CORE TECHNOLOGIES

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core technologies

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KOLKATA 700 013
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EMAIL: support@core-technologies.com
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1. Aim of the Experiment

Study of Chopper Controlled DC Motor Drive

2. Apparatus Required
1)
2)
3)
4)

Drive Unit
0.5 HP DC Motor
C. R. O.
Connecting wires

3. Operating Panel

Operating Panel

4. Theory of Operation

Schematic Diagram

Signal Waveforms

The above diagram consists of the following blocks:

4.1 DC Bus
The 220V A.C. is full-wave rectified and filtered to make a DC bus using four 25A
diodes, a filter capacitor, an inductor and a surge filter.

4.2 Ramp-Generator
The IC 555 is used as an astable multivibrator in the free-running ramp generator
configuration by using a current mirror. The current mirror starts charging the
capacitor towards Vcc at a constant rate. When the voltage across the capacitor equals
to 2/3 Vcc, the internal comparator turns on the internal transistor and the capacitor
rapidly discharges through the transistor. However, when the discharge voltage across
the capacitor equals to 1/3 Vcc, the internal comparator switches the internal transistor
off, and then the capacitor starts charging up again. The charge-discharge cycle keeps
on repeating. The frequency of the ramp generator is set between 2 KHz to 5 KHz.

4.3 PWM Control

A DC voltage is compared using a comparator, with the ramp-generator output to

provide pulses for PWM control. The more the DC voltage, the further away the ramp
cuts from start point of the ramp, thus giving an output pulse of variable width.
Therefore, when the MOSFET is switched using this signal, the DC voltage from the
DC bus is chopped. The output from the MOSFET is further filtered to give a DC
voltage.

4.4 MOSFET firing

The PWM output from the comparator is sent through an IC 555 configured as wave
shaper. The output of the IC 555 is used to drive a high-speed opto-isolator 6N135,
thereby isolating the signal side from the DC bus. The output of the opto-isolator is
further sent through an IC 555 configured as a wave shaper, which triggers the gate of
the MOSFET with respect to its source. The DC voltage required for powering the
high voltage side of the opto-isolator and MOSFET gate comes from an isolated DC
power supply of 9V. The output from the source of the MOSFET is connected to a
high-speed diode and inductor to filter the DC output and provide a smooth DC
waveform.

4.5 PID Controller

A proportionalintegralderivative controller (PID controller) is a generic control

loop feedback mechanism widely used in industrial control systems. A PID controller
attempts to correct the error between a measured process variable and a desired
setpoint by calculating and then outputting a corrective action that can adjust the
process accordingly.
The PID controller calculation (algorithm) involves three separate parameters; the
Proportional, the Integral and Derivative values. The Proportional value determines
the reaction to the current error, the Integral determines the reaction based on the sum
of recent errors and the Derivative determines the reaction to the rate at which the
error has been changing. The weighted sum of these three actions is used to adjust the
process via a control element such as the position of a control valve or the power
supply of a heating element.
By "tuning" the three constants in the PID controller algorithm the PID can provide
control action designed for specific process requirements. The response of the

controller can be described in terms of the responsiveness of the controller to an error,

the degree to which the controller overshoots the setpoint and the degree of system
oscillation. Note that the use of the PID algorithm for control does not guarantee
optimal control of the system or system stability.
Some applications may require using only one or two modes to provide the
appropriate system control. This is achieved by setting the gain of undesired control
outputs to zero. A PID controller will be called a PI, PD, P or I controller in the
absence of the respective control actions. PI controllers are particularly common,
since derivative action is very sensitive to measurement noise, and the absence of an
integral value may prevent the system from reaching its target value due to the control
action.
Block Diagram of a PID Controller

Proportional term
The proportional term makes a change to the output that is proportional to the current
error value. The proportional response can be adjusted by multiplying the error by a
constant Kp, called the proportional gain.

