Project Informationpoisson.me.dal.ca/.../Fall_Design_Report_Team11_V3.docx · Web viewA Simulink block diagram was developed using existing diagrams for magnetic levitation. Moving

Team #11 Embodiment Design Report

MECH 4010 & 4015Design Project I

FALL DESIGN REPORT

Magnetic Levitation Demonstration ApparatusTeam #11

Ajay PuppalaFuyuan Lin

Marlon McCombieXiaodong Wang

Submitted: December 3, 2013

MECH4010/4015 Magnetic Levitation Demonstration Apparatus Page 1 of 51

Team #11 Fall Term Report

Table of Contents

List of Figures..................................................................................................................................4

List of Tables...................................................................................................................................4

1. Project Information.................................................................................................................5

1.1. Project Title.....................................................................................................................51.2. Project Customer.............................................................................................................51.3. Group Members...............................................................................................................51.4. Useful Definitions and Acronyms...................................................................................5

2. Executive Summary...............................................................................................................6

3. Background and Context........................................................................................................7

3.1. Background and Overall Objective.................................................................................73.2. Requirements...................................................................................................................8

4. Summary of Design Alternatives...........................................................................................9

5. System Architecture.............................................................................................................11

5.1. Selected Design.............................................................................................................115.2. Subsystems / Components.............................................................................................11

6. Levitation: Electromagnet....................................................................................................14

6.1. Component Description.................................................................................................146.2. Component Design........................................................................................................14

7. System Feedback: Sensor.....................................................................................................17

7.1. Component Description.................................................................................................17

8. Microcontroller Unit.............................................................................................................18

8.1. Component Description.................................................................................................18

9. Signal Conditioning : Control Circuit..................................................................................20


10. User Interface.......................................................................................................................23




11. Feasibility & Risk Assessment.............................................................................................25

12. Testing and Verification Plan...............................................................................................26

13. Cost Estimates & Budget.....................................................................................................27

14. Progress Report....................................................................................................................29

15. Future Considerations...........................................................................................................31

15.1. Preliminary Apparatus Design......................................................................................31

16. Project Management Plan.....................................................................................................33

16.1. Organizational Responsibilities.....................................................................................3316.2. Work Breakdown Structure...........................................................................................3416.3. Schedule........................................................................................................................4216.4. Specialized Facilities and Resources.............................................................................44

16.4.1. Facilities..............................................................................................................4416.4.2. Additional Advisors............................................................................................44

17. References............................................................................................................................45

Appendix A Simulink block diagram for electromagnetic levitation............................................i

Appendix C Sample Programs.......................................................................................................iii

Appendix B Design Calculations for Electromagnet....................................................................v



List of Figures

Figure 1 Design Alternatives.....................................................................................................9Figure 2 Single electromagnet design with Hall Effect sensor.................................................11Figure 3 General Schematic of demonstration device...............................................................12Figure 4 Functional block diagram for the magnetic levitation apparatus................................13Figure 5 Magnetic field generated by the current carrying coil (courtesy of

superconductors.solidchem.net)..................................................................................14Figure 6 Picture of Hall Effect Sensor......................................................................................17Figure 7 Picture of Arduino UNO.............................................................................................18Figure 8 Electromagnetic coil driving circuit (Mekonikuv).....................................................21Figure 9 Sensor with amplifier circuit (Mekonikuv).................................................................21Figure 10 Arduino Simulink block diagram example................................................................24Figure 11 Hall Effect sensor output with and without permanent magnet (object)...................29Figure 12 Actual control circuit.................................................................................................30Figure 13 Proposed Apparatus design.........................................................................................32Figure 14 Fall term work breakdown structure...........................................................................35Figure 15 Research work breakdown structure...........................................................................36Figure 16 Product design work breakdown structure..................................................................37Figure 17 Concept evaluation breakdown structure....................................................................38Figure 18 Fall term WBS critical path chart...............................................................................39Figure 19 Winter term work breakdown structure......................................................................40Figure 20 Winter term WBS critical path chart..........................................................................41Figure 21 Simulink block diagram for electromagnetic levitation................................................i

List of Tables

Table 1 Selected criteria (highlighted) for physical apparatus design.......................................9Table 2 Arduino UNO specification summary........................................................................19Table 3 Component and materials cost breakdown.................................................................27Table 4 Required engineering expertise...................................................................................33Table 5 Allocation of team responsibilities.............................................................................34Table 6 Summary of project tasks for fall 2013 term..............................................................42Table 7 Breakdown of remaining hours of work for the winter break....................................43Table 8 Summary of project tasks for winter 2013 term.........................................................43Table 9 Design calculations for electromagnet..........................................................................v



1. Project Information

1.1. Project TitleMagnetic Levitation Demonstration Apparatus

1.2. Project CustomerDr Robert BauerProfessorMechanical Engineering DepartmentDalhousie University

1.3. Group MembersAjay Puppala email: [email protected] Lin email: [email protected] McCombie email:[email protected] Wang email: [email protected]

1.4. Useful Definitions and AcronymsPID - Proportional Integral Derivative ControlP - Proportional ControlPI - Proportional Integra ControlGUI - Graphical User InterfacePC - Personal ComputerPPE - Personal Protective EquipmentPCB - Printed Circuit BoardMagLev - Magnetic LevitationEM - ElectromagnetMCU - Microcontroller UnitPWM - pulse width modulationI/O - Input/outputEOPD - Electro-Optical Proximity DetectorRISC - Reduced instruction set computingCMOS - Complementary metal-oxide semiconductorAVR - no meaningISCP - In-circuit serial programmingEEPROM - Electrically Erasable Programmable Read-Only MemorySRAM - Static random-access memoryDC - Direct currentAC - Alternating currentWBS - Work Breakdown Structure


Team #11 Embodiment Design Report

2. Executive Summary

This report outlines the design process of the Magnetic Levitation Demonstration

Apparatus through the fall term of the final year Mechanical Engineering design project at

Dalhousie University. The contents of the document include project requirements, design

alternatives, subsystems for the selected design, current progress, future considerations,

testing plan, updated budget, technical drawings, and finally a plan of action for the winter

term.

The goal of our project is to design and build a portable and compact device that

magnetically levitates an object to demonstrate different control design theories presented in

MECH4900 Systems II. The theories must be tested using Mathworks Simulink. A Graphical User

Interface (GUI) in Simulink is desired so users can interact with the system conveniently.

The group made significant progress during the term in building a prototype for magnetic

levitation. A coil driver circuit and sensory signal conditioning circuit were built (using an existing

example) and were successfully tested using the Arduino; however, levitation has not been

achieved. The group is confident to achieve levitation in a day or two of working on the code

necessary to control the Arduino to perform levitation. A Simulink block diagram was developed

using existing diagrams for magnetic levitation. Moving forward, the group has planned to complete

the necessary programming for levitation and continue work on the Simulink block diagram during

the winter break. Additionally, materials required for the prototype will be ordered as most of them

were sourced from Dr. Bauer, our project supervisor, and Mr. Jonathan MacDonald, the Electrician

for the Mechanical Engineering department at the university.

The work breakdown structure (WBS) and corresponding schedule was completed and is

attached to this document in the Project Management section. The group has a very good

understanding of the project progress and tasks ahead.



