QNET Energy Conversion Board for NI ELVIS with NI ELVIS ......Quanser QNET add-on boards for the NI...

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CAPTIVATE. MOTIVATE. GRADUATE. USER MANUAL QNET Energy Conversion Board for NI ELVIS with NI ELVIS RIO Control Module Set Up and Configuration

Transcript of QNET Energy Conversion Board for NI ELVIS with NI ELVIS ......Quanser QNET add-on boards for the NI...

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CAPTIVATE. MOTIVATE. GRADUATE. [email protected] [email protected]

USER MANUALQNET Energy Conversion Board for NI ELVIS

with NI ELVIS RIO Control Module Set Up and Configuration

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© 2016 Quanser Inc., All rights reserved.

Quanser Inc.119 Spy CourtMarkham, OntarioL3R 5H6, [email protected]: 1-905-940-3575Fax: 1-905-940-3576

For more information on the solutions Quanser Inc. offers, please visit the web site at: http://www.quanser.com

This document and the software described in it are provided subject to a license agreement. Neither the software nor this document may beused or copied except as specified under the terms of that license agreement. All rights are reserved and no part may be reproduced, stored ina retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the priorwritten permission of Quanser Inc.

Japan VCCI Notice This is a Class A product based on the standard of the Voluntary Control Council for Interference (VCCI). If thisequipment is used in a domestic environment, radio interference may occur, in which case the user may be required to take corrective actions.

Waste Electrical and Electronic Equipment (WEEE)This symbol indicates that waste products must be disposed of separately from municipal household waste, according to Directive2002/96/EC of the European Parliament and the Council on waste electrical and electronic equipment (WEEE). All products at theend of their life cycle must be sent to a WEEE collection and recycling center. Proper WEEE disposal reduces the environmentalimpact and the risk to human health due to potentially hazardous substances used in such equipment. Your cooperation in properWEEE disposal will contribute to the effective usage of natural resources. For information about the available collection andrecycling scheme in a particular country, go to ni.com/citizenship/weee.

This product meets the essential requirements of applicable European Directives as follows:• 2006/95/EC; Low-Voltage Directive (safety)

• 2004/108/EC; Electromagnetic Compatibility Directive (EMC)Caution: This is a Class A product. This product may cause radio interference in a domestic environment, inwhich case the user may be required to take adequate measures.

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Contents

Safety Information 4

1 Introduction 5

2 System Hardware 62.1 System Schematic 62.2 Modes of operation 72.3 Hardware Components 112.4 Interfaces 132.5 Supervisor 182.6 Environmental 19

3 QNET Energy Conversion Setup 20

4 Troubleshooting 224.1 You are getting ’VI Missing’ messages 224.2 The AC generator motors are not responding 22

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Safety InformationThe following symbols and definitions are interchangeably used throughout the User Manual:

Symbol Description

Caution: consult documentation for additional information

Direct Current

| On (Power) [on NI ELVIS II unit]

⃝ Off (Power) [on NI ELVIS II unit]

Table 0.1: Symbols

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1 IntroductionThe Quanser QNET Energy Conversion Board for NI ELVIS with ELVIS RIO Control Module is pictured in Figure 1.1.It is a reconfigurable system designed to teach the fundamentals of energy conversion across the electrical andmechanical domains. The modular system supports a number of different configurations and measurements of keyparameters are achievable using the resources on the ELVIS RIO. Example experiments include open and closedloop SMPS (switched-mode power supply) control, 3-phase power generation, rectification, inverters, and powersystem integration and applications.

The main QNET Energy Conversion features include:

• Linear power amplifier

• Mechanically coupled motor assembly (3-phase generator)

• Rectifier

• SMPS with configurable buck or boost topology

• Inverter and transformer

• Linear current load

Figure 1.1: Quanser QNET Energy Conversion Board for NI ELVIS with ELVIS RIO Control Module

Caution

This equipment is designed to be used for educational and research purposes and isnot intended for use by the general public. The user is responsible to ensure that theequipment will be used by technically qualified personnel only.

