Linear Control System Lab Trainer

Project Title

Linear Control System Lab Trainer

Project Area of Specialization Electrical/Electronic EngineeringProject Summary

The idea of motor speed control is to keep the rotation of the motor at the set speed. When used in speed applications, speed feedback control the PMDC motor's speed or confirms that the motor is rotating at the desired speed. To maintain the speed, it requires the speed feedback at all times.

In this project, the PID controller is designed to control Motor Speed based on incoming information of system and Auto tuning by using Programmable Logic Controller (PLC). The control system is simulated by powerful software MATLAB and Simulink. Simulation results also show better performance of motor that reduce the rise time, steady state error and overshoot and increase system stability.

Project Objectives

The objective of this project is to use the algorithm of Proportional Integral Derivative (PID) controller to control the speed of the PMDC motor using Programmable Logic Controller (PLC) implementation. This project is based on controlling the speed of a Permanent Magnet Direct Current (PMDC) motor by designing a PID Controller using Programmable Logic Controller (PLC) as a platform using the MATLAB and Simulink software.

Project Implementation Method

Closed loop Method is most suitable for applications without position control requirements or the need of high accuracy of speed control.

The main advantage of using DC motors in today's world is the ability to easily control the speed and angle of the motor. The controller has more advantages than conventional control circuits. PID controller is widely used in industrial plants because it is simple and robust.

At first, motor speed is transferred to PLC by shaft encoder, then PLC according to the program and PID controller generate the control signal to reach the desired speed. The analog signal from the D/A module is transmitted to the DC drive. According to the received control signal, drive transfer required voltage to the motor. Every moment, signal of shaft encoder is received by PLC and PLC measures motor speed at any moment and produces signals for having optimum speed in the shortest time and low steady state error and low overshoot in stable state. HMI monitor display the coefficients of the PID controller and desired speed and motor speed and motor speed versus time graph. A basic diagram of control is shown below.

Basic working of PLC

• The Programmable Logic Controller (PLC). Typically, the basic functional components of a PLC system are a processor unit, memory, power supply unit, input/output interface section, communications interface, and programming device.

The  processor  unit  or  central  processing  unit  (CPU)  is  the  unit  containing  the  microprocessor.  This

• The  processor  unit  or  CPU  is  the  unit  containing  the  microprocessor.  This interprets  the  input signals  and  carries  out the  control  actions, according  to  the  program stored  in  its memory, communicating the decisions as action signals to the outputs.
• The power supply unit is needed to convert the mains AC voltage to the low DC voltage necessary for the processor and the circuits in the input and output interface modules.
• The programming device is used to enter the required program into the memory of the processor. The program is developed in the device and then transferred to the memory unit of the PLC.
• The memory unit is where the program for the microprocessor is stored. The memory unit also stores input data from for processing and buffers data for output.
• The input and output sections are where the processor receives information from external devices and communicates information to external devices. The inputs might be from proximity sensors. The outputs might be connected to motor starter actuators. Input and output devices can be classified by signal type, such as digital or analogue.
• The communications interface is used to receive and transmit data on communication networks. It manages device verification, data acquisition, synchronization between user applications, and connection management. The below figure shows the basic arrangement.

Benefits of the Project

Proportional Integral Derivative (PID) controllers are widely used in industrial practice over 60 years ago. The invention of PID control is in 1910 (largely owing to Elmer Sperry’s ship autopilot) and the straightforward Ziegler-Nichols (Z-N) tuning rule in 1942. Today, PID is used in more than 90% of practical control systems, ranging from consumer electronics such as cameras to industrial processes such as chemical processes.

• In industries we need everything to precise and control for that it is best to design control system for that.

• The PID controller helps get our output (velocity, temperature, position) where we want it, in a short time, with minimal overshoot, and with little error.
• It also the most adopted controllers in the industry due to the good cost and given benefits to the industry.
• Many nonlinear processes can be controlled using the well-known and industrially proven PID controller.
• A considerable direct performance increase (financial gain) is demanded when replacing a conventional control system with an advanced one.
• The maintenance costs of an inadequate conventional control solution may be less obvious.
• The tricky part of controller design is to figure out just how much of a corrective effort the controller should apply to the process in each case. Some situation requires tighter control of the process variable than On-Off control can provide. Proportional control provides better control because its output operate linearly anywhere between fully on and fully off.
• As its name implies, its output changes proportionally to the input error signal. Proportional controller simply multiplies the error by a constant to compute its next output.

Technical Details of Final Deliverable

In industries mostly the motors are burn out because of high power or load, so we design a control system to minimize this problem. For that we design Speed control of dc motor using PID controller implementation with PLC (control system). So whenever the load is varied to the motor the speed will be varied. To constant that speed under varied load we feedback the error to the input and it compare the previous input and the difference is encounter by PID.

This Project is Trainer shape and the real time simulation is also showed on the PC. The students can easily understand the effect of varying load on the motor in Mechanical Model as well as in the PC also.The motor specification is given below.

And the project MIlestone is listed below.

Final Deliverable of the Project HW/SW integrated systemCore Industry OthersOther IndustriesCore Technology OthersOther TechnologiesSustainable Development Goals Industry, Innovation and InfrastructureRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	75810
Motor	Equipment	1	10000	10000
PLC	Equipment	1	20000	20000
Debugging cable	Equipment	1	4500	4500
Feedback sensor	Equipment	1	9500	9500
Motor driver	Equipment	1	7810	7810
Highly precise Power Supply	Equipment	1	6200	6200
Mechanical structure	Miscellaneous	1	10000	10000
ip 65 standard connector	Equipment	1	7800	7800