3. Background and Context

3.1. Background and Overall Objective

Demonstrations provide the opportunity for students to predict theoretical outcomes of real

life applications of course material which in turn allow them to confirm their initial understanding

of those same concepts. Where students are not able to confirm their understanding of a given

concept, the instructor can use demonstrations to discuss any differences between their initial

understanding and what the demonstration actually shows. Visual demonstrations help to bridge

the gap between the applications of course material and what is being taught in class; this can be

illustrated using graphical analyses of the concepts to represent real life examples. Consequently,

the purpose of this project is to design a magnetic levitation demonstration apparatus or the

purpose of demonstrating the different design control theories presented in the Mechanical

Engineering course MECH4900-Control Systems II. The apparatus is intended to serve as a platform

for a real-life example of the implementation of control theories such as proportional, derivative,

integral, and a combination of the three control methods. Control Systems II not only makes use of

the design theories mentioned but also includes the graphical representation and analyses of these

control theory responses. The use of a live demonstration will provide real-life feedback of the

manipulation of control theories so that students may see, first-hand, the application of the course

material. Although diagrams may be a step further to having a better visual understanding of a

concept, a demonstration that produces live feedback vastly improves the delivery of course

material. This concept is similar to a salesman increasing the appeal of a product by showing its

many uses through infomercials; i.e. demonstrations of the basic use of a known concept (e.g.

blending with the Magic Bullet). The only difference for course material from this analogy is that

the concepts being taught are new to students and may not be initially understood from course

lectures.

Thus, the scope of our project is to design and build a portable and compact device that

magnetically levitates an object to demonstrate different control design theories presented in

MECH4900 Systems II.



3.2. Requirements Purpose

o Build portable demonstration device

o Magnetically levitate object

o Demonstrate theories presented in MECH4900(4905) Control Systems II

Visual Requirements

o Shall be viewable from the back of a classroom (15-20ft) and/or using cameras

o Levitate object for range of approximately 15 mm

User Convenience & Safety

o Easy to carry; i.e. lightweight

Levitated object will be approximately 30mm in diameter and weigh no

more than 10 g

Apparatus shall be no more than 1.5 kg (or about the weight of a standard

laptop)

No steel toed boots shall be required for transportation of apparatus (i.e.

there shall be no crushing potential to user’s feet)

o Apparatus shall pose no electrical risk to user

Power Requirements

o Conventional 120 VAC input from a conventionally purchased (and thus

replaceable) power supply

User Interactive Requirements

o User shall interact with the device using a graphical user interface (GUI)

o Device shall be ready to operate once plugged into PC

Demonstrative Requirements

o Comparison of desired, simulated, manipulated, and measured controller variables

o Nyquist plots

o Bode diagrams

o Lag, lead, lag-lead compensation techniques

o P, PI, PID control

Miscellaneous

o Shall be an active controller

o Budget no more than $1,000



4. Summary of Design Alternatives

Different concepts were generated based on different levitation techniques, object motion,

and sensors shown in Table 1. The circuitry and microcontroller were excluded from the concept

selection as these components do not affect the physical design of the apparatus.

Table 1 Selected criteria (highlighted) for physical apparatus design

Levitation Technique

ObjectMicrocontroller Sensor

Material Shape MotionPermanent

MagnetsChrome Steel

Rectangular prism

Horizontal Arduino Hall Effect

Electromagnetic Regular Steel Circular disk VerticalLEGO Mindstorm

NXT 2.0Reflective

Electrodynamics Neodymium Solid sphere Angled BeagleBoard Optical ProximitySuperconducting Composite Hollow sphere Altera DE2 Photoelectric

DiamagneticCapacitive

DisplacementInductive ProximityUltrasonic

The following figure includes the major concepts generated during the brainstorming

process of the design selection process.

Figure 1 Design Alternatives

The first concept is the single electromagnet with a Hall Effect sensor. This design is simple

and easy to configure. A major disadvantage of this design is that it the Hall Effect sensor senses

magnetic field strength which must be converted to a position for the levitated object. To



compensate for this problem, a photoelectric sensor can be used (concept 2) in which case the

stand design has to be changed to accommodate LED bulbs and an associated photoelectric sensor.

An underlining problem for both the first and second concepts is that the field strength may not be

sufficient to levitate the object in the desired range (see requirements).

Consequently, the next few design alternatives were proposed to allow a greater magnetic

field strength for the system. Concept 3 shows two electromagnets which could possibly extend the

range of the magnetic levitation. However, this design may pose other problems in terms of stability

and obtaining levitation since two electromagnets must be coordinated to achieve levitation.

Alternative four was proposed to improve stability by using electrodynamic levitation instead of

electromagnetic with multiple coils in a parallel configuration. The major cause for concern for

concept four is that the visibility of levitation may be reduced due to obstruction by the coils. Also,

the total cost for building the device would increase substantially considering the number coils

used in the design.

Concept five, a MagLev Track Design, is different from the latter designs. For the MagLev

Track design, the levitating disk is properly constrained to move along a vertical path. This implies

proper stability for motion of the object and levitation can be seen through the gaps between the

electromagnets. The demonstrative requirements could jeopardized as it may seem that the disk is

supported by the tracks. Additionally, it would cost more money to build compared to other design

due to the increased material needed for the tracks.

The last concept considered for design alternatives is Concept six, a Torodial coil design.

The object is levitated in a circular transparent tube with electromagnets at regular intervals. When

power is supplied to the magnets, the object is expected to spin depending on the force of attraction

and/or repelled by the magnets. The major trouble with this design is actually building and testing

the device. The complexity of the design is too high and if it can be done it will be very impressive.

All the concepts consider for design alternatives were evaluated using a rubric that is

presented in the Appendix. The basic requirements are weighted the most for selection criteria

compared to the parts, design, and cost assessment. Based on the evaluation, it was decided that

the single coil electromagnetic sensor is best for the design. Consequently, concepts one

and two were determined to be the best solutions.



5. System Architecture

5.1. Selected DesignIt was decided to move forward with a single coil electromagnetic source as shown in Figure 2,

using a Hall Effect sensor. A single coil electromagnet was chosen for the design since it is more

simplistic to build and test and has been used for electromagnetic levitation before (Mekonikuv

Blog, Lieberman). The Hall Effect sensor was chosen mainly because it was used in the example

used for the coil driving and sensor amplifying circuit by Lieberman. It is important to note that all

the above components were also chosen because of their low cost.

Figure 2 Single electromagnet design with Hall Effect sensor

5.2. Subsystems / Components

Figure 3 shows a general schematic of the system components needed to build a functional

magnetic levitation demonstration apparatus based on the specified requirements.



Figure 3 General Schematic of demonstration device

For magnetic levitation to be achieved for the purpose of demonstrating various design

techniques presented in Control Systems II, a user would need to vary a magnetic field which in

theory should vary the position of a levitating object. A varying magnetic field is most commonly

achieved by a non-permanent magnet or more specifically by using an electromagnet.

Electromagnets allows for a varying input current to be applied to them for the purpose of

manipulating a magnetic field and hence the position of a magnetically levitating object. In Figure 3,

the electromagnet is represented by the magnetic source.

