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LabAB2 - Report - Safwaan Syed

The document discusses the determination of encoder pulses per rotation and the impact of speed and Requested Packet Interval (RPI) on error and repeatability in a PLC-controlled system. It outlines calculations for encoder rotation and details how varying RPIs affect stopping accuracy, with 2 ms and 0.317 ms providing the best performance in terms of low error and high repeatability, while 100 ms leads to significant inaccuracies. In conclusion, optimal RPI settings are crucial for achieving precise control in motion tasks.

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Safwaan Syed
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2 views11 pages

LabAB2 - Report - Safwaan Syed

The document discusses the determination of encoder pulses per rotation and the impact of speed and Requested Packet Interval (RPI) on error and repeatability in a PLC-controlled system. It outlines calculations for encoder rotation and details how varying RPIs affect stopping accuracy, with 2 ms and 0.317 ms providing the best performance in terms of low error and high repeatability, while 100 ms leads to significant inaccuracies. In conclusion, optimal RPI settings are crucial for achieving precise control in motion tasks.

Uploaded by

Safwaan Syed
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Process Control Lab AB2

Prof. James Wang


SAFWAAN SYED MAAZ
8964223.
Part III: Determine the number of encoder
pulses per encoder rotation and scale encoder
The ladder logic counts encoder pulses between Z-pulses to determine pulses per rotation.
A CTU counter increments on each Z-pulse detection. High-speed counter values are
stored and subtracted to find the di erence in pulses. The pulse di erence is converted to
position increments using division. A reset and visual indication are included for process
control and monitoring.
The calculation for Part III will be:
1. E ective diameter = 80.12 + (2 × 3.05) = 86.22 mm
2. Circumference = π × 86.22 = 270.82 mm
3. 1 encoder rotation = 1.3 motor rotations (sprocket rotations)
4. So, 1 encoder rotation = 1.3 × 270.82 = 352.07 mm
5. Therefore, 1 pulse = 352.07/1808(actual pulses) mm=0.1947
6. Mm travelled = 1/0.1947 = 5.136
7. Scaled Value = Current count/5. 136
Part IV: Move Sequence PLC Program
 What e ect does speed have on error and error repeatability (closeness between
the results of successive measurement)? Explain.

 In systems governed by Variable Frequency Drives (VFDs), the process of speeding


up, slowing down, and halting requires a finite amount of time. As the system
operates at higher speeds, achieving accurate stopping points becomes increasingly
challenging, leading to greater positioning errors and reduced repeatability.
 At slower speeds, the system benefits from extended time to decelerate smoothly,
allowing the drive to make fine-tuned corrections, resulting in more precise stops.
However, when the system runs at higher frequencies, the inertia—or the system's
tendency to keep moving after a stop command—is much stronger. This momentum
causes the machine to overshoot the intended stop location.
 Furthermore, higher operating speeds reduce the available reaction time for both
electrical and mechanical components, making it di icult to achieve consistent stop
points. Repeatability, defined as the system’s ability to halt at the same position
across multiple cycles, is significantly better at low speeds. This is because minor
di erences in resistance, weight, or timing can be easily corrected. In contrast, the
same minor variations at high speeds can cause significant shifts in the stopping
location.
 In summary, operating at elevated speeds leads to greater stopping inaccuracies due to
delayed response and momentum. Precision-demanding tasks benefit from lower speeds
or the use of advanced braking and control mechanisms that help mitigate errors
occurring at higher velocities.
Part V: Periodic Task for the Move Sequence
 What e ect does RPI have on error and error repeatability? Explain for all four Periodic
Routine Intervals recorded.
 The Requested Packet Interval (RPI) determines how frequently the PLC updates the
VFD with speed and position data. This interval directly impacts the system’s stopping
accuracy and how reliably it can stop at the same position across multiple cycles. In this
study, RPIs of 2 ms, 55 ms, and 100 ms were tested, each showing varying effects on
positional error and repeatability.

At 2 ms RPI, the system receives updates very frequently, enabling near-instant control
adjustments. This results in precise motor stopping with minimal overshoot and
undershoot during each cycle. The average absolute error recorded is 198.57 mm,
showing high positional accuracy. A low standard deviation of 2.89 mm indicates
excellent repeatability across all cycles. Such rapid feedback improves the system’s
ability to stop at nearly the same position every time. This makes it ideal for tasks
requiring consistent and precise motion control. However, extremely fast update rates
can overload the VFD or network communication. This may introduce instability if the
hardware is not capable of handling high-speed data exchange.
At an RPI of 55 ms, the system receives updates at a moderately fast rate, allowing it to
react to stop commands more e iciently than at longer intervals. The recorded mean
absolute error is 220.41 mm, and the standard deviation is only 1.30 mm, indicating a
good level of stopping accuracy and consistent repeatability across cycles.
Although the error is not as low as at 2 ms, it is still significantly better than what’s
typically observed at 100 ms. The system shows reliable and repeatable performance,
making this RPI a suitable compromise for operations where moderate speeds and
balanced control are required.
With an RPI of 100 ms, the system experiences significant delays in communication,
causing late registration of stop commands. As a result, the motor overshoots the
setpoint by a wide margin, with a mean absolute error of 242.58 mm. Additionally, the
standard deviation of 21.38 mm reflects poor repeatability, as the stopping position
varies widely from cycle to cycle.
This infrequent update rate leads to imprecise control, especially at higher speeds where
even small delays can result in major overshoot. Overall, the system becomes less
predictable, with both accuracy and consistency being severely a ected at this RPI
setting.
At an RPI of 0.317 ms, the system achieves excellent control performance with highly
responsive updates. The mean absolute error is 198.57 mm, and the standard
deviation is just 2.89 mm, indicating both low error and exceptional repeatability.
Compared to 2 ms, 55 ms, and 100 ms settings, this RPI o ers one of the most stable
and accurate stopping behaviors. The frequent communication cycle allows the drive to
react swiftly and consistently to stop commands, making it ideal for precision-driven
applications.
IN CONCLUSION:

 RPI at 100 ms: Results in high positioning errors, low repeatability, and unreliable
stopping due to sluggish system response.
 RPI at 55 ms: Delivers moderate error levels with better consistency—an e ective
compromise for most control tasks.
 RPI at 2 ms: Achieves very low error and excellent repeatability, though excessive
update frequency may risk system instability.
 RPI at 0.317 ms: Offers highly accurate stopping with minimal error and excellent
repeatability, making it ideal for precision tasks—without showing signs of
instability.

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