Change of response for varying Kp

The proportional term is given by:

Pout = Kp e(t)
Where
Pout
Kp
e
t

: Proportional output
: Proportional Gain, a tuning parameter
: Error = SP PV
: Time or instantaneous time (the present)

A high proportional gain results in a large change in the output for a given change in
the error. If the proportional gain is too high, the system can become unstable. In
contrast, a small gain results in a small output response to a large input error, and a
less responsive (or sensitive) controller. If the proportional gain is too low, the control
action may be too small when responding to system disturbances.
In the absence of disturbances, pure proportional control will not settle at its target
value, but will retain a steady state error that is a function of the proportional gain and
the process gain. Despite the steady-state offset, both tuning theory and industrial
practice indicate that it is the proportional term that should contribute the bulk of the
output change.

Integral term
The contribution from the integral term is proportional to both the magnitude of the
error and the duration of the error. Summing the instantaneous error over time
(integrating the error) gives the accumulated offset that should have been corrected
previously. The accumulated error is then multiplied by the integral gain and added to
the controller output. The magnitude of the contribution of the integral term to the
overall control action is determined by the integral gain, Ki.

Change of response for varying Ki

The integral term is given by:

t
Iout = Ki e() d
0
Where
Iout
Ki
e

: Integral output
: Integral Gain, a tuning parameter
: Error = SP PV
: Time in the past contributing to the integral response

The integral term (when added to the proportional term) accelerates the movement of
the process towards setpoint and eliminates the residual steady-state error that occurs
with a proportional only controller. However, since the integral term is responding to
accumulated errors from the past, it can cause the present value to overshoot the
setpoint value (cross over the setpoint and then create a deviation in the other
direction).

Derivative term
The rate of change of the process error is calculated by determining the slope of the
error over time (i.e. its first derivative with respect to time) and multiplying this rate
of change by the derivative gain Kd. The magnitude of the contribution of the
derivative term to the overall control action is termed the derivative gain, Kd.

Change of response for varying Kd

The derivative term is given by:

Dout = Kd de/dt

Where
Dout
Kd
e
t

: Derivative output
: Derivative Gain, a tuning parameter
: Error = SP PV
: Time or instantaneous time (the present)

The derivative term slows the rate of change of the controller output and this effect is
most noticeable close to the controller set point. Hence, derivative control is used to
reduce the magnitude of the overshoot produced by the integral component and
improve the combined controller-process stability. However, differentiation of a signal
amplifies noise and thus this term in the controller is highly sensitive to noise in the
error term, and can cause a process to become unstable if the noise and the derivative
gain are sufficiently large.

The output from the three terms, the proportional, the integral and the derivative terms
are summed to calculate the output of the PID controller. Defining u(t) as the
controller output, the final form of the PID algorithm is:

t
u(t) = MV(t) = Kp(t) + Ki e() d + Kd de/dt
0
and the tuning parameters are
Kp: Proportional Gain
Larger Kp typically means faster response since the larger the error, the larger the
Proportional term compensation. An excessively large proportional gain will lead to
process instability and oscillation.
Ki: Integral Gain
Larger Ki implies steady state errors are eliminated quicker. The trade-off is larger
overshoot: any negative error integrated during transient response must be integrated
away by positive error before we reach steady state.
Kd: Derivative Gain
Larger Kd decreases overshoot, but slows down transient response and may lead to
instability due to signal noise amplification in the differentiation of the error.

4.6 Speed Measurement

The shaft of the motor is connected an optical encoder. The encoder has a circular
plastic disc having 100 alternate black and transparent stripes. The disc is passed
through an opto-interrupter MOC7811. Pulses are generated when the disc turns with
100 pulses per revolution.
The pulses from the sensor are shaped using an op-amp configures as a comparator.
The pulses are fed into a microprocessor-based display for indication of the speed in
RPM.
MOC7811 has four connections, i.e. D+ & D- for Detector and E+ & E- for emitter.
The connections from the motor setup to the drive unit should be made one to one. On
rotation of the motor, if the tachometer fails to display the speed, the connections
should be checked. In case of sensor failure, do not run the drive unit in closed loop.

4.7 Load Setup

The load setup for the motor is a flat pulley and friction belt braking system. A
friction belt goes around a flat pulley with a spring balance on one side and a nut-bolt
arrangement on the other. On tightening the nut the friction between the rope and
pulley increases to create a larger load on the motor.

4.8 DC Motor Field

The field coil of the DC motor is supplied with 220V DC rectified from the main
supply. The current in the field coil is sensed and is used to switch on a relay. The
indication FIELD OK displays the status. On field failure the relay is cut off and
disconnects the armature supply.