It is required to use MATLAB/Simulink to design controllers for demonstration of the

different control theories presented in Systems II. The designed controllers must then be able to

control the apparatus to achieve the desired control being demonstrated; this is achieved through

the microcontroller unit. Using MATLAB/Simulink a user will be able to communicate with the

microcontroller which would then execute the desired I/O signals to perform the desired control of

the electromagnetic field. Once this communication is achieved, some form of feedback becomes

necessary to inform the designed controller of the output result of its input to the electromagnet. A

sensor will be responsible for providing this feedback. Generally, the microcontroller would be

instructed, by the user/designed controller through MATLAB/Simulink, to retrieve necessary data

from the sensor during the implementation of the control demonstration. The microcontroller then

sends this information back to MATLAB/Simulink where it is presented to the user in graphical

form.

The amount of current and voltage required to power an electromagnet (usually 12V) to

levitate a reasonably visible object is more than the amount that can be supplied by a

microcontroller unit which usually gives a maximum output voltage of 5V. Consequently, an

external power supply is required. Therefore, before any input is given to the electromagnet or any

data is retrieved from the sensor, some form of signal conditioning is required to:



1. Maintain a relatively steady magnetic field

2. Sensitize system feedback

3. Protect the system and the user from electrical harm

Signal conditioning is handled by the circuitry. In order to maintain a steady magnetic field, a steady

input current must be supplied to the electromagnet. In addition, a more sensitive sensor would

produce a more sensitive feedback on the position of the levitating object. Finally, it is required to

design and build a safe-to-use apparatus; thus, it is required to have protective measures designed

into the systems signal transmission so that users are protected from electrical injury and the

apparatus is protected from electrical damage. The next figure summarizes the required

functionality of the operating device. The final design shall meet these major functionality

requirements.

Figure 4 Functional block diagram for the magnetic levitation apparatus

In addition, an Arduino UNO was used for the project because it was one of two readily available

microcontrollers for testing from the University. The other microcontroller was a LEGO

Minsdstorms NXT 2.0 but this microcontroller was decided against because it is more expensive

than the Arduino. The requirements of the microcontroller are minimal; i.e. not many I/O digital or

analog pins are required for any of the design alternatives presented. The required I/O capabilities

of the microcontroller can be achieved with either the Arduino or LEGO NXT.


INPUT

Control method generated in MATLAB/Simulink

Current supplied to the magnetic coil

PROCESSExecute the control method from

MATLAB/Simulink through microcontroller

Maintain the desired position of a levitated object using position

feedback from sensor(s)

Record data from sensor(s) over a specified duration of the

demostration

OUTPUT

Position feedback of object from sensor

Graphical display of recorded data


6. Levitation: Electromagnet

6.1. Component DescriptionElectromagnets are a type of magnet that can generate a magnetic field when current is

allowed to pass through it (see figure 4). The field induces flux on ferromagnetic material that is

introduced in the field. It is important to design an electromagnet that would meet the

requirements of the project in terms of range of levitation of the object, required flux to hold the

object in place, duration of levitation, and power supply limitations. Off the shelf electromagnets

are available; however, they are designed and used for different purposes. Finding the right one and

testing it would be cumbersome. Instead, designing an electromagnet based on the required

strength of the magnetic field is suitable and most appropriate for this project.

Figure 5 Magnetic field generated by the current carrying coil (courtesy of superconductors.solidchem.net)

6.2. Component DesignThe electromagnet design is based on a few assumptions which are listed as follows:

The magnetic ball is subjected to gravitational and magnetic forces

air friction and damping effects are legible

The air gap range is assumed to be between 30 to 50mm

The electromagnet core diameter is 30mm and its length is 100mm

The number of turns in the solenoid is 1000 turns

The diameter of the levitated object is 25mm

The length of solenoid is 100mm and

The stacking factor is 0.9



Based on assumptions made on the diameter of the levitating object as well as the density of steel, it

is easy to get the volume as well as the mass of levitating objects. Air gap is an important parameter

that will determine the amount of current that goes through the electromagnet and the force

required to levitate the magnetic ball. Since the air gap is assumed, the force balance on the object is

Fmagnet=Fgravity=mg=0.01kg∗9.81ms2 =0.981kg, where m is the mass of the object, g is

gravitational acceleration. Pole area is calculated as A=0.0017m2 with the magnetic force, the

magnetic field needed to levitate the object can be calculated by using the following equation:

B= 2√ 2∗μo∗FmagnetA

=2√ 2∗(4∗π∗10−7)∗0.981

0.0017=0.0027wb /m2

where F is the magnetic force (N), B is the magnetic field generated by the electromagnet (T), A is

the pole area of the electromagnet (m2), and µo is the permeability of free space for air it is always

4 x 10π -7 HM-1. The calculation is to estimate the maximum magnetic field needed. Another factor is

that the magnetic field B saturated at certain value, which is approximately 1.6T. This will set a limit

on the maximum force per unit core area that the electromagnet can exert The strength of magnetic

field B can be used to calculate the flux density, Ф in the air gap ,A the surface area of magnetic core

using the equation:

Φ=BA

The magnetizing force H in the air gap can be calculated using the following equation:

H= Bμo

= 0.00274∗π∗10−7 =2145.35 AT /m

The magneto- motive force (mmf). It primarily depends on magnetizing force, H and air gap l. It is

possible to calculate the current value based on the assumption made on the air gap and number of

turns that are mounted on the magnetic core. The following is the equation used to calculate the

current,

I=mmfN

=H ×lN

=2145.35∗0.011000

=0.714 A

The current value will be used to choose the wire gage. Each gage has the maximum current that

can tolerate. It is necessary to compare the calculated current values with those limits on each gage

wire. Finally the gage 30 wire is chosen. The wire diameter for gage 30 wire is 0.254mm.The

maximum number of turns on the first layer is 69.38 calculated by dividing the length of solenoid

by the wire diameter of gage 30. The total number of layers is 1.7 calculated by total number of

turns (1000) dividing the total number of turns on the first layer and stack factor of 0.9. The total



length of wire is found to be 69.38m . the total length of wire for the cylinder is 12.29 m or 40 ft

approximately. Based on the unit resistor of chosen wire, it is easy to calculate the resistance of

wire is 0.32Ω (Shuaibu & Adamu).



7. System Feedback: Sensor

7.1. Component DescriptionThe Hall Effect sensor was chosen for the project as it is a commonly used magnetic sensor

found most commonly in motor vehicles to detect the position of rotating parts. Figure 6 shows an

example of a Hall Effect sensor.

Figure 6 Picture of Hall Effect Sensor

The Hall Effect sensor is an analog position sensor that operates by generating a steady electrical

output, when excited, which can be altered to a higher state when a magnetic field is placed near its

body (Honeywell SS49 datasheet). The Hall Effect sensor output voltage intensifies with decreasing

distance between its body and a magnetic source. The Hall Effect sensor is an important component

of the apparatus as it is responsible for position sensing of the levitating object and thus, for

providing position feedback to designed controllers.



8. Microcontroller Unit

8.1. Component DescriptionThe selected Microcontroller for the project is the Arduino UNO (Figure 7). The Arduino UNO is

based on the ATmega328 (Arduino UNO webpage), a low-power CMOS 8-bit microcontroller based

on AVR enhanced RISC architecture. The ATmega328 is designed to optimize power consumption

versus processing speed (ATmega238 datasheet). The Arduino UNO consists of 14 digital I/O pins

(including six pins that can be used as PWM outputs), six analog inputs, a 16 MHz ceramic

resonator, a USB connection, a power jack, an ICSP header, and a reset button. Additionally, it can

be powered through USB or with an AC-to-DC adapter or battery. Unlike preceding boards, the UNO

uses Atmega16U2 programmed as a USB-to-serial. Table 2 summarizes the specifications of the

Arduino UNO board.

