United Arab Emirates University College Of Engineering Department of Electrical Engineering ELEC 433 - Instrumentation & Control Lab

Experiment 7: Position Control Crane

Done By: Sultan Al Zeidi 200611559

Mohammad Al Jabarat 200633205

Instructor: Eng. Ahmed Abdrabou Eng. Sameer Mohammad

Experiment 1 Date: Submission Date:

13/12/2011 10/01/2011

Fall 2011

Introduction:
This experiment is used to get familiar with the positioning technique which is commonly used in various applications. The objective is to control the position of the crane carriage along the three axes x, y and z. In this experiment the PI controller will be designed using Broda method to control the motion in the x-axis.

Objective
The objective of this experiment is to control a crane carriage in x-axis in both open and closed loop.

Equipment:
Data acquisition (DAQ) type NI 6229 USB to acquire data from the encoders and send the control signal from a computer to the motor controllers. Three encoders (US Digital EM6) to measure the position of the crane by providing electrical signals from -10V to +10V using a D/A converters. Three DC motor controllers (Maxon) receive a signal from -10V to +10V from the data acquisition to move the crane in the forward and reverse direction. The controller has the option to connect a limit switches to stop at the end positions limits. Three DC motors 12VDC. Four proximity switches (metal detectors) connected to the motor controller to stop the motor at end positions in the forward and reverse directions for x and y axis. Power Supply 220VAC to 12-18VDC.

Mechanical construction of the crane, includes two chains to move crane carriage in both x and y axis.

Procedure
Stage 1: In this stage, the parts location and the function of each part checked carefully and The connection of the DC motor studied briefly, in addition The inputs and outputs to the Data Acquisition were defined. It was found that the inputs to the Data Acquisition for the x-axis have addresses of 1 and 3 and the outputs have the addresses of 15 and 16 , finally the block diagram of the open loop system was drawn as shown in figure one .

Figure 1: the open loop system

Stage 2 The main goal of this stage is make calibration for the crane using LabVIEWSignalExpress software , the calibration done between the measured voltage and the actual distance on the crane itself (only for x-axis) . The benefit of this calibration is changing the voltage to a measured distance. The steps of calibration are listed below: The data acquisition was switched on. The power supply E66 was Turned on. The 1/0/2 switch was turned to the position 1 which is the Manual mode.

Start the LabVIEWSignalExpress software. the Add Step menu was opened , after that Acquire Signal Analog Input DAQmx

Voltage, and then ai0 (for x-axis position) was selected calibrators name was written Number of samples to

RSE was selected

average 10 and sample rate 10. Calibrate ai0 range to 0 - 10 V by using the red and green push buttons to move the crane to the most right position (0) and the most left position (10) respectively in the x-axis direction. Move the crane carriage using the buttons of x-axis (green and red) in the same time record the distance measured by the encoder and acquired by the DAQ. Fill the table between the actual distance (measure the x-axis displacement with a meter scale in front of you) and the measured voltage values. A graph was plotted for the measured voltage and the actual distance as shown in Figure 2. It was noticed that the relationship is linear. The measured signal was calibrated using the calibrate button in signal express.

Actual Value (cm) Measured Voltage (V)

0 0

20 2.1

40 3.85

59 5.55

80 7.51

100 9.32

106 9.95

Table 1: Actual distances & measured values

Actual Value Vs Measured Voltage

12 10

Measured Voltage (V)r

8 6 4 2 0 0 20 40 60 80 100 120

Actual Value (cm)

Figure 1: Measured Voltage vs. Actual Distances

Stage 3: Open loop operation: Step response The step response of the system in open loop was studded but this system is unstable, so the crane was moved in the x-axis in both directions until stops by the end positions proximity switches.

The 1/0/2 selector was turned to the position 2 which is in Auto mode. The Labview file (open loop1_29_09) was opened and the sample rate 10 s/sec was inserted. The analog input channel ai0 and the analog output ao0 were selected. The program was started by clicking the start continuously button in the upper left side of the front panel in the Labview file. Different values (positive and negative values) were inserted to move the crane to the left and to the right.

The stored file was loaded using Matlab and plot of the control input (U) and the position (POS) of the Open loop system were plotted as shown in Figure 3.

Figure 2: Control input and position

The transfer function of the system was found from the plot as follows:

K!

( y 2  y1 ) (y ! (u y (t [(u 2  u1 ) y (t 2  t1 )]

(5.715  4.068) [(0.5) y (1)] K ! 3.294 K! X ! t  t0 X ! 56.8  55 X ! 1.8s / 10 X ! 0.18

G ( s) !

K Xs e s

G ( s) !

3.294 0..18 s e s

The values of P and I were found as follows: Bp ! 125 KX ! 125 v 3.294 v 0.18 ! 74.115 100 ! 1.35 BP I ! 6.66 KX 2 ! 6.66 v 3.294 v (0.18) 2 ! 0.711 Kp !

Figure 3: Front Panel of the open loop system

Stage 4: Closed Loop Control (P-Control)

The file KP(x) _04_10_09_test was Opened the closed loop to run the closed loop control. the sample frequency was Set to 10Hz the analog input channel which was calibrated in open loop was selected. and analog output ao0 was selected. the location where you need to store the data was defined. Substituted first the proportional only and consider 1/Ti =0 The behavior of the system shown below:

Figure 5: Kip =1.35

As shown in figure 5 with Kip = 1.35 that equal the value which founded from the calculation. It was observed that the error is reduced but still there is error.

Figure 6: Kip =2

From figure 6 with kp=2 the steady state error equal zero. To sum up if kp increased the steady state error decreased but there will be overshooting.

figure 6: Kip =0.8

As shown in figure 6 the Kip=0.8 the steady state error increase but the response time decreased.

Stage 5: Closed Loop Control (P-I - Control)

In this stage the (P-I) control considered and the result listed in figures below:

Figure 7: Kip =1.35, Ti = 0.01

As shown in figure 7, when the Ti =0.01 there will be steady state error in the system, but time response decreased.

Figure 8: Kip =0.5, Ti = 0.7

As shown in figure 8, if the Ti increased, there will overshoot in the system, and take more time to oscillate.

Figure 8: Kip =0.255, Ti = 0.003

As shown in figure 8, the steady state error reduced to be zero.

Conclusion
In conclusion, the performance of unstable system was studied and position techniques were used to control a crane carriage in x-axis in both open and closed loop.