dSPACE DS1103 Control Workstation Tutorial and DC Motor Speed Control

Tutorial

By Annemarie Thomas

Advisor: Dr. Winfred Anakwa May 11, 2009

Table of Contents Introduction ................................................................................................... 1

Controller........................................................................................................................ 1 ControlDesk .................................................................................................................... 1 CLP1103 Connector Panel ............................................................................................. 2 Motor System .................................................................................................................. 2 Optical Encoder System .................................................................................................. 2

Equipment ..................................................................................................... 2 Setup/Startup................................................................................................. 4 Detecting the DS1103 .................................................................................... 6 Creating a New Simulink Model ................................................................. 8 Opening MATLAB/Simulink .................................................................... 14
Option A:....................................................................................................................... 14 Option B:....................................................................................................................... 15

Building/Downloading a Model ................................................................. 17 Monitoring/Controlling/Recording Values .............................................. 22

Normal Process ............................................................................................................. 22 CaptureSettings Instrument .......................................................................................... 31

Motor Speed Control Application ............................................................. 38 References .................................................................................................... 58

Introduction
The purpose of this tutorial is to introduce Bradley Universitys dSPACE DS1103 Workstation to new users. Use of this tutorial will minimize the time required for students (of senior undergraduate level or higher) to become proficient in using the workstation. This should allow them to spend less time learning about the workstation, so they can spend more time designing and implementing more complex control systems. The example system used in this tutorial is a DC motor speed control system. The controller has been designed and simulated using both the Simulink and the dSPACE blocksets, the MATLABto-DSP interface libraries, Real-Time Interface to Simulink, and Real-Time Workshop, all located on the workstation PC. The controller will be downloaded onto the Texas Instruments TM320F240 DSP [1] located on the DS1103 board. A general block diagram for the system is shown in figure 1 below.
ControlDesk (Desired Speed Input)

Motor System DS1103 CLP1103 Connector Panel Optical Encoder

Load Applied to Motor Shaft By Brake

Figure 1: Motor Speed Control System Block Diagram.

Controller The controller was designed using hand and MATLAB calculations and Simulink Simulation. It was then added to the Simulink Model that was downloaded to the DS1103 DSP. For more information see the final project report for this project [2].

ControlDesk ControlDesk serves multiple purposes. It provides the interface for downloading controller models onto the DSP and provides the ability to interface with the entire system so inputs, such as the desired motor speed, can be altered and output data can be monitored on the PC display in real-time.

2 CLP1103 Connector Panel The CLP1103 Connector Panel serves as an interface between the DS1103 and all external hardware. The CLP1103 Connector Panel contains connectors for twenty (20) Analog-to-Digital inputs, eight (8) Digital-to-Analog outputs, and several other connectors that can be used for Digital I/O, Slave/DSP I/O, Incremental Encoder Interfacing, CAN interfacing, and Serial Interfacing. [3]. Only the Slave I/O (for PWM output) and Incremental Encoder interfaces are used in this tutorial.

Motor System The Motor System includes a motor and additional analog components, most of which are listed in the Equipment section that follows.

Optical Encoder System The Optical Encoder System is an optical encoder connected to the motor with necessary pull-up resistors and power/ground connections added.

Equipment
Required Equipment for this tutorial is: The dSPACE DS1103 Workstation. (See figure 2 on the next page.) Pittman GM9236C534-R2 DC Motor. HEDS 9100 Two Channel Optical Incremental Encoder Module and 512 CPR code wheel (attached to the internal motor shaft). Magtrol HB-420 Brake. TIP120 Transistor. IN4004 Diode. SN7407 Hex Inverters. Connectors with wires for the pins used as inputs and outputs to the CLP1103 Connector Panel. (See more details in the Motor Speed Control Application section.) Other required/desired electronic components (resistors and wires), power supplies, and measurement devices. All of this equipment was readily available at Bradley University at the time this tutorial was written. Note1: The next several sections are general processes that should be followed. Skip to the section titled Motor Speed Control Application to follow these steps in an actual application. Even if the example application is not being used, reading through the instructions in that section may provide some additional hints and tips that might make using the system easier.