Figure 7 Picture of Arduino UNO.

The Arduino can be described as the hub of the magnetic levitation device and will be

responsible for controlling the power input of the electromagnet, retrieving data from the device’s

sensor, and returning the retrieved data back to MATLAB/Simulink to be plotted and displayed on a

PC. Consequently, the Arduino will be responsible for executing the function of controllers designed

in MATLAB/Simulink. For the Arduino to be controlled using MATLAB/Simulink, special I/O

integration toolboxes are needed. These toolboxes allow users to interface with and command the

Arduino using MATLAB syntax or by uploading controllers through Simulink.



Table 2 Arduino UNO specification summary

MCU Component Specification

Microcontroller ATmega328

Operating Voltage 5V

Input Voltage (recommended) 7-12V

Input Voltage (limits) 6-20V

Digital I/O Pins 14 (of which 6 provide PWM output)

Analog Input Pins 6

DC Current per I/O Pin 40 mA

DC Current for 3.3V Pin 50 mA

Flash Memory 32 KB (ATmega328) of which 0.5 KB used by bootloader

SRAM 2 KB (ATmega328)

EEPROM 1 KB (ATmega328)

Clock Speed 16 MHz



9. Signal Conditioning : Control Circuit

9.1. Component DescriptionNow that the processing control and sensing components of the apparatus are defined,

some form of signal conditioning is needed for the input current to the electromagnet and the

retrieval of the output voltage (data) coming from the sensor. Signal conditioning is crucial to the

manipulation of the raw I/O signals for further processing. For instance, a smooth electrical signal

is required to provide stable magnetic polarity and also a stable magnetic field strength in the

electromagnet. Additionally, it is required to amplify the electrical output of the sensor for further

use by MATLAB/Simulink for graphical display of data.

9.2. Component Design As mentioned in the description, the electromagnet requires a steady current flow through

its coils to be able to provide stable magnetic polarity and also a stable magnetic field strength.

However, current is transmitted in the form of an analog signal; thus, its signal varies or oscillates

during transmission. Consequently, a raw current signal would not be most suitable for powering

the electromagnet. Therefore, it is necessary to implement a form of signal conditioning that would

allow for a relatively steady flow of current into the electromagnet and hence a relatively steady

magnetic field strength. This conditioning can be supplemented by the use of a capacitor which is

often used in electrical circuits to smooth the output of power supplies (i.e. the power supplied by

the Arduino). In addition to this some form of switch is required to control the magnetic field

strength based on position of the levitating object (provided by the sensor). Figure 8 shows a

configuration of an electromagnet coil driving circuit that makes use of the above signal

conditioning methods (Mekonikuv).



Figure 8 Electromagnetic coil driving circuit (Mekonikuv)

The driving circuit is setup to receive input from the Arduino (Digitalout3), to provide a smooth

electrical signal by use of a capacitor (C1), to switch the coil on and off with a transistor, and finally

to protect the transistor from fly-back currents using a rectifier diode (1N4001). Note that the coil

component in the coil driver circuit is the electromagnet coil.

The sensor of choice for the project was a Hall Effect sensor. On its own the Hall Effect

sensor does not produce a suitable enough feedback. For a given input voltage, when disengaged

from a magnetic field, the Hall Effect sensor produces an output voltage of about 2.48V and when

engaged, it produces an output voltage of about 4.0V. For more sensitive feedback, the sensor

output must be amplified; thus, an amplifying circuit must be built using operational amplifiers (op-

amps). The output of the sensor is connected through two op-amps which in turn is output to an

analog input pin of the Arduino. The amplifying circuit used by Mekonikuv is shown below:

Figure 9 Sensor with amplifier circuit (Mekonikuv).



The output signal from the sensor is used to determine the position of the levitated object;

then, this data is used to provide feedback to the system which determines the necessary current to

be supplied to the electromagnet to maintain the levitating object at a required position. The op-

amp configuration used in

Figure 9 Sensor with amplifier circuit (Mekonikuv). subtracts approximately 1.5V at the

first op-amp stage and then amplifies by a factor of approximately 3V (Mekonikuv). Another

sensing method was also proposed by Lieberman that makes use of a differential setup of Hall

Effect sensors (two sensors fixed above and below the electromagnet) to isolates the magnetic field

of the levitating object.



10. User Interface

10.1. Component DescriptionThe required user interface for the project is MATLAB and Simulink. MATLAB is a high-level

programming language and interactive environment for numerical computation, visualization, and

programming (MathWorks MATLAB website). Simulink is a block diagram environment for

multidomain simulation and model-based design. It supports system-level design, simulation,

automatic code generation, and continuous test and verification of embedded systems (MathWorks

website). MATLAB and Simulink are both frequently used environments for the Systems II course.

Consequently, it is a required component of this project to be able to design and demonstrate

magnetic levitation using the design theories taught in Systems II using MATLAB and/or Simulink.

The Arduino is commonly controlled using its own development environment which uses

proprietary C language; this is different from the language used in MATLAB and does not

incorporate use of block diagrams for code execution. However, it is possible to communicate with

the Arduino using MATLAB and Simulink through available Arduino support packages or

Toolboxes. MATLAB and Simulink each require a separate toolbox for the Arduino which can be

downloaded from the MathWorks website. The toolboxes are based on a server program running

on the board which listens to I/O commands arriving via serial port.

10.2. Component Design As mentioned above, Simulink is a block diagram environment. Essentially, the magnetic

levitation system can be simulated in Simulink using a block diagram specifically designed to

control magnetic levitation. Appendix B shows an example of a block diagram designed by the team

for testing.

It was designed to be complemented by a driving MATLAB script; however, for the project,

it is required to upload the designed block diagram to the Arduino for demonstration of a designed

controller. Uploading Simulink block diagrams to the Arduino is facilitated by the support toolbox

mentioned above. Figure 10 shows an example of the block diagrams made available by the

Arduino Simulink toolbox.



Figure 10 Arduino Simulink block diagram example

The main purpose of MATLAB is mainly for the project design to substitute Simulink block diagram

commands to test out required functions of the various components of the apparatus until more

information is acquired on how to use Simulink to achieve the desired control of the Arduino.



11. Feasibility & Risk Assessment

The concept design, single electromagnet design with the Hall Effect sensor, was selected

after evaluating all concepts. The major components of the design include the single electromagnet

levitation, permanent magnet made of Neodymium, Hall Effect sensor, and Arduino

microcontroller. Almost all of the components are available in retail stores in Halifax, N.S. except

for the electromagnet which may has to be ordered custom-made or hand built according to the

magnetic field strength requirement. This concept design has the option of conducting ether

repulsion or attraction levitation depending on its position/orientation on the apparatus.

Consequently, this design provides the option of testing out both methods of electromagnetic

levitation (i.e. attraction or repulsion). Testing of the device and the operating circuitry can also be

a cause for concern in the project as these components determine the feasibility of the design to

meet the project’s requirements.

