Developing a New Affordable DC Motor Laboratory Kit for an Existing Undergraduate Controls Course
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This is a paper presentation from the 2015 American Control Conference (ACC) invited session on Controls Education. The full paper can be found here: http://ieeexplore.ieee.org/xpl/articleDetails.jsp?reload=true&arnumber=7171159.
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Developing a New Affordable DC Motor Laboratory Kit for an Existing Undergraduate Controls Course
- 1. Developing a New Affordable DC Motor Laboratory Kit for an Existing Undergraduate Controls Course Rebecca M. Reck, PhD Candidate & R.S. Sreenivas, Associate Professor Department of Industrial and Enterprise Systems Engineering University of Illinois at Urbana-Champaign 2015 American Control Conference
- 2. Outline • Background & Motivation • Introduction to Control Systems Course • Kit Development • Conclusions and Future Work 2Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved.
- 3. Motivation • Expand the access to hands-on controls laboratory experiments • Update existing equipment • Use updated processes for simulation and design 3Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved.
- 4. Current Lab Costs • The cost of equipment per station varies in cost from • $80 (Gunasekaran and Potluri, 2012) to • $32,493.74 (Egbert, 2009) 4Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved.
- 5. Alternatives to campus labs Virtual Labs Remote Labs Kits Pros: • Low cost • Usually simulation • Only need a computer • Many opportunities Pros: • Use real equipment • More hours available • Do not have to be on campus Pros: • Low Cost • Hands on • Portable • Real systems Cons: • Lack of “real world” problems • Not hands on • Visualization is abstract Cons: • Network infrastructure • Network security • Limited interaction Cons: • Development • Procurement • Support Casini et al., 2003; Uran and Jezernick, 2008; Nickerson et al., 2007 Aktan et al., 1996; Ionescu et al., 2013; Hyder et al., 2009; Casini et al., 2003 Borgstrom et al., 2012; Stark et al., 2013; Cruz-Martin et al., 2012; Kim, 2011; Sarik and Kymissis, 2010 5Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved.
- 6. Introduction to Control Systems • Apply the following course concepts: • System identification • System frequency response • Stability • PID control • Using a DC motor and the associated sensors 6Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved.
- 7. Laboratory Experiments • Lab 1: Introduction to Sensors and DC Motor • Lab 2: Introduction to Simulink and the Raspberry Pi • Lab 3: 1st Principles Systems Identification • Lab 4: Step and Frequency Response System Identification • Lab 5: Control of a DC Motor 7Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved.
- 8. Before Item Cost HP 33120A Function Generator $ 2,487.00 HP 34401A Multimeter $ 1,159.00 HP 6632A DC Power Supply $ 1,320.00 Custom built patch panel, power supplies, and amplifier $ 475.00 Comdyna GP-6 Analog Computer $ 1,500.00 DC Motor, enclosure, and sensors $ 450.00 Dell Precision T3400 PC $ 1,094.00 Agilent Technologies DSO6012A Oscilloscope $ 6,159.00 Miscellaneous Wires $ 195.31 Total $ 14,839.31 8Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved.
- 9. After Item Cost Raspberry Pi Model B $ 39.95 12V DC motor $ 12.95 3D Printed stand for motor and potentiometer $ 5.00 Bread board $ 5.95 H bridge (L293D) $ 2.50 ADC (MCP3008) $ 2.30 Power Supplies $ 24.85 Rotary position sensor $ 2.60 Photo Interrupter $ 3.45 Pi T-cobbler breakout and cable $ 6.95 SD Card $ 17.09 Wires, resistors and LEDs $ 2.34 Total $ 125.93 9Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved.
- 10. Circuit Board Layout 10Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved.
- 11. 11 Proportional + Speed Controller Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved.
- 12. 12 Proportional + Speed Controller Performance Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved.
- 13. Challenges • Consistency of 3D printing • Speed of network • Raspberry Pi support package in MATLAB is a user specific installation • Ground noise • Number of holes in optical encoder 13Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved.
- 14. Conclusions • A kit that costs approximately $130 is being used in GE320 this semester • It uses MATLAB and Simulink for development • The kit weighs around 13 oz. and fits in a shoe box, making it easy to ship • The kits design is flexible enough to be applied in other departments or courses 14Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved.
- 15. Future Work • Compare the effectiveness of the kit vs. the existing equipment in GE320 • Explore opportunities to use the kit in an online course or future integration between the lecture and the laboratory experiments in the existing course. • Comparing low-cost hardware for use in control systems laboratories http://bit.ly/controlsR1 15Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved.
- 16. Rebecca M. Reck Ph.D. Student rebecca@rebeccaee.com http://rebeccaee.com R. S. Sreenivas Associate Professor rsree@illinois.edu https://tinyurl.com/ka55vw9 16 Department of Industrial and Enterprise Systems Engineering University of Illinois at Urbana-Champaign Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved.
Editor's Notes
- General Engineering Degree Both Required Courses
- Story about RHIT to IA state Story about aligning with industry Model based design
- Cost: Per bench in a physical space with limited time ABET
- Alternatives: Virtual – usually simulation therefore low cost however usually very little if any real world issues like noise Remote labs – save on time in the physical space and still use real equipment, however can cause issues with network infrastructure and security Kits – low cost, can be used out side of the lab sessions, can be more integrated with the course or used in projects, however more are needed and more support
- Talk about class structure: size, lecture, lab, etc. -60-70 students in the fall, 40-50 in the spring -Work on lab in pairs for 6 of the 16 weeks of the semester -Lecture is 2 times per week for 80 minutes each Continuous time
- Mention Agilent VEE for controlling equipment GP-6 not made anymore
- Refer to the paper for a list of labs that it has been tested with Raspberry Pi is an ARM based, single board computer that is approximately the size of a deck of cards. Designed to meet the same educational objectives as the existing equipment Lab instructions and pre/post-lab questions were kept the same.
- MCP3002/SPI Conversion to Radians Encoder Conversion to Radians/Sec
- Approximately the same cost as a text book and can be used for at least 2 courses