Figure 2: Workstation

Note2: If additional information is required, please refer to the final project report for this project [2] or contact Dr. Anakwa at Bradley University.

Setup/Startup
1. Turn on the DS1103 Board using the power switch on the back of the expansion box.

Figure 3: Back View of Expansion Box with switch highlighted.

2. Open ControlDesk from the Start Menu. To open ControlDesk go to: Start EE Applications dSPACE Tools ControlDesk

Figure 4: Location of ControlDesk Icon in the Start Menu

5 3. Scroll to the bottom of the ControlDesk Disclaimer dialog box when it appears and select Accept.

Figure 5: ControlDesk Disclaimer dialog box.

Note: This disclaimer does not affect this workstation since the PC is currently running the Windows XP operating system, not Windows Vista. 4. ControlDesk should now be open.

Figure 6: ControlDesk Window

Note: ControlDesk will complain if the DS1103 board is not turned on first.

Detecting the DS1103

Note: These steps should not need to be followed every time the system is used. These steps are generally needed the first time the workstation is setup and any time after when an error occurs in MATLAB when code is being built announces that the board has not been detected or the ds1103 and Slave DSP do not appear in the Platform tab in ControlDesk.

Figure 7: View of Platform tab in ControlDesk before and after DS1103 has been detected.

1. Select Register from the menu in ControlDesk. To select Register, in the main menu go to: Platform Initialization Register

Figure 8: Location of Register selection in ControlDesk main menu.

7 2. From the Register Board dialog box that appears, select DS1103 PPC Controller Board from the Type dropdown menu and set the Port address to 300. Then select the Register button.

Figure 9: Correct selections in Register Board dialog box.

3. The DS1103 Board and DSP should now be reported as detected in the ControlDesk Platform tab.

Figure 10: DS1103 and Slave DSP shown in the Platform tab with the system stopped.

Creating a New Simulink Model

For best results, a new Simulink Model should be opened from ControlDesk itself. If other processes are used to create a new Simulink Model, there is a chance that there will be issues when the steps in the Building/Downloading Model section later in this document are followed. Once the model is created, the instructions in the Opening MATLAB/Simulink section can be used to re-open, edit, and build the model in the future. 1. Create a folder on the Desktop or another location on the computer for your project.

9 2. Open ControlDesk and Select the Platform tab of the left menu window. Note: Do not close ControlDesk until all the steps in this section of the tutorial are completed.

Figure 11: Location of Platform tab in ControlDesk.

10 3. In the Platform window, Right-click Simulink and Select New Model from the menu that appears.

Figure 12: Creating a New Model from ControlDesk.

11 4. Select the folder that was created for the project from the Look in: drop down menu at the top of the New Model window. Type in a name for the new Simulink Model file in the File Name: box, and then, Select the Open button.

Figure 13: Naming the new Simulink Model File.

12 5. Locate the Simulink Model that opened with the name entered in the previous step and Build it. To Build the Model from the models main menu go to: Tools Real-Time Workshop Build Model

Figure 14: Selecting Build Model.

Note: To see the Build process running, view the MATLAB Command Window.

13 6. Delete the Simulink blocks from the model but do not delete the grey RTI Data icon.

Figure 15: New Simulink model showing RTI Data icon and DS1103 PWM block added.

7. Start adding Simulink blocks to the model for the project. Save the model before closing it.

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Opening MATLAB/Simulink
There are Several Ways to open MATLAB and Simulink when a Simulink model has already been created. Two possible options are listed below. Option A: Open the existing .mdl file for the project from its folder on the drive. Note: This only works if you have an existing model. 1. Find the .mdl file on the drive and double-click the file to open it. (This will cause both MATLAB and Simulink to open.)

Figure 16: test.mdl file selected to be opened.

2. Select the RTI1103 button in the Select dSPACE RTI Platform Support dialog box that appears in MATLAB.

Figure 17: Select dSPACE RTI Platform Support dialog box.