5. Operation of Motor Controller

5.1 Introduction
The Digital Motor Controller is a PID Controller with some additional features
required to operate DC/AC1/AC3 motors. The control unit consists of a
four-digital digital display unit for displaying various parameters, some
indicating LEDs and some buttons for setting of parameters and running of
the motor.
The motor speed is sensed using an optical encoder. The speed, set point, error
and control parameters are displayed on the digital display panel one by one
by selecting the viewing parameter using the SET button. The parameters may
be changed and save by using the edit buttons.
The motor controller provides the facility to run the motor in open or closed
loop. Different faults are indicated on the display unit.
The controller also incorporates safety features like soft-start and open/closed
loop transfer through zero speed.

5.2 Speed Measurement

The motor speed is sensed using an optical encoder that generates 100 pulses
per revolution. These pulses are counted and the frequency in Hz is calculated
every 100 msec. The PID algorithm is executed and the output is used to drive
the signal section of the specific drive.

5.3 Open Loop Operation

In the open loop operation, the output to the drive section may be varied from
0 to 100%. No feedback or control action is taken. The output and the speed or
process variable may be displayed using the SET button.

5.4 Closed Loop Control

In the closed loop, the output to the drive section is controlled using a PID
algorithm. The PID section describes in detail the operation and functioning of
the PID algorithm. The PID parameters may be changed while the motor is
running. The set point may be varied between 0.0 to 50Hz. The various
parameters like set point, process variable (speed), error, proportional gain,
integral gain, derivative gain and output are displayed on the digital display.
The parameter required to be observed/modified may be selected using the
SET button.

5.5 Operation
5.5.1 Operating Panel
The front fascia consists of 4 7-segment displays, 14 LEDs and 8 switches.
The 7-segment display indicates the various parameters. The LEDs indicate
the mode of operation, motor status and the parameter being viewed. The
switches are used to set different parameters and switch between different
modes.

5.5.2 Operating Panel Layout

5.5.3 Description of Switches

REMOTE/LOCAL Remote / Local Switch
Select between Remote and Local modes of operation. Change over only
possible when the motor is stopped.
OPEN/CLOSED Open / Closed Loop switch
Select between Open Loop and Closed Loop modes of operation. Change over
only possible when the motor is stopped.
RUN Motor Run switch
Used to run the motor.
STOP Motor Stop switch
Used to stop the motor.
SET Select / Exit switch
In normal mode, it is used to select the display mode. In editing mode, it is
used to quit without saving the parameter.
INC Increment switch
Used to increase the value of the parameter to be edited.
DEC Decrement switch
Used to decrease the value of the parameter to be edited.
ENT Enter switch
Used to save the parameter that is being edited.

5.5.4 Description of LEDs

RE Remote Mode Indicator
LO Local Mode Indicator
OP Open Loop Mode Indicator
CL Closed Loop Mode Indicator
RUN Run Operation Indicator
STOP Stop Operation Indicator
SP Set Point Indicator
PV Process Value Indicator

ER Error Value Indicator

KP Kp Value Indicator
KI Ki Value Indicator
KD Kd Value Indicator
OU Output Value Indicator
FA Fault Indicator

5.5.5 Open-Loop Operation

When the unit is powered on, it is in the Open Loop mode by default. The
motor is stopped and the set point = 0.0
Press SEL to toggle between PV and OUT displays.
Press O/C to toggle between Open Loop and Closed Loop modes.
In the open loop mode, only the output can be set. The value of output can be
from 0.0 ~ 100.0%. Please note that the motor may not rotate below a certain
minimum output. The output may be set by pressing the INC or DEC buttons
and confirmed by pressing ENT. If the motor is on, the output value is
instantaneously transferred to the soft-start algorithm so that it is slowly
reflected on the output. The output value is not saved on power off.

5.5.6 Closed-Loop Operation

Press O/C to toggle between Open Loop and Closed Loop modes.
Press SEL to display the various parameters in the following sequence.