In terms of availability of materials, the Hall Effect sensor and Arduino microcontroller can

be obtained from a local electronics store in Halifax called Jentronics. Permanent magnets made of

Neodymium are available at Princess Auto; however, these are disk shaped. Initial prototype and

testing phase can be carried out with the available magnet size but further research is needed to

find a spherical neodymium magnet locally; these can be purchased online. The circuit needed for

the system can be built with a prototype board, wires, and electrical components that can be bought

at Jentronics. Putting them together according to the requirement may require research into

electric circuits and guidance from Electrical advisors. Once the layout for the circuitry is

determined it can be made into a permanent circuit using a perforated prototype board or using a

custom made PCB design that can be prointed at a local PCB contract manufacturer, Sunsel Systems.

There are multiple options for the electromagnet design. Calculations in Appendix C

indicate the initial approach towards building the electromagnet. There are various limitations and

parameters that need to be determined. Off the shelf electromagnets are available; however, testing

is required to determine whether this is suitable or needs to be built based on specified calculations

for the apparatus.

A major challenge anticipated for the project is the integration of the components to achieve

functionality through input methods from MATLAB/Simulink. The group has so far successful

interfaced the microcontroller with MATLAB and Simulink. Other challenges include building a

block diagram, executing control methods from Control Systems II course syllabus, retrieving data

from the sensor, and adhering to the project requirements.



12. Testing and Verification Plan

There are a variety of different shapes of magnets that can be tested to confirm the concerns

of shape on object levitation. As mentioned above in the Feasibility section, different materials and

shapes of magnets are available for purchase; thus, tests will be conducted on as many different

shapes before making a final decision. In addition, it is possible to purchase electromagnets at local

hardware stores for testing, as opposed to purchasing wires and electromagnet core materials

separately without certainty of success. The electromagnets available for purchase come in the

form of pneumatic switches and igniters; these can be taken apart to retrieve the electromagnet

solenoid.

Given that the MCU must act as an I/O hub, it is important to test out this basic functionality

in the simplest manner possible to verify its usefulness to the project. A common means of testing

out I/O applications is by toggling LEDs on and off to determine whether signal transmission is

possible. However, this may not be the most effective means of confirming data retrieval from the

MCU for the intended purpose of magnetic levitation. Consequently, a viable alternative to testing

data retrieval would be to connect a simple sensor to be powered and read by the MCU; for

example, a temperature sensor. Successful execution of basic I/O tests, as mentioned, will prove

that the necessary control of a magnetic levitating device can be achieved. Toggling the on/off state

of an LED is proof of concept that the required external supply to the electromagnet can be

regulated as needed; but being able to regulate an electromagnet would be a better proof of concept

of levitation. Retrieving data from a sensor will also be proof of concept that it is possible to retrieve

position data for feedback for the levitation. The next step in testing and verification would be to

attempt the same test mentioned above, but this time using the Simulink toolboxes. Successfully

accomplishing communication or control of the MCU using Simulink would prove that it is possible

to control the magnetic levitation device using the chosen MCU and Simulink. In other words, this

would fulfill part of the necessary functional requirements of the project.



13. Cost Estimates & Budget

Table 2 outlines the expected project expenses. Most of the electronic components are

bought from Digi-key which is probably the cheapest supplier in market. Materials have to be

ordered through Digi-Key website, which incurs shipment and handling cost. Princess Auto and

Home Depot are local stores in Dartmouth; there is no additional shipment charge. The total project

cost is $565 including taxes and shipment. Additional 10% contingency cost is added to account for

any uncertainty in cost estimation.

The estimated budget is well within the $1,000 allowance. The extra $600 will be used to

print the circuit board and order extra materials that may be exhausted during testing of the device;

such as, electrical components and other sensors like the photoelectric sensor.

Table 3 Component and materials cost breakdown

Materials Unit Cost

Amount Cost Supplier Part Number

ELECTRONICSArduino $30.31 2 $60.62 Digi-Key A000073

Perforated Prototype Board $15.35 1 $15.35 Digi-Key A000032

USB Cable $2.23 1 $2.23 Digi-Key 3021001-03

Hall Effect Sensor $1.00 2 $2.00 Digi-KeyAH337-

WGTR-ND140 pc. Wire Kit $10.12 1 $10.12 Digi-Key 438-1049-ND

60 pc resistor kit $27.00 1 $27.00 Digi-Key RS105-ND

Potentiometer $27.40 2 $54.80 Digi-Key 5310-ND

Capacitors $0.40 5 $2.00 Digi-Key P15819CT-ND

Rectifier $0.15 5 $0.75 Digi-Key1N4007DICT-

NDTransistor $0.55 5 $2.75 Digi-Key MPSA06-ND

Operation Amplifier $0.64 5 $3.20 Digi-KeyAP358SGDICT

-ND12 V wall adaptor $77.42 1 $77.42 Digi-Key 285-2021-ND

Neodymium Magnet $4.99 1 $4.99Princess

Auto8183915

Electromagnet $12.99 3 $38.97Princess

Auto8465254

RAW MATERIALS

Knotty Pine (2x3x6) $6.15 3 $18.45Home Depot

228268

H. Paulin Nails $8.96 1 $8.96Home Depot

832514

Black Corrosion-Resistant 1100 Aluminum Foil, 24" X10' Roll

$33.66 1 $33.66McMaster

Carr7073T26

Sub Total $363.27

Billing Total $363.27



Taxes $54.49Estimated Shipping & Handling $150.00

Total $512.5710% Contingency $567.76



14. Progress Report

The group made significant advancements towards building a functional prototype for the

project. The control circuit is now complete and was thoroughly tested. Initial solenoid testing was

done using an igniter solenoid which was rated at 80A; the current solenoid being tested is rated

for 1.3A. It was possible to achieve magnetic field manipulation of the solenoid using the Arduino.

There were some initial problems with burning out transistors which was solved by using a power

supply that was rated for a higher current than the solenoid being tested.

The sensor signal conditioning circuit was also successfully tested with the Arduino. Data

from the Hall Effect sensor was acquired through Arduino for different pole engagements of a

permanent magnet (during activating of the solenoid) and the data was recorded as shown in

Figure 11. The program code used to accomplish the figure below is given in the Appendix.

0 100 200 300 400 500 600 700 800350

400

450

500

550

600

650

Hall Effect Sensor Response to PWM Magnetic Field

Without Ob-ject

With Object

Sample Number

Hal

l Eff

ect

Sen

sor

Ou

tpu

t

Figure 11 Hall Effect sensor output with and without permanent magnet (object)

The permanent magnet was introduced in addition to the solenoid’s field to understand the

effect on the sensor output. Results clearly indicate an increase or decrease in the signal amplitude

based on the orientation of the magnet. The excel graph from test results is provided in the

Appendix. In addition, an emergency mechanism from an existing levitation program was used to

shut off the signal to the coil when the magnet got too close to the solenoid. This clearly indicated

that levitation using this prototype is imminent but further examination of the Arduino code is



required to achieve the this outcome. Figure 12 shows the completed sensor signal conditioning

circuit and the coil driver circuit.