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2 System Hardware2.1 System SchematicThe QNET Energy Conversion provides an integrated communication interface with the NI ELVIS RIO ControlModule. The interaction between the different system components on the QNET Energy Conversion is illustratedin Figure 2.1. The NI ELVIS RIO Control Module is interfaced to the PC or laptop via USB link. The NI ELVIS RIOControl Module provides command signals to the QNET Energy Conversion components. An on board supervisoris used to safeguard the hardware and to set the mode of operation.

Figure 2.1: Interaction between QNET Energy Conversion components

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2.2 Modes of operationThe QNET Energy Conversion may be configured to represent the modes that are outlined below. This isaccomplished over a communications interface between the ELVIS RIO and the supervisor. After selecting a mode,the supervisor will automatically connect the appropriate modules on the board.

2.2.1 3-Phase Power

This mode includes the linear amplifier, as well as the 3-phase AC generator components (no rectifier).

Figure 2.2: Three phase power configuration

2.2.2 Boost Converter

This mode includes the linear amplifier, switched mode power supply (in boost) and the variable load components.

Figure 2.3: Boost converter configuration

2.2.3 Buck Converter

This mode includes the linear amplifier, switched mode power supply (in buck) and the variable load components.

Figure 2.4: Buck converter configuration

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2.2.4 Inverter

This mode includes the linear amplifier and the single phase inverter components.

Figure 2.5: Inverter configuration

2.2.5 Rectifier

This mode includes the linear amplifier, 3-phase AC generator and rectifier components.

Figure 2.6: Rectifier configuration

2.2.6 Generator-to-Boost

This mode includes the linear amplifier, 3-phase AC generator, rectifier, switched mode power supply (in boost) andvariable load components.

Figure 2.7: Generator to Boost configuration

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2.2.7 Generator-to-Boost-to-Inverter

This mode includes the linear amplifier, 3-phase AC generator, rectifier, switched mode power supply (in boost) andsingle phase inverter components.

Figure 2.8: Generator to boost to inverter configuration

2.2.8 Generator-to-Buck

This mode includes the linear amplifier, 3-phase AC generator, rectifier, switched mode power supply (in buck) andvariable load components.

Figure 2.9: Generator to buck configuration

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2.2.9 Buck-to-Inverter

Thismode includes the linear amplifier, switchedmode power supply (in buck) and single phase inverter components.

Figure 2.10: Buck to inverter configuration

2.2.10 Boost-to-Inverter

This mode includes the linear amplifier, switched mode power supply (in boost) and single phase invertercomponents.

Figure 2.11: Boost to inverter configuration

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2.3 Hardware ComponentsThe main components comprising the QNET Energy Conversion board are labelled in Figure 2.12, and are listed inTable 2.1.

ID# Description1 NI ELVIS RIO Control Module2 USB connector port to PC3 24V 2A power connector4 Status LEDs for the supervisor, 24V-2A supply and system enable5 Brushed DC motor used to drive AC generator6 Brushless DC motor used as AC generator7 Single phase inverter capacitors8 Isolated step down power transformer

Table 2.1: QNET Energy Conversion component nomenclature

Figure 2.12: General layout of QNET Energy Conversion

CautionExposed moving parts near the AC-generator assemble.

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CautionComponents can get hot near the upper right corner of the board.

2.3.1 Linear Amplifier

The QNET Energy Conversion uses a power op amp to supply either the DC motor or the SMPS, depending on themode of operation. It has a voltage compliance of 0 to 20V.

2.3.2 3-phase AC Generator and Rectifier

The QNET Energy Conversion uses the Anaheim Automation BLWR11D-24V-10000 brushless DC Motor as a3-phase AC Generator. The specification sheet can be found at: Anaheim Automation BLWR11D-24V-10000.