15 Option B: Open MATLAB from ControlDesk. This process does require more steps. 1. From ControlDesk, right-click Simulink in the Platform tab, and select Open MATLAB. (This will open just a MATLAB Command Window.)

Figure 18: Link to Open MATLAB from ControlDesk.

2. To open the Simulink Library Browser, enter simulink into the MATLAB Command Window.

Figure 19: Enter "simulink" into the MATLAB Command Window.

16 3. Next, Open the existing .mdl file using the Simulink Library Browser main menu. To Open an existing file go to: File Open. Then find and select your file on the drive and select the Open button in the Open dialog box.

Figure 20: Opening an existing file from the Simulink Library Browser.

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Building/Downloading a Model
1. Open the Configuration Parameters window from the main menu of your open model window. To open the Configuration Parameters window go to: Simulation Configuration Parameters

Figure 21: Opening the Configuration Parameters window.

18 2. Set the required/desired parameters in the Configuration Parameters window. Make sure to set the sampling time (Fixed-step size) to the correct value for the project. To change the sampling time go to: Solver Fixed-step size. Then, Set to desired sampling time.

Figure 22: Configuration Parameters window with sampling time set to 0.001s or 1ms.

19 3. Set the Real-Time Workshop settings and select the Build button to build and download code from the Simulink model. (Code building progress is output to the MATLAB Command Window.) Real-Time Workshop Settings: a. System target file: rti1103.tlc b. Language: C c. Make command: make_rti d. Template makefile: rti1103.tmf e. Select checkbox for Generate makefile Note1: ControlDesk needs to be open for this step to complete all processes well. There will be no error message if ControlDesk is not open, but certain tabs in ControlDesk used for monitoring and controlling variables will not be automatically opened.

Figure 23: Real-Time Workshop Settings.

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Figure 24: End of output in MATLAB Command Window for a successful build.

21 Note2: To make sure the files generated are placed in the folder desired, it is advisable to select the File Selector tab at the bottom of the ControlDesk window, select and right-click the folder where the files should be placed, and select Change to Working Directory before building any code each time.

Figure 25: Setting the Working Directory/Build folder.

4. The code should be built and downloaded and running on the DS1103 and Slave DSP now.

22

Monitoring/Controlling/Recording Values
Layouts are one of the more interesting functions in ControlDesk. They allow the value of constant/input blocks, gain blocks, and perhaps some other blocks to from the Simulink model downloaded to the DS1103 to be changed while the system is running. They also allow real-time reporting of output values and saving/recording of values over a time period for analysis/viewing in MATLAB later.

Normal Process 1. Create a new layout or Open an existing layout using the ControlDesk main menu. A. To Open an existing file go to: File Open. Then find and select your file on the drive and select the Open button in the Open dialog box. B. To Create a new file go to: File New Layout. Note: Make sure to save and rename your file before closing it later.

Figure 26: Create a new layout.

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2. Expand the layout window that appears in the ControlDesk workspace to fit most of the workspace by dragging the double-headed arrows that appear when the mouse passes over the edges of the window.

Figure 27: Expanded layout window in ControlDesk.

3. Set ControlDesk to Edit Mode by either selecting it from the toolbar or by selecting it from the Instrumentation dropdown menu of the main menu. (The Virtual Instruments side panel should appear.)

Figure 28: Selecting Edit Mode in ControlDesk.

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4. Now Virtual Instruments and Data Acquisition Tools can be added to the layout. This is done by single-clicking instruments in the side panel (without holding the mouse button down), then clicking and then holding the mouse button down in the layout window while dragging the corner of the box that begins to appear for that particular instrument.

Figure 29: Adding a Virtual Instrument.

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Figure 30: Adding Plotter Array from the Data Acquisition Menu.

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5. Verify a tab for the .sdf file generated for the project is available near the bottom of the ControlDesk window. If it is not, rebuild the project using the instructions in the Building/Downloading a Model section of this tutorial, beginning on page 13.

Figure 31: Location of .sdf tab in the ControlDesk window.

