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Developing a New Affordable
DC Motor Laboratory Kit for an Existing Undergraduate
Controls CourseRebecca M. Reck, PhD Candidate & R.S. Sreenivas, Associate Professor
Department of Industrial and Enterprise Systems EngineeringUniversity of Illinois at Urbana-Champaign
2015 American Control Conference
Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved. 2
Outline• Background & Motivation• Introduction to Control Systems Course• Kit Development• Conclusions and Future Work
Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved. 3
Motivation• Expand the access to hands-on controls laboratory
experiments
•Update existing equipment
•Use updated processes for simulation and design
Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved. 4
Current Lab Costs• The cost of equipment per station varies in cost from • $80 (Gunasekaran and Potluri, 2012) to • $32,493.74 (Egbert, 2009)
Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved. 5
Alternatives to campus labsVirtual Labs Remote Labs KitsPros:• Low cost• Usually simulation• Only need a computer• Many opportunities
Pros:• Use real equipment • More hours available• Do not have to be on
campus
Pros: • Low Cost• Hands on• Portable• Real systems
Cons:• Lack of “real world”
problems• Not hands on• Visualization is abstract
Cons:• Network infrastructure• Network security• Limited interaction
Cons:• Development • Procurement• Support
Casini et al., 2003; Uran and Jezernick, 2008; Nickerson et al., 2007
Aktan et al., 1996; Ionescu et al., 2013; Hyder et al., 2009; Casini et al., 2003
Borgstrom et al., 2012; Stark et al., 2013; Cruz-Martin et al., 2012; Kim, 2011; Sarik and Kymissis, 2010
Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved. 6
Introduction to Control Systems•Apply the following course concepts:• System identification• System frequency response• Stability• PID control
•Using a DC motor and the associated sensors
Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved. 7
Laboratory Experiments
• Lab 1: Introduction to Sensors and DC Motor
• Lab 2: Introduction to Simulink and the Raspberry Pi
• Lab 3: 1st Principles Systems Identification
• Lab 4: Step and Frequency Response System Identification
• Lab 5: Control of a DC Motor
Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved. 8
BeforeItem Cost
HP 33120A Function Generator $ 2,487.00
HP 34401A Multimeter $ 1,159.00
HP 6632A DC Power Supply $ 1,320.00
Custom built patch panel, power supplies, and amplifier
$ 475.00
Comdyna GP-6 Analog Computer $ 1,500.00
DC Motor, enclosure, and sensors $ 450.00
Dell Precision T3400 PC $ 1,094.00
Agilent Technologies DSO6012A Oscilloscope $ 6,159.00Miscellaneous Wires $ 195.31
Total $ 14,839.31
Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved. 9
AfterItem Cost
Raspberry Pi Model B $ 39.95
12V DC motor $ 12.95
3D Printed stand for motor and potentiometer $ 5.00
Bread board $ 5.95H bridge (L293D) $ 2.50
ADC (MCP3008) $ 2.30
Power Supplies $ 24.85
Rotary position sensor $ 2.60Photo Interrupter $ 3.45
Pi T-cobbler breakout and cable $ 6.95
SD Card $ 17.09
Wires, resistors and LEDs $ 2.34
Total $ 125.93
Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved. 12
Proportional + Speed Controller Performance
Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved. 13
Challenges• Consistency of 3D printing• Speed of network• Raspberry Pi support package in
MATLAB is a user specific installation• Ground noise• Number of holes in optical
encoder
Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved. 14
Conclusions• A kit that costs approximately $130 is being used in GE320 this semester
• It uses MATLAB and Simulink for development
• The kit weighs around 13 oz. and fits in a shoe box, making it easy to ship
• The kits design is flexible enough to be applied in other departments or courses
Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved. 15
Future Work• Compare the effectiveness of the kit vs. the existing equipment in
GE320
• Explore opportunities to use the kit in an online course or future integration between the lecture and the laboratory experiments in the existing course.
• Comparing low-cost hardware for use in control systems laboratorieshttp://bit.ly/controlsR1
Copyright 2015, R.M. Reck & R.S. Sreenivas. All rights reserved. 16
Rebecca M. ReckPh.D. [email protected]://rebeccaee.com
R. S. SreenivasAssociate [email protected]://tinyurl.com/ka55vw9
Department of Industrial and Enterprise Systems EngineeringUniversity of Illinois at Urbana-Champaign