor on the title that need to be done, then followed by doing the literature study from a number of journal papers and books to understand the contents of the project. Other than that, other tasks commenced as on the proposed dates. Table 6.1: Project Gantt chart for Semester one Activity FYP briefing session Discussion with the supervisor about the suitable topic for project Study on the background of the suggested project Search and gain information Submit proposal 2013 September October November December Prepare for presentation Presentation of FYP 1 Prepare reports Report submission
75 55 Table 6.2: Project Gantt chart for Semester two Activity Study on the PID controller 2014 February March April May June Software configuration Simulation and PLC programming Troubleshooting and improvement Final system test Presentation FYP 2 Thesis and journal writeup Thesis and journal submission to be published Table 6.2 shows the project Gantt chart for semester two. In contrast to semester one, there was an unexpected long delay in some tasks due to the long programming time. However, the final project is able to be presented as scheduled although there is an unexpected problem at the end of the hardware troubleshooting.
76 56 REFERENCES [1] N.S. Nise. Control System Engineering, John Wiley & Sons, Inc., 6 th Edition, USA, [2] Petruzella, Frank D. Programmable logic controllers. Tata McGraw-Hill Education, [3] Manual Servo Trainer CE110, Control Engineering, Sensors and Instrumentation, TecQuipment Ltd. [4] OMRON Manual, A Beginner s Guide to PLC Vol.2. (2001) [5] Control Laboratory Manual, Angular Speed Control and Angular Position Control, Faculti kejuruteraan Elektrik, Universiti Technologi Malaysia; 2003 [6] Bartelt, Terry LM. Instrumentation and process control. Thomson Delmar Learning, [7] Manyari-Rivera, Manuel, and João Carlos Basilio. Integrated online autotuning and digital implementation of PID controllers in industrial processes. Control and Automation (ICCA), th IEEE International Conference on. IEEE, [8] Kissling, S., et al. Application of iterative feedback tuning (IFT) to speed and position control of a servo drive. Control Engineering Practice 17.7 (2009): [9] Zein El Din, A. S. High performance PLC controlled stepper motor in robot manipulator. Industrial Electronics, ISIE'96., Proceedings of the IEEE International Symposium on. Vol. 2. IEEE, 1996.
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