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6. To connect/assign variables from the Simulink model downloaded to the DS1103, locate the variable in the .sdf menu(s) and then click-and-drag it to its instrument in the layout. (Generally, the values of constants and gain blocks in the model can be monitored and modified/controlled in real-time and outputs/connections between blocks can be monitored only.) Note: To connect to the outputs of dSPACE blocks in the downloaded Simulink model, a gain (of 1) block needs to be connected to the output of the block if nothing else is connected to it other than a terminator block.

Figure 32: Connecting Variables to Instruments.

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Figure 33: Completed layout with location of additional connections not shown in Figure 28 highlighted.

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7. Change the properties of the instruments as desired. Accessing the Properties menu(s) for a particular instrument done by either: A. Left-clicking the instrument to select it and then selecting Properties from the ControlDesk main menu View menu. B. Right-clicking the instrument and selecting Properties.

Figure 34: Two methods of opening the Properties dialog for an instrument.

Find the property that should change under one of the tabs and change it. (Generally, only Max and Min Range values need to be changed and/or Range Check Mode needs to be Enabled, but other properties such as the color of the instrument and text can be changed as well.)

Figure 35: Changing the Range of the DutyCycle Slider input.

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8. Verify the instruments now functions as desired without affecting the system (or the other instruments) using Test Mode, which is found in a similar manner to Edit Mode in Step 3 of this section. (This is useful to verify that the Range enabled for Check Mode for an instrument such as the NumericInput instrument - not used in this section - rejects values input that are outside that range.)

Figure 36: Location of Test Mode button on main toolbar.

9. To use the instruments to control and monitor that actual, running, real-time system, select Animation Mode in a similar manner to selecting Edit Mode in Step 3 of this section. (It appears Properties can also be modified in this mode.)

Figure 37: System running with Animation Mode active.

10. Additional instruments such as the CaptureSettings instrument, used for saving/recording data, can be added later by repeating Steps 3-9 of this section for the new instrument. It should also be possible to create and use multiple layouts at the same time. Note: For instructions/details about the CaptureSettings instrument, see the CaptureSettings Instrument subsection that follows.

31 CaptureSettings Instrument The CaptureSettings instrument found in the Data Acquisition instrument menu allows data output on PlotterArray instruments (and only PlotterArray instruments) to be saved/recorded for later analysis/use in MATLAB or perhaps some other program.

Figure 38: CaptureSettings instrument (red boxes) added to a layout with associated PlotterArrays (blue boxes). A NumericInput instrument is also included in this layout below the slider.

32 The CaptureSettings instrument is added in the same way as any other instrument (See Steps 3-9 in the Normal Process subsection previous to this one.), but the space provided for it must be large enough to access all its functions and most of the Properties can also be accessed using the Settings button on the instrument.

Figure 39: Most tabs in the Properties and Settings dialog boxes for the CaptureSettings instrument are exactly the same.

Note: For this tutorial only the Stream to Disk Acquisition method was used in its simplest form. To see more functions of this instrument, search for How to Generate and Save Reference Data or Working with Data Captures in the ControlDesk Help menu found on the ControlDesk main menu bar. After the CaptureSettings instrument has been added and PlotterArrays have been added for the variables that should be recorded: 1. Set the top dropdown menu for the instrument is to PPC - HostService. (The name for the project will be included as well.) 2. Open the Settings or Properties dialog for the CaptureSettings Instrument and select the Acquisition tab. Select the bullet box for Stream to Disk.

33 3. Select the button with at the end of the line for Stream to Disk and create or select a file for the data to be saved to. The file will be saved as an .idf file.

Figure 40: Set Stream to Disk mode and create/select location for captured data.

4. Select OK at the bottom of the dialog box to exit the menu. 5. If the Start button on the instrument is selected now, ControlDesk may report an error with the Length or Downsampling Settings. Arbitrarily setting the Length to 2 will fix this for the example application.

Figure 41: Setting the Length for the capture to 2 seconds.

34 6. Select Start on the instrument to start saving data, and then Select Stop when the desired data capture is completed.

Figure 42: Saving data.

