This document describes a project to improve the process control of a hydraulic pressure profile generator for testing master cylinders. The current test rig uses a PLC for control which has issues with sampling accuracy and software loop times at higher pressures. The project aims to develop a dedicated FPGA-based PID controller to generate various pressure profiles for steering and braking applications with improved stability and control at pressures over 100 bar/sec. Key steps include selecting sensors, actuators, and an FPGA controller, system identification, PID tuning, and comparing the performance of the PLC and FPGA controllers.
This document describes a project to improve the process control of a hydraulic pressure profile generator for testing master cylinders. The current test rig uses a PLC for control which has issues with sampling accuracy and software loop times at higher pressures. The project aims to develop a dedicated FPGA-based PID controller to generate various pressure profiles for steering and braking applications with improved stability and control at pressures over 100 bar/sec. Key steps include selecting sensors, actuators, and an FPGA controller, system identification, PID tuning, and comparing the performance of the PLC and FPGA controllers.
This document describes a project to improve the process control of a hydraulic pressure profile generator for testing master cylinders. The current test rig uses a PLC for control which has issues with sampling accuracy and software loop times at higher pressures. The project aims to develop a dedicated FPGA-based PID controller to generate various pressure profiles for steering and braking applications with improved stability and control at pressures over 100 bar/sec. Key steps include selecting sensors, actuators, and an FPGA controller, system identification, PID tuning, and comparing the performance of the PLC and FPGA controllers.
This document describes a project to improve the process control of a hydraulic pressure profile generator for testing master cylinders. The current test rig uses a PLC for control which has issues with sampling accuracy and software loop times at higher pressures. The project aims to develop a dedicated FPGA-based PID controller to generate various pressure profiles for steering and braking applications with improved stability and control at pressures over 100 bar/sec. Key steps include selecting sensors, actuators, and an FPGA controller, system identification, PID tuning, and comparing the performance of the PLC and FPGA controllers.
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HYDRAULIC PRESSURE
PROFILE GENERATOR GUIDED BY EXT GUIDE: Mr. K.KRISHNAPPA MANAGER , TECHNOLOGY DEVELOPMENT (ELECTRICAL DEPT) BRAKES INDIA PVT LTD, PADI- 600050 .
INT GUIDE :PROF.G DHARANI BAI PRESENTED BY : MADHUSUDANAN A
ASSOCIATE PROFESSOR (DEPT OF SENSOR AND BIOMEDICAL) (16MSS0011) VIT UNIVERSITY,VELLORE-632014. OBJECTIVE
• To improve the process control of the testing system
• Sampling and loop time must be accurate for the system ABSTRACT • Master Cylinder is a component that converts pedal effort into hydraulic pressure using brake fluid. It’s necessary to test and validate the performance of Master Cylinder. • At present in Tire 1 Automotive company are utilizing a test rig framework to examine the performance of master cylinder. • Stability Of Test Rig becomes problem when a PLC involved due to sampling and Software Loop. • System is analysed and dedicated FPGA based PID employed. • Various profiles are generated and used for steering and braking applications. FLOW METHODOLOGY INPUT SET VALUE FOR BOTH PROCESS BLOCK DIAGRAM OF THE EXISTING SYSTEM PLC PROGRAM PID PART OUTPUT OF EXISTING SYSTEM FOR VARIOUS PEDAL PRESSURE DRAWBACKS
• Control of pressure beyond 100 bar/sec is difficult.