Figure 12 Actual control circuit

Concurrent to the work on the prototype, the group made progress with the Simulink block

diagram presented in the Appendix of this document. We developed a full understanding of the

components required for the block diagram like the saturation block, low pass filter for signal

conditioning, and input functions/parameters. The driver file required to verify the block diagram

has to be written before all the parameters for the individual blocks can to be determined. In

summary, a control circuit for levitation was built and successfully tested for manipulation of a

solenoid and retrieval of feedback data from a Hall Effect sensor. Additionally, a Simulink block

diagram was design based on existing magnetic levitation projects.



15. Future Considerations

Completion of the prototype is the foremost goal for the group. The plan to test out the full

working prototype is postponed for the winter break. Programming the sensor signal conditioning

circuit is needed to achieve levitation and it is the current task in hand. A program written in the

Arduino’s IDE will be used to differentiate the magnetic field generated by the solenoid and the

object to be used as feedback to determine the necessary magnetic field generation for levitation.

The next major task for the group is to complete the Simulink block diagram to replicate the

Arduino code for levitation (once completed) using the Simulink Arduino toolbox support and then

to integrate System II control theories. Additionally, an UI for the Simulink block diagram needs to

be designed and will act as the front end application for the device.

The fall term comes to an end with the submission of the fall design report and peer

assessments. Parts would be ordered during the break so that they would arrive when the building

phase begins in winter term. Building phase would involve completion building a stand for the

apparatus based on the proposed 3D model and building an electromagnet based on calculated

requirements. Integration and testing of the devices would follow after the building phase. The

summary of all tasks and estimated duration for completion is listed in the Schedule section of the

Project Management Plan.

If the range of levitation is too low, the group will need to consider building a more powerful

electromagnet or adding an extra electromagnet to repel the levitated object from the bottom to

extend the range, basically switching to double electromagnet suspension design. The cost of

adding an extra electromagnet is also considered in the budget.

15.1. Preliminary Apparatus DesignA 3D model of the intended apparatus chassis was altered completely for a realistic and

feasible design (Figure 13). More details are incorporated in this model including a power supply

unit, the control circuit, and the Arduino. It was decided to place the electromagnet inside the

chassis. It was decided that the chassis be made of wood and sheet metal (for easy access to

components). The cost of the building material was considered in the budget analysis section of the

document. Workshop facilities in Dalhousie engineering department would be used for the

construction of the chassis.



Figure 13 Proposed Apparatus design



16. Project Management Plan

16.1. Organizational Responsibilities

This project is a collective obligation that requires individual members to communicate,

cooperate and coordinate. In the Conceptual Design Report, a table is created to list the anticipated

engineering expertise required for project.

Table 4 Required engineering expertise

Technical Area Team Member Responsible

Level of Expertise Required

Technical Communication

Ajay Puppala Fuyuan LinXiadong WangMarlon McCombie

IntermediateThis skill is important for the necessary documentation and communication required for the duration of the project

Research & Development

Ajay Puppala Fuyuan LinXiadong Wang

IntermediateDetail research must be carried out. This will help to determine the parameters necessary for levitation and component selection and testing. This expertise is important to the overall success of the project

Circuit Analysis Marlon McCombieFuyuan Lin

IntermediateA clear understanding of the function of circuit components is required for reliable and effective transfer of power and data among the components.

Microcontrollers Marlon McCombie AmateurA basic understanding of microcontrollers and programming is required to be able to test and communicate with the system components and the required GUI.

MATLAB/Simulink Controller Design

Ajay Puppala Xiadong WangMarlon McCombie

IntermediateAn intermediate level of understanding for this technical area is required for successful communication and testing between the microcontroller and the required GUI and simulation and testing of the apparatus’ ability to meet the projects main requirement for demonstration.

Apart from the technical point of view, it is also important to look at roles of individuals from a

project management point of view:



Table 5 Allocation of team responsibilities

Name Title ResponsibilitiesAjay Puppala Project Manager - Division of work and duties

- Keep track of developments in the project

Marlon McCombie Chief Technology Officer - External Communication - In charge of research and application of technology required for the project

Fuyuan Lin Chief Design Specialist - Study of various design- Development of Solid Works model

Xiadong Wang Chief Financial Officer - Development of Budget- Study ways to cut costs and optimize design.

The roles designated above are only nominal. It is expected by individuals to contribute in other

areas as required.

16.2. Work Breakdown Structure

The design cycle for the project mainly consists of research, product design, development,

and testing. Figure 14 maps the first level of the work breakdown structure (WBS). A 3 level WBS

was adopted in the project management which is explained in the subsequent pages. Apart from the

regular product development, budget for material purchase for development prototype acts as a

constraining factor for the selection and implementation of concepts generated during the design

generation stage. Documentation that needs to be completed during the project is also listed in the

following figure.



Figure 14 Fall term work breakdown structure

The subsections are further divided with an effort to get good insight and understand the

specifics of each element. This is the level 2 of the WBS. The research phase of the project comprises

determination of requirements, division into focus groups, and survey of literature using different

techniques, and summary and analysis of the findings. Figure 15 explains what should be done for

each of the subsections. For example, the requirements should consider the purpose of the project,

visual requirements, power and demonstrative requirements.


Fall term WBS

1. Research

1.1 Requirements

1.2 Focus Groups

1.3 Survey

1.4Research Analysis

1.5Findings & Evaluation

2. Product Design

2.1 Concept

Generation

2.2 Concept Evalution

2.3 Concept Selection

2.4 Feasibility

Analysis

2.5 Method of

Testing

3. Product Developement

3.1 Calculations & Solid Works

Model

3.2 List of Materials

3.3 Prototype

3.4Prototype

Testing

3.5Design Verification

& Improvements

4. Financial Management

4.1 Bill of

Materials

4.2 Budget Analysis

5. Documentation

5.1 Requirements

Document

5.2 Conceptual

Report

5.3 Embodiment Report

5.4 Interim

Presentations

5.5 Web Page

5.6Term Report


Figure 15 Research work breakdown structure

Similar to the research section, the product design is also divided into specific categories

that might help to conduct and optimize the design selection process.


1. Research

1.1 Requirements

1.1.1 Purpose

1.1.2 Visual Requirements

1.1.3 User Convenience &

Safety

1.1.4 Power Requirements

1.1.5 Interactive

Rrequirements

1.1.6 Demonstrative Requirements

1.2 Focus Groups

1.2.1 Magnetic Levitation

1.2.2 Levitated Object

1.2.3 Sensors

1.2.4 Microcontroller

1.2.5 Circuitory

1.3 Survey

1.3.1 Journals &

Publications

1.3.2 Vendor Sites &

Catalogues

1.3.3 Databases

1.3.4 MECH 4900

Textbooks & Lecture Notes

1.4Research Analysis

1.5Findings & Evaluation


Figure 16 Product design work breakdown structure

Each component in the concept evaluation section can be further broken down to get a good

understanding of the criteria for evaluating designs generated in the 2.1 section. Careful evaluation

of each one of these criteria is necessary to select appropriate design for the project. This was

already done in the concept selection report.