Note: This will overwrite any data stored previously in the .idf file created earlier. If the data should not be rewritten follow Steps 1-2 again between captures an Create/Select a .idf file with a different name. 7. Convert the .idf file to a MATLAB .mat file by Selecting Convert IDF File from the Tools menu on the ControlDesk main menu, and then Selecting the .idf file containing the saved data and Selecting/Creating the .mat file the converted data should be saved to using the Source File and Destination File(s) buttons and Selecting the Convert button.

Figure 43: Converting an .idf file to a .mat file.

35 8. Open the .mat file from the location it was saved to on the drive.

Figure 44: Open the .mat file.

9. Select the Finish button from the MATLAB Import Wizard dialog box that opens.

Figure 45: MATLAB Import Wizard dialog box.

36 10. From the MATLAB Workspace, Double-click (or Right-click and Select Open Selection) the structure with the same name as the .mat file to open the Variable Editor for the file.

11. Plot the data (or manipulate it in some other manner). The X structure contains the time values in its Data array. The values for the variables that were recorded are found in the Data arrays for each <1x1 struct> of the Y structure. To determine which variable is found in each <1x1 struct> of Y, Double-click the structure to open it and look at the Value of its Name label. (See figure 47 on next page.) The full identifying label for each variable can be found at the top of the Variable Editor window when it is open. Example MATLAB code to plot both variables from the figures in this section on the same plot:
>> >> >> >> plot(data_5_6.X.Data, data_5_6.Y(1,1).Data) %in or RPM_in hold on plot(data_5_6.X.Data, data_5_6.Y(1,2).Data) %out or RPM_out hold off

(Plot shown in figure 46 on the next page.)

37

500 400 300 in out

Y=Speed(RPM)

200 100 0 -100 -200

0.5

1.5

2.5 X=Time(s)

3.5

4.5

Figure 46: Example data plotted in MATLAB with labels/color added manually.

Figure 47: Locating the Data for the RPM_in variable. (RPM_out was in data_5_6.Y(1,2).)

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Motor Speed Control Application

1. Construct the motor subsystem shown in the figure below, also connecting the optical encoder and code wheel to the internal motor shaft and adding the brake. Also add the 5 Volt power connection and the 2.7 k pull-up resistors between 5 Volts and the encoder channels, A and B. Verify 5 Volt and 25 Volt DC power supplies are set correctly before connecting to the system.

Figure 48: Motor Hardware Schematic.

For the motor-optical encoder system provided at Bradley University, the motor and optical encoder connections are shown in the figure on the next page. The pin assignment for the TIP120 NPN transistor is shown in the figure below.

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Figure 49: TIP120 NPN transistor pin assignment.

Figure 50: Motor and encoder connections for system at Bradley University.

40 2. Make all connections between the Connector Panel, the encoder and the Motor System. The required connections to the Slave I/O and Inc1 connectors are shown in the figures that follow. Note: Colors listed are for the wires used on the current version of the connectors at Bradley University.

Figure 51: PWM connections on Slave I/O connector.

Figure 52: Encoder Connections to/from Inc1 connector.

Note: Once code has been downloaded at later steps of these instructions, it is generally best to turn the power supplies on after downloading the code and turn them off before stopping the code from running in ControlDesk.

41 3. Now that all the hardware connections are complete, the work with ControlDesk and Simulink can begin. Start by following the instructions in the sections of this tutorial labeled: a. Setup/Startup b. Detecting the DS1103 c. Creating a New Simulink Model Leave the model open after saving it or re-open it using the instructions in the Opening MATLAB/Simulink section. 4. Now, Add the DS1103 dSPACE blocks needed for PWM generation and Encoder input capture can be added. These blocks are found in the Simulink Library Browser under the dSPACE RTI1103 heading on the left menu window.

Figure 53: Location of dSPACE DS1103 blocks in the Simulink Library Browser.

42 4a. Locate the PWM block labeled DS1103SL_DSP_PWM at: dSPACE RTI1103 DS1103 SLAVE DSP DS1103SL_DSP_PWM. Click and Drag the block into the model created for the project.