The generator is driven using a Micro-drives M2232U-24-GS-050 brushed DC Motor. The specification sheet canbe found at: Micro-drives M2232U-24-GS-050.

The rectifier can be dynamically configured for 3-phase or single phase operation with or without bulk capacitors of1µF and 10µF.

2.3.3 Switched Mode Power Supply

The switched mode power supply can be configured as a buck or a boost. A maximum switching frequency of25MHz is enforced for both topologies. The boost configuration is limited to a duty cycle range of 0 to 50 % and anOn-time of 150 µs. The maximum boost output voltage is 30 V.

2.3.4 Variable Load

The variable load on the QNET Energy Conversion board is a current sink. It is capable of sinking 250 mA or more,given a source above 7V with a low output impedance. Attempting to command loads in excess of 250 mA will causethe load to saturate near 300 mA.

2.3.5 1-Phase Inverter

This includes an isolated step down power transformer to a resistor load. The maximum input voltage is 30 V, whichis the maximum output from the switch mode power supply. The inverter needs a minimum voltage of 10.5 V tooperate. Once enabled, a minimum input voltage of 8.5 V must be maintained.

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2.4 Interfaces

2.4.1 Control SPI Interface

This SPI interface operates with 16-bit data at 5 MHz or lower, with CPOL = 0 (clock polarity) and CPHA = 0 (clockphase). Data is transmitted MSb (most significant bit) first. The NI ELVIS RIO Control Module acts as a master. Thisinterface is used to set the board mode, clear the watchdog and set the values of user controlled switches. The pindefinitions are defined in Table 2.2.

Def PinCSn MXP_A_DIO4CLK MXP_A_DIO5MOSI MXP_A_DIO7MISO MXP_A_DIO6

Table 2.2: Control SPI Interface pin definitions

The data input contains the raw supervisor code, as described above, as well as a board ready bit as shown inFigure 2.13a. The board ready bit is set after the board is ready to be used after changing the mode from reset. Theboard ready bit is cleared after the board is put into reset or if it enters the supervisor state.

(a) Input Data format (b) Output Data format

Figure 2.13: Control SPI 16-bit data configuration

The data output is split into two bytes. The upper byte is a preamble and the interpretation of the lower byte dependson the value in the preamble. The format is as shown in Figure 2.13b.

The preamble and lower byte behavior are as described in Table 2.3.

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Preamble Lower Byte Description

0x9A 0xAA Clear the watchdog

0xA0

0x00 Set the board mode to reset

0x01 Set the board mode to 3 phase inverter

0x02 Set the board mode to boost converter

0x03 Set the board mode to buck converter

0x04 Set the board mode to generator-to-boost

0x05 Set the board mode to inverter

0x06 Set the board mode to rectifier

0x07 Set the board mode to generator-to-boost-to-inverter

0x08 Set the board mode to generator-to-buck

0x09 Set the board mode to buck-to-inverter

0x0A Set the board mode to boost-to-inverter

0xA1

0bxxxxxxx1 Connect the transformer load switch

0bxxxxxxx0 Disconnect the transformer load switch

0bxxxxxx1x Connect the 10 µF rectifier bulk capacitor

0bxxxxxx0x Disconnect the 10 µF rectifier bulk capacitor

0bxxxxx1xx Connect the 1 µF rectifier bulk capacitor

0bxxxxx0xx Disconnect the 1 µF rectifier bulk capacitor

0bxxxx1xxx Connect the BLDC num_phases switch

0bxxxx0xxx Disconnect the BLDC num_phases switch

Table 2.3: Preamble and lower byte behavior

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2.4.2 Inverter SPI Interface

This interface is reserved exclusively for commanding the inverter voltage. The pin definitions are as described inTable 2.4.