2. Prodcut Design

2.1 Concept Generation

2.1.1 Electromagnetic

Suspension

2.1.2Electrodynamic

Replusion

2.1.3Vertical Maglev

Track

2.1.4Toroidal

Electromagnetic Track

2.2 Concept Evalution

2.2.1 Basic Requirements

2.2.2Parts Requirements

2.2.3Design Assessment

2.2.4Cost Assessment

2.3 Concept Selection 2.4 Feasibility Analysis

2.4.1 Avaliability of Materials

2.4.2 Supporting Calculations

2.4.3 Challenges

2.5 Method of Testing

2.5.1 Levitation

2.5.2 Sensor

2.5.3 Matlab/Simulink

2.5.4 MCU


Figure 17 Concept evaluation breakdown structure

The structure helps to identify the steps involved in the design selection and development

process. Critical path shown in Figure 16 in the following page indicates the sequence of steps

required for proper completion of the project for this term. A spiral design method is adopted for

the development. The documentation and budgetary input are also incorporated into the flow

chart.


2.2 Concept Evaluation

2.2.1 Basic Requirements

2.2.1.1 Viewability &

Stability

2.2.1.2Portablility

2.2.1.3Simulink

& GUI

2.2.1.4 Implementation of

Control Design Theories

2.2.2 Parts Requirements

2.2.2.1Electromagnet

2.2.2.2Sensor

Effectiveness

2.2.2.3MCU

2.2.2.4Displacement of Levitating Object

2.2.2.5 Frame Support

2.2.3 Design Assessment

2.2.3.1 Design Complexity

2.2.3.2 Ease to Build

2.2.3.3 Holistic Judgement

2.2.4 Cost Assessment

2.2.4.1Cost of wiring for

electromagnet

2.2.4.2 Cost of sensor

2.2.4.3 Cost of

microprocessor

2.2.4.4 Cost of frame

2.2.4.5 Cost of circuitory

Figure 18 Fall term WBS critical path chart

The work requirement for the project during winter mainly consists of gathering parts,

coding with Simulink, system integration, and testing. A 2 level WBS was developed for the winter

term. Documentation that needs to be completed during the project is also listed in the Figure 17.

Figure 19 Winter term work breakdown structure

The above structure helps to identify the steps involved in the building phase, integration of

subsystems, and testing the integrated device. Figure 18 in the following page indicates the

sequence of steps required for building, testing, and validating the model. It clearly shows steps to

take if the model does not function properly or meet the requirements of the project. The

documentation and budgetary input are also incorporated into the flow chart.

Winter Term WBS

1. Building Phase

1.1 Gather Parts

1.2 Build Simulink Block

Diagram

1.3 Build Electromagnet

1.4 Build Circuitry

1.5 Build Chasis

2. System Integration

2.1 Simulink & Microcontroller

2.2 Microcontroller

& Circuitry

2.3 Circuitry &

Physical Levit.

3. Testing Phase

3.1 Testing System

Components

3.2 Test Integrated

Subsystems

3.3 Full scale testing

3.4 Collect and Sample data

3.5 Validate Model

4. Financial Management

4.1 Purchasing Parts

4.2 Updating Cost Analysis

4. Documentation

4.1 Build Report

4.2 Winter Presentations

4.3 Final Report

Figure 20 Winter term WBS critical path chart

16.3. Schedule

The following schedule is generated based on the WBS from the last section. Most of the

work for this term is almost completed except for the prototype and initial testing. The schedule in

Table 5 is adjusted to complete the tasks by the end of the break so that we are back on schedule for

the winter term. The next major objective for the group is to complete the prototype and order the

materials by 17th December, 2013. This is the last possible date for the group to work together after

which some of us planning to go home for holidays.

Table 6 Summary of project tasks for fall 2013 term

Task Name Duration

Start Finish Responsibility% Work Completed

Preliminary Research 6 days 9/25/13 10/2/13 Individual Effort 100%Group organization & house keeping

3 days 9/26/13 9/29/13 Group Effort 100%

Focus Groups for Subsystems

7 days 9/30/13 10/8/13

Electromagnetic Theory & Calculations - Fuyuan & Xiadong, Microcontroller & Circuitry - Marlon, Design & Sensors - Ajay

100%

Scope/Requirements 4 days10/15/13

10/18/13

Marlon & Ajay 100%

Analysis Review Pannel Inputs

1 day10/20/13

10/20/13

Group 100%

Summary of Findings of Focus Groups

2 days10/20/13

10/21/13

Individual 100%

Concept Generation and Selection

3 days10/24/13

10/27/13

Group 100%

Theory Evaluation and Calculations

3 days10/31/13

11/4/13 Fuyuan & Xiadong 100%

Conceptual Design Report

3 days 11/5/13 11/7/13 Marlon & Ajay 100%

Solid Works Model 1 day11/20/13

11/20/13

Fuyuan & Xiadong 100%

List of Materials required for Prototype

1 day11/20/13

11/20/13

Group 100%

Material Collection 5 days 11/4/13 11/8/13 Ajay 100%

Embodiment Report 3 days11/20/13

11/22/13

Group Effort 100%

Prototype Building 14 days11/10/13

11/27/13

Marlon & Ajay 85%

Prototype Testing 4 days11/24/13

11/27/13

Marlon 45%

Interim Presentation 5 days11/24/13

11/28/13

Group Effort 100%

Fall Design Report 5 days 11/27/1 12/3/13 Group Effort 100%


3

Purchase Parts 1 day12/10/13

12/11/13

Group 85%

The group personally invested money to purchase the parts needed for the prototype with

the exception of the control circuit components and the power supply. Invoices from purchases will

be submitted to the Mechanical Department office with consent from the project supervisor to

claim the sum.

Next table in the section indicates the required number hours from individual team

members and as group to finish the remaining tasks left in this term. We are planning to work in the

break so we are well prepared for the 2014 winter term.

Table 7 Breakdown of remaining hours of work for the winter break

Team Member Name Major Responsibility Hours of Work RequiredMarlon McCombie Complete Prototype for

Levitation12

Ajay Puppala MathWorks Simulink 10Fuyuan Lin Solid Works Modeling 6Xiadong Wang MathWorks Simulink 8Group Ordering Required Materials 5Total Hours of Work Required 41

Winter term, 2014 schedule is laid out based on WBS from Figures 17 and 18. The following

table estimates the time it takes to complete the tasks due in the term. It also indicates the

percentage of work completed for each task. A value higher than zero (please note the values are

only an approximation) suggests that work from fall term can be used directly towards completion

of the tasks in the winter term.

Table 8 Summary of project tasks for winter 2013 term

Task Name Duration Finish Responsibility % Work Completed

Gather Parts 2 days 1st week January Marlon & Ajay 15%Review Fall Report 1 day 1st week January Group task 0%Building PhasePrototype Testing 3 days 1st -2nd week January Marlon & Xiadong 30%Complete Simulink Block Diagram

7 days 2nd -3rd week January Fuyuan & Ajay 25%

Implement Control Theories 4 days 3rd week January Group 0%Build GUI using Simulink 4 days 4th week January Fuyuan & Ajay 0%Rebuild circuitry 1 day 4th week January Marlon 85%Build Stand & Electromagnet 3 days 4th week January Xiadong 5%System Integration 5 days 2nd week February Group task 35%Testing Phase



Set up System in Lab 3 days 2nd week February Group task 0%Testing system 15 days 3rd– 4th wk. February Group task 0%Collect and Sample data 10 days 1st -3rd week March Scheduling 0%Test completion 2 days 4th week March Marlon & Ajay 0%DeliverablesBuild Report 4 days 2nd week February Group task 20%Update Website 2 days 1st week April Ajay 15%Final Report 4 days 1st week April Group task 15%Final Presentations 2 days 1st week April Group task 10%