Figure 54: Locating and Adding the PWM block.

43 4b. Some features such as the encoder blocks require more than one block to function. One block has outputs. The other block is for more general settings that would also apply to other related (encoder) blocks if they were used. Locate the Encoder blocks labeled DS1103ENC_SETUP and DS1103ENC_POS_C1 at: dSPACE RTI1103 DS1103 MASTER PPC DS1103ENC_SETUP. And dSPACE RTI1103 DS1103 MASTER PPC DS1103ENC_POS_C1. Click and Drag both blocks into the model created for the project.

Figure 55: Locating and Adding the encoder blocks.

44 5. Add and Connect constant, gain, terminator, and ground blocks to the Simulink project then save the project, but do not close it. a. Add a constant block and connect it to PWM Channel 1 of the PWM block. Set its value to a number between 0 and 1. Change the label of the block to DutyCycle. (This is the range for the input to the block as a percentage (0.5 = 50%) of the duty cycle.) b. Connect gain blocks to Enc position and Enc delta position. Set the gain of these blocks to 1. Label the connections going into or out of these blocks Enc1 and Enc2. (If these gain blocks are not added at this point, the outputs will probably not be monitorable in ControlDesk later.) c. Connect the PWM Channel 2, PWM Channel 3, and PWM Channel 4 inputs to the PWM block to ground since they are not being used in this project. (Any connections that are open need to be attached to either a terminator or ground.) d. Connect the output of the gain blocks to terminator blocks.

Figure 56: Simulink model after adding blocks and connections and saving. The DutyCycle is set to 50%.

45 6. Change the Properties/Settings/Parameters of the PWM block. (No encoder settings need to be changed since the Inc1 connector input is being used.) To do this, Right-click the block and Select Open Block from the drop down menu. Then, change the appropriate settings. Change the following DS1103SL_DSP_PWM Settings in the dialog box that appears: a. Unit tab: Frequency = 12000 Hz b. Initialization tab: For Channel 1: PWM Stop = output with duty cycle, Range = 0 (The ST2PWM output being used is Channel 1 of this block.) c. PWM Stop and Termination tab: Remove check from box for set Ch X for all channels.

Figure 57: PWM block settings.

46 7. Change the Sample time of the Gain blocks to 1/12000 seconds by Right-clicking the blocks, Selecting Gain Parameters, and Changing the Sample time in each block to 1/12000 on the Main tab of the dialog window that appears.

Figure 58: Changing the sampling time of gain blocks.

8. Connect the channels of an oscilloscope to the PWM output and one of the channels of the optical encoder in the hardware circuit. 9. Build and Download the model to the DS1103 board using the instructions found in the section of this tutorial labeled Building/Downloading a Model, setting the Fixed-step size for the model to 1/12000. (When this step is complete, the system should be running and the DutyCycle should be initialized to the value set in the model.)

47 10. Now, it is time to have some fun with ControlDesk. Create a layout in ControlDesk following the directions in the Monitoring/Controlling/Recording Values section of this tutorial. Connect the following variables/values to the type of instrument(s) indicated. a. DutyCycle: Slider (Change Max Range to 1) and Display and PlotterArray b. Enc1: Display c. Enc2: Display

Figure 59: Layout in ControlDesk with system running and slider used to change the DutyCycle.

11. Observe that changing the DutyCycle value using the slider changes the duty cycle of the PWM measurement on the oscilloscope to a similar percentage and changes the encoder frequency observed. Also observe that the DutyCycle has approximately a 12 kHz frequency using the oscilloscope. 12. Observe that in the case of this system, the absolute value of the Enc1 output on the ControlDesk Layout generally increases since the motor shaft is only rotating in one direction and it is probably measuring distance. Multiplying the Enc2 output on the ControlDesk Layout by the inverse of the sampling time (the frequency), 12000 in this case should approximately correspond to the Encoder frequency reported on the oscilloscope.

48 13. Now, Delete the instruments from the ControlDesk layout and save it. Also, Delete the DutyCycle and Gain blocks from the Simulink model, Delete the Enc1 label, and reconnect the Enc position output to its terminator block. Save the model.