Def PinCSn MXP_B_DIO6CLK MXP_B_DIO5MOSI MXP_B_DIO7

Table 2.4: Inverter SPI Interface pin definitions

This interface only contains data output. The inverter voltage command is signed and corresponds to the percentageof the amplitude being commanded to the inverter driver. For example -1024 commands the maximum negativevoltage and 1023 commands the maximum positive voltage. This uses the 2’s complement via 11 bits, as shown inFigure 2.14

Figure 2.14: Inverter SPI 16-bit data configuration

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2.4.3 I/O channels

The outputs are defined in Table 2.5. The inputs are defined in Table 2.6.

Name Source Min Max Conversion

Source Voltage MXP_A_A01 0 V 22 V DAC_raw = SourceV oltage0.24 ∗ADC_LSB_weight

Source Voltage MXP_B_A01 0 A 0.3 A DAC_raw = SourceCurrent18 ∗ADC_LSB_weight

SMPS PWM MXP_A_DIO10 0% 100% N/A

Inverter Command Inverter SPIInterface

-100% 100% [-1024 1023] mapped to [-1 1]

Transformer LoadSwitch

Control SPIInterface

ON OFF N/A

BLDC num_phasesSwitch

Control SPIInterface

ON OFF N/A

10 µF Rectifier bulkcapacitor

Control SPIInterface

ON OFF N/A

1 µF Rectifier bulkcapacitor

Control SPIInterface

ON OFF N/A

MXP_A_ADC_MUX_A MXP_B_DIO12 0 1 N/A

MXP_A_ADC_MUX_B MXP_B_DIO11 0 1 N/A

MXP_B_ADC_MUX_A MXP_B_DIO10 0 1 N/A

MXP_B_ADC_MUX_B MXP_B_DIO09 0 1 N/A

Table 2.5: Output pins defined in the custom FPGA code

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Name Source MuxValue

Conversion

Hall A Sensor MXP_A_DIO0 N/A

Hall B Sensor MXP_A_DIO1 N/A

Hall C Sensor MXP_A_DIO2 N/A

Linear Sink Temperature MXP_B_AI0 00 = ADC_raw−40019.5 ∗ 1000 ∗ADC_LSB_weight

BLDC B2C Voltage MXP_A_AI2 00 = (ADC_raw − 2048) ∗ 5 ∗ADC_LSB_weight

BLDC Phase B voltage MXP_A_AI1 00 = (ADC_raw − 2048) ∗ 5 ∗ADC_LSB_weight

Source Current MXP_A_AI3 00 = ADC_raw−13522 ∗ADC_LSB_weight

Rectifier Diode Current MXP_A_AI0 00 = ADC_raw−13522 ∗ADC_LSB_weight

SMPS Output Voltage MXP_B_AI2 00 = ADC_raw ∗ 11 ∗ADC_LSB_weight

BLDC Phase A Voltage MXP_A_AI1 01 = (ADC_raw − 2048) ∗ 5 ∗ADC_LSB_weight

BLDC Phase A Current MXP_A_AI2 01 = (ADC_raw − 2048) ∗ADC_LSB_weight

BLDC Phase C Current MXP_A_AI3 01 = (ADC_raw − 2048) ∗ADC_LSB_weight

SMPS Output Current MXP_B_AI3 01 = ADC_raw−13522 ∗ADC_LSB_weight

Linear Sink Current MXP_B_AI0 01 = ADC_raw18 ∗ADC_LSB_weight

BLDC A2B Voltage MXP_A_AI1 10 = (ADC_raw − 2048) ∗ 5 ∗ADC_LSB_weight

BLDC Phase C Voltage MXP_A_AI2 10 = (ADC_raw − 2048) ∗ 5 ∗ADC_LSB_weight

BLDC Phase B Current MXP_A_AI3 10 = (ADC_raw − 2048) ∗ADC_LSB_weight

Transformer Output Voltage MXP_B_AI0 10 = (ADC_raw − 2048) ∗ 10 ∗ADC_LSB_weight

SMPS Input Voltage MXP_B_AI3 10 = ADC_raw ∗ 11 ∗ADC_LSB_weight

Source Temperature MXP_A_AI0 11 = ADC_raw−40019.5 ∗ 1000 ∗ADC_LSB_weight

BLDC C2A Voltage MXP_A_AI2 11 = (ADC_raw − 2048) ∗ 5 ∗ADC_LSB_weight

Transformer Input Voltage MXP_B_AI0 11 = (ADC_raw − 2048) ∗ 10 ∗ADC_LSB_weight

Source Voltage MXP_A_AI3 11 = ADC_raw ∗ 7.49 ∗ADC_LSB_weight

SMPS Input Current MXP_B_AI3 11 = ADC_raw−13522 ∗ADC_LSB_weight

SMPS Inductor Current MXP_B_AI3 00 = ADC_raw−13522 ∗ADC_LSB_weight

Table 2.6: Input pins defined in the custom FPGA code

