DC Motor Control ProjectGroup A

ALEXANDER M FUNKLAM D NGUYEN

JAKEISHA D THOMPSONPAULETTE J VERNON

ERIC G ZAISER

12/03/01

IntroductionMotor DesignMotor Construction ProblemsControl DesignControl ProblemsFinal ResultsConclusion

Project OverviewDesign, construct, and control a dc homemade motor, commutation system, control system, and a speed measurement device such that the machine assembly rotates at selected speeds

Create a detailed web-page to outline the development process

Specifications

The outer diameter of the rotor: 1.5 and 4.5 inches.The length of the rotor housing: 2 and 6 inches.A commutator must be built.Standard magnets must be usedSupply jacks must be supplied for an unknown resistance

Schedule

SCHEDULE FOR DESIGN OF DC MOTOR

August September October November December

TASKS:

27

12

22

2 16 30

3

Motor Research

Motor Design

Motor Construction

Motor Testing

Controls Research

Controls Design

Controls Construction

Controls Testing

Midterm Oral

X

Bonus Day

X

Final Competition

X

Final Oral

X

Motor DesignFour Pole MotorSimplex Lap Winding

45 windings26 gauge Copper Wire

Steel Stator – 3.5“ inner diameter and 4” outer diameter16 magnets(1” by ½“ by ¼“) acting as 4 polesJB Weld to place magnets

Steel rotor-2” diameter25 1/8” thick, 2.5” outer diameter discs; 12-0.35” diameter holes

Motor Design4 brushes alternating at 90°3/8” ShaftPolyurethane lamination

DC Permanent Magnet Motor

4 Pole Simplex Lap Winding

1.5 inch inner diameter copper pipe12 segments required for four pole operationVinyl insulation from the shaftBrush contact12 segments (2 x 0.78 inches )Epoxy to fill in slots

Commutator

Motor Construction ProblemsUneven commutator barsDrilling through copper for hooksCommutator bars popping off Misalignment of magnets in the statorFitting the bearings onto the shaftSliding of shaft as motor was spinningFriction in commutator from lack of epoxy

The Final Product

Control BasicHardware SetupInitial Research Regarding MotorsLimited Theoretical Modeling“Control Theory” group shifted to “Test & Fix” Group

Control Implementation

EncoderOpen Loop/Bonus dayPID implementationTweaking/TuningCompetition

Control System in Simulink

Control Problems

Encoder-relatedMountingCable

Motor-relatedFrictionDrift/alignment

Simulink-relatedDisappearing feedback

Final ResultsBonus Day :300 rpm 10 pointsCompetition Day: 1st PlaceAverage Steady State Error of +/- 5.33 RPMTransient score of .4165

Transient Response

ConclusionMotor design was outstandingSteady state control was outstandingControl system was outstanding

Group A is Great!!