Figure 60: Simulink model after Step 13 is completed.

49 14. Setup/Add the blocks to the Simulink model for the RPM output calculation/conversion. a. Re-label the Enc delta position output connection count_out. b. Add another gain block between Gain1 and the terminator block. c. Label these two gain blocks count_to_Hz and Hz_to_RPM and set the sample time for each block to 1/12000 (See Step 7 in this section). d. Change the gain of the count_to_Hz block to 12000 and of the Hz_to_RPM block to 0.019881. e. Label the connection between the two gain blocks Hz and between the second gain block and the terminator RPM_out. (RPM_out is the actual output for the system.) Note: Leave enough space between the encoder block output and the first gain block for an additional connection in the upward direction later.)

Figure 61: Simulink model after Step 14 is completed.

50 15. Add the desired RPM input block and conversion blocks. a. Add a Constant block and two (2) Gain blocks toward the top on the Simulink model. b. Label the constant block RPM_in and change its gain to 0. c. Connect the two gain blocks to the output of the RPM_in block in series with one another. d. Label the first Gain block RPM_to_Hz and the second Gain block Hz_to_count and set the sample time for both blocks to 1/12000. e. Change the gain of the RPM_to_Hz block to 50.2996 and of the Hz_to_count block to , and label the connection between the two gain blocks Hz. Note: It will be necessary to increase the size of the window for the model and rearrange some blocks to fit all the blocks in the model at this step or at some point later in the process.

Figure 62: Simulink model after Step 15 is completed.

51 16. Add a Sum block with one positive and one negative input with a sample time of 1/12000. Connect count_out to the negative terminal and the output of the Hz_to_count block to the positive terminal, and label this connection count_in.

Figure 63: New Sum block parameters.

Figure 64: Simulink model after Step 16 is completed.

52 17. Add the Controller. a. Add three (3) Gain blocks and a Discrete Transfer Fcn block to the Simulink model and set the sample time for each block to 1/12000. b. Connect the Gain blocks in series with one another. Then connect the first block to the output of the Sum block and the third block to the input of the Discrete Transfer Fcn block. c. Label the Gain blocks (from first to last) K, Kz, and Kz3 and the Discrete Transfer Fcn block Gc. d. Change the gain of K to 72.0631, of Kz to 0.482282, and of Kz3 to 7. e. In the DiscreteTransferFcn Parameters dialog box for Gc, change the Numerator coefficient to [1 .0024 -0.9976] and the Denominator coefficient to [1 -1.931 0.931].

Figure 65: New Discrete Transfer Function block parameters.

Figure 66: Simulink model after Step 17 is completed.

53 18. Add a Gain block and connect it to the output of Gc. Label it Hz_DutyCycle. Also label the connection between the two blocks TF_out. Set the gain of Hz_DutyCycle to 0.00003 and its sample time to 1/12000. (This block is required because the output of Gc is a frequency and the PWM Channel 1 input is a percentage. (This block coverts the frequency in Hz to a percentage of the maximum input the system is designed for, approximately 660 RPM.) 19. Add a Saturation block and connect it between the Hz_DutyCycle output and the PWM Channel 1 input. Set its sample time to 1/12000, and Set its Upper limit to 1 and its Lower limit to 0. Label the block 0_to_1 and its connection to PWM Channel 1 DutyCycle.

Figure 67: New Saturation block parameters.

Figure 68: Simulink model after Step 19 is completed.

54 20. Make the Controller subsystem by selecting the K, Kz, Kz3, and Gc blocks (Ctrl+Shift and Click OR Drag box over the blocks), and then Selecting Create Subsystem from the Edit selection on the main menu of the Simulink model. Label the Subsystem Controller. 21. Re-label the connection between the Controller and Hz_DutyCycle TF_out. 22. Double-click the Controller to open it and change the label of In1 to Sum and of Out1 to TF_out. Also delete the label of the connection labeled TF_out. (The Simulink model is now complete.)

Figure 69: Simulink model after Step 22 is completed.