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2.5 SupervisorOn power-up, the QNET Energy Conversion goes into a reset mode. In this mode, all outputs from the NI ELVISRIO Control Module are disabled, the external 24 V supply is electronically disconnected from the circuit and allswitches go to safe values. The SPI interface can be used to change the mode from reset to one of the modesidentified in subsection 2.2. Depending on the mode that is selected, some of the supervisor conditions in Table 2.7will be enforced. The purpose of this is to prevent the user from accidentally damaging the hardware. If any of thesupervisor conditions are violated, the QNET Energy Conversion will go into a supervisor state. The supervisor stateis similar to reset mode in that the external 24 V supply is electronically disconnected, all outputs are disabled andswitches are set to safe states. The only way to get the QNET Energy Conversion out of the supervisor state is toput the device back into reset mode, or cycle the power.

ErrorCode

Name AlwaysActive?

Description/Cause

0x0000 None Yes No supervisor violations detected.0x0001 Power Good Yes External 24 V power supply brownout or not detected at all.0x0002 Watchdog Expired Yes A watchdog must be cleared every 25 ms (cleared over SPI

interface).0x0004 Boost over-voltage Yes The voltage at the output of the SMPS exceeds 30 V.0x0008 Boost ON-time limit No Boost switch was conducting for more than 150 µs.0x0010 Boost max duty cycle No PWM Duty Cycle exceeded 50 % for boost switch.0x0020 Inverter

under-voltageNo The inverter needs to be supplied with a minimum voltage

in order to operate. It will be enabled when it’s supplyvoltage crosses around 10.5 V. After it has been enabled, thissupervisor condition is violated if the inverter supply voltageever dips below around 8.5 V.

0x0040 DC Motor Stall No If the DC motor is driven with more than 14 V, the Hallsensors will be monitored by the supervisor to determinewhether the motor is stalled.

0x0080 Buck under-voltage No The buck converter needs to be supplied with a minimumvoltage in order to operate. It will be enabled when it’s supplyvoltage crosses around 6.5 V. After it has been enabled, thissupervisor condition is violated if the buck supply voltageever dips below around 5.5 V.

0x0100 SMPS maximumfrequency

No SMPS PWM frequency exceeds 25 kHz.

0x0200 Sourceover-temperature

Yes Linear Amplifier temperature sensor exceeds around 45◦C.

0x0400 Sinkover-temperature

Yes Variable Load temperature sensor exceeds around 70◦C.

Table 2.7: QNET Energy Conversion supervisor conditions

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2.6 EnvironmentalThe QNET Energy Conversion is designed to function under the following environmental conditions:

• Standard rating

• Indoor use only

• Temperature 5 ◦C to 40 ◦C

• Altitude up to 2000 m

• Maximum relative humidity of 80 % up to 31 ◦C decreasing linearly to 50 % relative humidity at 40 ◦C

• Pollution Degree 2

• Mains supply voltage fluctuations up to ±10 % of the nominal voltage

• Maximum transient overvoltage 2500 V

• Marked degree of protection to IEC 60529: Ordinary Equipment (IPX0)

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3 QNET Energy Conversion SetupThe procedure to install the QNET Energy Conversion module on the NI ELVIS RIO Control module is detailed inthis section. The NI ELVIS II+ and NI ELVIS RIO Control module components used in the installation procedure arelocated and marked by an ID number in Figure 3.1, and described in Table 3.1.