16.4. Specialized Facilities and Resources

16.4.1. Facilities

The following is a list of facilities that are required for the project duration and a short

description for their necessity:

Design workbench

o For testing prototype apparatus and for storing materials and components

to allow easy access by team members

Measurements Laboratory (C255)

o For testing EM with varying current input using an bench power supply;

especially in the unlikely case that the currents needed for levitation are

potentially dangerous

Machine Shop/Carpentry Shop

o For fabricating a suitable chassis for the final apparatus

16.4.2. Additional Advisors

Name: Dr. Ya-Jun PanPosition: Professor, Mechanical Dept.Email: [email protected]

Name: Dr. Timothy LittlePosition: Professor, Electrical Dept. Email: [email protected]

Name: Jonathan MacDonaldPosition: Electrical Technician, Mechanical Dept.Email: [email protected]

Name: Angus MacPhersonPosition: Mechanical Technician, Mechanical Dept. Email: [email protected]



Name: Corey MacNeilPosition: Automation Specialist, Jentronics Ltd.Email: [email protected]



17. References

Brandt, E. H. "Levitation in Physics." N.p., 20 Jan. 1989. Web. 28 Oct. 2013.]

"Electronic Components Distributor | DigiKey Corp. | CA Home Page. N.p., n.d. Sat. 03 Nov. 2013

“LEGO Mindstorms Online Store.” http://shop.lego.com/en-CA/LEGO-MINDSTORMS-NXT-2-0-

8547. Retrieved November 6, 2013

“Liquidware Online Store” http://www.liquidware.com/shop/show/ARD-UNO/. Retrieved

November 6, 2013

"RobotShop : The World's Leading Robot Store." RobotShop. N.p., n.d. Sat. 03 Nov. 2013

Thompson, Marc T. "Eddy Current Magnetic Levitation: Models and Experiments." IEEE. N.p., 200.

Web. 28 Oct. 2013.

Williams, Lance. "Electromagnetic Levitation Thesis." N.p., 2005. Web. 28 Oct. 2013.

Shuaibu, D. S. S. & Adamu, S. S., “Design, Development and Testing of an Electromagnet for magnetic

levitation system”, Nigeria, Publication date unknown

“MathWorks MATLAB/Simulink website.” http://www.mathworks.com/products/simulink/. Retrieved

November 20, 2013

Lieberman, J. 2005, “Magnetic levitation project.” http://bea.st/sight/levitation/. Retrieved

November 20, 2013

Mikonikuv Blog, “Arduino Magnet Levitation – detailed description.”

http://mekonik.wordpress.com/2009/03/17/arduino-magnet-levitation/. Retrieved

November 20, 2013

Arduino UNO webpage. http://arduino.cc/en/Main/arduinoBoardUno. Retrieved November 20,

2013

ATmega238 datasheet. http://www.atmel.com/Images/doc8161.pdf. Retrieved November 20,

2013

Honeywell SS49 datasheet. http://www.wellsve.com/sft503/Counterpoint3_1.pdf. Retrieved

November 20, 2013



Appendix A Simulink block diagram for electromagnetic levitation

Figure 21 Simulink block diagram for electromagnetic levitation

MECH4010/4015 Magnetic Levitation Demonstration Apparatus Page i of li


Appendix C Sample Programs This example code was modified from examples supplied by the Arduino IDE.int led = 3;#define sensorPin 0int monitoring = false;

// the setup routine runs once when you press reset:void setup() // initialize the digital pin as an output. pinMode(led, OUTPUT);

Serial.begin(9600); Serial.println("Ready"); Serial.println("m - toggle monitoring");

// the loop routine runs over and over again forever:void loop() // fade in from min to max in increments of 5 points: for(int fadeValue = 0 ; fadeValue <= 255; fadeValue +=5) // sets the value (range from 0 to 255): analogWrite(led, fadeValue); // wait for 15 milliseconds to see the dimming effect delay(15);

int sensor=analogRead(sensorPin); checkSerial();

if (monitoring) Serial.println(sensor);

// fade out from max to min in increments of 5 points: for(int fadeValue = 255 ; fadeValue >= 0; fadeValue -=5) // sets the value (range from 0 to 255): analogWrite(led, fadeValue); // wait for 15 milliseconds to see the dimming effect delay(15);

int sensor=analogRead(sensorPin); checkSerial();

if (monitoring) Serial.println(sensor);

void checkSerial() if (Serial.available())

MECH4010/4015 Magnetic Levitation Demonstration Apparatus Page iii of li


char ch = Serial.read(); if (ch == 'm') monitoring = ! monitoring;

MECH4010/4015 Magnetic Levitation Demonstration Apparatus Page iv of li


Appendix B Design Calculations for Electromagnet

Table 9 Design calculations for electromagnet

Options 1.000 2.000 3.000 4.000 LimitationCore Diameter (former) (mm)

30.000 30.000 30.000 30.000 30.000

Density of object (kg/m^3) 7850.000 7850.000 7850.000 7850.000 7850.000Diameter of object (mm) 25.000 25.000 25.000 25.000 25.000Volume of ball (m^3) 0.000 0.000 0.000 0.000 0.000Mass of ball (kg) 0.064 0.064 0.064 0.064 0.064Gravity 9.810 9.810 9.810 9.810 10.810Pole area 0.001 0.001 0.001 0.001 0.001B (wb/m^2) 0.059 0.059 0.059 0.059 0.059Air gap (mm) 100.000 90.000 80.000 0.000 300.000Turns (n) 1000.000 1000.000 1000.000 1000.000 1000.000r (half diameter of core) (mm)

15.000 15.000 15.000 15.000 15.000

Length of former (mm) 100.000 100.000 100.000 100.000 100.000Cylinder (total area) (m^2) 0.011 0.011 0.011 0.011 0.011H (AT/m) 46997.891 46997.891 46997.891 46997.891 46997.891Magneto-motive force (mmf) 4699.789 4229.810 3759.831 0.000 14099.367I (A) 4.700 4.230 3.760 0.000 14.099F (N) 15.042 15.042 15.042 15.042 15.042Wire chosen AWG 19 gage() (mm) 0.912 0.912 0.912 0.912 0.912Maximum number of wires in the first layer

109.666 109.666 109.666 109.666 109.666

Stacking factor 0.900 0.900 0.900 0.900 0.900Total # of layers 10.132 10.132 10.132 10.132 10.132Total length of wire (layers) 1039.264 1039.264 1039.264 1039.264 1039.264Total length of wire (total cylinder) (mm)

102574.682 102574.682 102574.682 102574.682 102574.682

(m) 102.575 102.575 102.575 102.575 102.575The unitl Resistor of chosen wire (Ohms per 1000 ft)

8.051 8.051 8.051 8.051 8.051

Total Resistor 2.709 2.709 2.709 2.709 2.709Total Voltage 12.734 11.460 10.187 0.000 38.201Heat produced by wire 34.501 31.051 27.601 0.000 103.502

MECH4010/4015 Magnetic Levitation Demonstration Apparatus Page v of li

Documents

Project Informationpoisson.me.dal.ca/.../Fall_Design_Report_Team11_V3.docx · Web viewA Simulink block diagram was developed using existing diagrams for magnetic levitation. Moving