Figure 70: Controller subsystem shown in the figure above.

23. Make sure to Save the completed Simulink model. 24. Build and Download the code to the DS1103 board by following the instructions in the Building/Downloading a Model section of this tutorial. (The Fixed-step size should still be 1/12000)

55 25. Now, it is time to edit the ControlDesk layout. Open the existing layout and follow the instructions in the Monitoring/Controlling/Recording Values section of this tutorial to Connect the following variables/values to the type of instrument(s) indicated. a. RPM_in: Display, Slider, NumericInput, and PlotterArray. (Change the Max Range of the Slider and NumericInput to 660.) b. RPM_out: Display and PlotterArray c. DutyCycle: Display

Figure 71: Layout in ControlDesk with system running and slider used to change RPM_in.

56 26. Observe that using the NumericInput for RPM_in provides for better observation of the actual Step Response of the System. Also observe that if voltage is applied to the brake, especially at mid-range input values, the DutyCycle will increase to compensate and maintain RPM_out near the desired value. (Generally RPM_in of 200 RPM was used in testing. For high speed inputs such as 660 RPM, RPM_out will show decreases in its value as more brake voltage is applied but will e stable.) Note: The maximum value before the brake stops is around 10+ Volts if the voltage is increased slowly. Dropping the voltage to somewhere between 5 and 8 Volts should cause the motor to start running again, but it may take some time for the system to start the motor and stabilize its speed. 27. In order to record data, Add a CaptureSettings instrument by following the instructions in the CaptureSettings Instrument subsection of the Monitoring/Controlling/Recording Values section of this tutorial.

Figure 72: ControlDesk layout with CaptureSettings instrument added and the system running. (Step response for 200 RPM observed using NumericInput to change RPM_in from 0 to 200 while system was running.)

28. Capture data and Plot it in MATLAB. (This is also explained in the CaptureSettings Instrument subsection mentioned in Step 27 above.)

57 29. Now, for another cool feature of ControlDesk. The value of any gain or constant block in the Simulink model can be changed without rebuilding and downloading code and while the system is running. (There might be other blocks that work as well.) Use the instructions in the Monitoring/Controlling/Recording Values section of this tutorial to connect Kz3 (Gain) to a Display and a NumericInput instrument in the ControlDesk Layout. 30. Apply 10 Volts to the brake. Set RPM_in to 0. Start the CaptureSettings instrument. Quickly change RPM_in to 200. Observe RPM_out on its PlotterArray, and quickly Stop the CaptureSettings instrument before the 0 to 200 transition disappears. The data can be plotted in MATLAB if desired. 31. Set Kz3 to 20 and repeat Step 30 above. Compare the results. (There should be a visible spike/overshoot in RPM_out for Kz3 = 20 that is not in the Kz3 = 7 RPM_out output.)

Figure 73: ControlDesk layout with Kz3 instruments added and system running with RPM_out response to RPM_in=200, Kz3=20, and brake voltage=10V shown.

32. Set the brake voltage to 0 Volts and Kz3 back to 7 The tutorial is completed.

58

References
[1] DS1103 PPC Controller Board, Germany: dSPACE, July 2008. [2] Annemarie Thomas. "dSPACE DS1103 Control Workstation Tutorial and DC Motor Speed Control: Project Report", Senior Project Report, Bradley University ECE Department, May 2009. [3] Connector and LED Panels, Catalog 2008, Germany: dSPACE GmbH, 2008, p. 302. [4] ControlDesk Experiment Guide For ControlDesk 3.2, Germany: dSPACE GmbH, 2008, Release 6.1. [5] dSPACE System First Work Steps For DS1103, DS1104, DS1005, DS1006, and Micro Auto Box, Germany: dSPACE GmbH, 2007, Release 6.0. [6] Real-Time Interface (RTI and RTI-MP) Implementation Guide, Germany: dSPACE GmbH, 2008, Release 6.1. [7] DS1103 PPC Controller Board Hardware Installation and Configuration, Germany: dSPACE GmbH, 2007, Release 6.0.