Note: The NI ELVIS RIO Control Module and QNET Energy Conversion are compatible with both the NI ELVIS IIand NI ELVIS II+.

Caution

If the equipment is used in a manner not specified by the manufacturer, the protectionprovided by the equipment may be impaired.

Figure 3.1: Components on NI ELVIS II+ and NI ELVIS RIO Control module

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ID# Description1 NI ELVIS II+2 NI ELVIS RIO Control Module3 Power Cable for NI ELVIS II+4 USB Connection between ELVIS RIO CM and PC5 Active LED6 Prototyping Board power switch7 Prototyping Board power LED8 NI ELVIS RIO Control Module power LED9 MXP Connector (male end)

Table 3.1: NI ELVIS II+ and ELVIS RIO CM components

CautionDo NOT make the following connections while power is supplied to the hardware!

Caution

The unit is provided with a grounded cord to be used with a properly grounded outletonly, this is a safety feature, do not disable it.

Follow these instructions to setup a QNET Energy Conversion board on an NI ELVIS II+:

1. Position the handle of the QNET Energy Conversion over the bracket at the front of the NI ELVIS II+ to ensureproper mechanical support. Slide the female MXP connector of the QNET Energy Conversion module into themale MXP connector on the NI ELVIS RIO Control Module. Make sure it is connected properly.

2. Connect the USB cable from the NI ELVIS RIO Control Module to the PC. Note that a USB connection to theNI ELVIS II+ is not required.

3. Connect the NI ELVIS II+ power cable.

4. Connect the supplied QNET power supply to the 24V power connector for motors on the QNET EnergyConversion, as labeled in 2.1.

5. Power the NI ELVIS II+ by turning ON the System Power Switch on the rear panel, and the Active LED shouldturn orange in under 2 s.

6. Turn ON the Prototyping Board Power switch, and the Prototyping board power LED as well as the NI ELVISRIO Control Module power LED should turn green in under 2 s.

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4 TroubleshootingMost hardware/software errors are reported through the Supervisor. See 2.5 for more details. Please review thefollowing before contacting Quanser’s technical support.

1. Verify the connections outlined in Section 3 in this guide.

2. Make sure all cables are firmly connected.

4.1 You are getting 'VI Missing' messages1. Make sure you installed all the LabVIEW add-ons listed in the Quick-Start Guide.

2. Verify that the correct LabVIEW version is installed (2016, as the VIs are not backward compatible).

4.2 The AC generator motors are not responding1. Ensure that the 2-pin cable to the brushed DC motor is connected.

2. Ensure that the 8-pin 3-phase AC connector coming out of the AC generator is connected.

3. Ensure that the supervisor isn’t reporting any errors and that the 24V power is connected.

4. Ensure that the DC motor - AC generator assembly is freely moving.

If problems still persist, obtain support from Quanser by going to www.quanser.com and click on the Tech Supportlink. Fill in the form with all the requested software and hardware information as well as a description of the problemencountered. Also, make sure your e-mail address and telephone number are included. Submit the form and atechnical support person will contact you.

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[email protected] [email protected]

USER MANUALQNET Energy Conversion Board for NI ELVIS

with NI ELVIS RIO Control Module Set Up and Configuration

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Quanser QNET add-on boards for the NI ELVIS platform teach introductory control topics in undergraduate labs cost-effectively. All QNETs are offered with comprehensive courseware that have been developed to enhance the student learning experience.

To request a demonstration or quote, please email [email protected]

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