• Hold Time is more. • Peak deviation effects the process BLOCK DIAGRAM OF THE PROPOSED SYSTEM SELECTION OF SENSOR ,ACTUATOR AND CONTROLLER • ACTUATOR-LINATOR SERVO VALVE: Power:24V DC Linearity:1% Full Scale Based on Valve Hysteresis: <1% Full Scale Switching Time: 0-100% about 5ms,+/-100% about 7ms CONTROLLER-RHYTRON FPGA BASED PID : Power supply 24VDC. 16 in-/outputs 24V, optional 48 in-/outputs 24V, input current 2mA, output current max. 100mA. A/D resolution 16 bit and D/A resolution 14 bit. SELECTION OF SENSOR ,ACTUATOR AND CONTROLLER • Based on the industrial requirements among different makes of sensor,actuator and controller,i.e., the following make is chosen: • SENSOR-WIKA PRESSURE TRANSMITTER: Range:0-250 bar Non-Linearity:0.125% Output: 0-10v,4-20mA SYSTEM IDENTIFICATION • System identification is a technique used for creating mathematical model of the system. • An open loop measurement setup is developed and experiment is performed. • The Response Of the Curve is Analysed and transfer function of the model is build up. DATA ACQUISITION USING LabVIEW DATA ACQUISITION USING Lab VIEW ACQUIRED RESPONSE TRANSFER FUNCTION MODELLING
• From the above obtained graph ,inference provide the following details: • It is first order system with gain k=30.53 and time constant tau=0.0146 • The general first order system is given by: G(s)=k/1+tau S • The obtained transfer function is G(S)=30.53/1+0.146S CHARACTERISTICS OF TRANSFER FUNCTION FROM STEP RESPONSE • Rise time,Tr=0.321s • Settling time,Ts=0.571s PID TUNING FOR THE UNCONTROLLED PLANT
• To improve the stability and controllability of the plant ,PID controller is designed and tuned manually with the guidance from PID TUNER available in MATLAB. TUNING PARAMETERS ALGORITHM FLOW
• Interact with system model
• Identify linearization points • Linearize model over region • Get the specification of controller • Determine controller parameter • Verify the matching of controller parameters with specification • Apply controller to model OUTPUT RESPONSE WITH INPUT CHARACTERISTICS OF OUTPUT RESPONSE PROPOSED PROCESS BASED TEST RIG OUTPUT OF PROPOSED PROCESS FOR VARIOUS PEDAL PRESSURE COMPARISION OF RESULTS FOR PLC AND FPGA FOR HIGH PEDAL PRESSURE STATISTICAL ANALYSIS FOR PLC AND FPGA PERFORMANCE GRAPHICAL RESULT FOR PERFORMANCE OF PLC AND FPGA REFERENCES
• Ǻström, K. J., & Hägglund, T. (1995). PID controllers: theory, design, and tuning. Instrument Society of America, Research Triangle Park, NC, 10.
• Wang, Q. G., Fung, H. W., & Zhang, Y. (1999). PID tuning with exact gain and phase margins. ISA transactions, 38(3), 243-249.
• Visioli, A. (2012). Research trends for PID controllers. Acta Polytechnica,
52(5).
• Mikhalevich, S. S., Baydali, S. A., & Manenti, F. (2015). Development of a
tunable method for PID controllers to achieve the desired phase margin. Journal of Process Control, 25, 28-34. REFERENCES
• Ang, K. H., Chong, G., & Li, Y. (2005). PID control system analysis, design, and technology, IEEE transactions on control systems technology, 13(4), 559-576.
• Åström, K. J., & Hägglund, T. (2006), Advanced PID control, In the
Instrumentation, Systems, and Automation Society.
• Day, A. J. (2014), Braking of road vehicles, Butterworth-Heinemann.
• Gahinet, P., Chen, R., & Eryilmaz, B. (2013). U.S. Patent No. 8,467,888. Washington, DC: U.S. Patent and Trademark Office. THANK YOU
B.Sc. of Control Engineering Graduation Project "Electro Pneumatic Technology Study, Data Measurement and Develop A Control System For Pressure Process Rig 38-714 by Using Arduino"
B.Sc. of Control Engineering Graduation Project "Electro Pneumatic Technology Study, Data Measurement and Develop A Control System For Pressure Process Rig 38-714 by Using Arduino"