K P E
K KVS O
D
R
I P P U
R
T
In the closed loop mode, the following parameters may be set.
PARAMETER

RANGE

SP Set Point
KP Proportional Gain
KI Integral Gain
KD Derivative Gain

0.0 ~ 50.0 Hz
0.0 ~ 20.0
0.0 ~ 70.0 s-1
0.0 ~ 20.0 s

The value of set point can be varied from 0.0 ~ 50.0Hz. Please note that the
motor may not if adequate gain is not selected. All parameters may be set by
pressing the INC or DEC buttons and confirmed by pressing ENT. The effect
is instantaneous. The values of Kp, Ki and Kd are saved on power failure.

Additionally, the following parameters may be displayed.

PARAMETER
PV Process Value
ERR Error
OUT Output

RANGE
0.0 ~ 50.0 Hz
-50.0 ~ 50.0 Hz
0.0 ~ 100.0 %

5.6 Fault Indications

Faults are indicated on the digital display. The various faults, their indications
and sources are given below:
Fault

Display

Reason

Field Failure

FFAU

Field not
connected/faulty
Internal DC Bus
Not Ready.
Armature Current
has gone above the
limit.

DC Bus Not nrdy

Ready
Over Current oCur

Applicable
Drives
CP-DL-1
CP-DL-2
CP-DL-2
CP-DL-4
CP-DL-1
CP-DL-2
CP-DL-3
CP-DL-4

Comments
Requires
Power On.
At startup
only.
Requires
Power On.

6. Procedure

ARMATURE

220 V
AC

L
N

DRIVE UNIT

AA

AA

FF

FF
FIELD

DC MOTOR
0.5 HP

SPEED
SENSOR

Connection Diagram

Experiment 1: Open Loop Operation

1) Use connecting wires to connect the motor, drive unit and mains according to the
connection diagram.
2) Connect the A.C. mains cord to the power socket, but do not switch on the M.C.B.
3) Switch on the M.C.B. and see if the voltmeter, ammeter and tachometer come on.
If they do not turn on or if the FIELD OK LED doesnt come on, then switch of
the M.C.B. and report the problem to the instructor.
4) Remove load from the loading arrangement.
5) Wait for Not Ready Signal to go.

6) Set the output to 10% using the buttons. Put the motor in RUN mode. Observe the
voltage, current and speed readings on the displays. The motor may not rotate at
10% output. This is normal.
7) Increase the output is steps of 10% and observe the readings. If the motor does not
rotate after 50V, switch of the drive unit and check the motor connections.
8) Note the readings in observation table.
9) Repeat the above experiment with variable load by applying different loads using
the loading system in steps of 0.5kg.
10) Draw a graph of Voltage vs. Speed for different load values.
11) Draw a graph of Current vs. Speed for different load values.

SN

Speed (RMP)

Voltage (V)

Current (I)

Observation Table

Experiment 2: Closed Loop Operation

1) Use connecting wires to connect the motor, drive unit and mains according to the
connection diagram.
2) Connect the A.C. mains cord to the power socket, but do not switch on the M.C.B.
3) Switch on the M.C.B. and see if the voltmeter, ammeter and tachometer come on.
If they do not turn on or if the FIELD OK LED doesnt come on, then switch of
the M.C.B. and report the problem to the instructor.
4) Apply a minimum load (non-zero) using the loading arrangement.
5) Wait for Not Ready signal to go.
6) Set the operation to closed loop mode.
7) Check the default settings. (P = 4.7, I = 1.7, D = 0.0).
8) Set the set point at 5.0Hz (300 RPM) using the buttons. Put the motor in RUN
mode. Observe the voltage, current and speed readings on the displays.

9) If the motor does not rotate, switch of the drive unit and check the motor
connections.
10) Note the readings in observation table.
11) Repeat the above experiment with variable load by applying different loads using
the loading system in steps of 0.5kg. Please check if the motor is drawing current
in excess of 90% of its rating.
12) Draw a graph of Voltage vs. Speed for different load values.
13) Draw a graph of Current vs. Speed for different load values.
14) Repeat the above experiment for speeds of 10.0Hz (600RPM), 15.0Hz (900 RPM)
and 20.0Hz (1200 RPM).
15) Draw a graph of Voltage vs. Load for different Speed values.
16) Draw a graph of Current vs. Load for different Speed values.

SN

Load (Kg)

Voltage (V)

Observation Table

Current (I)