Design of a Low-Cost Air Levitation System for Teaching Control Engineering
Abstract
:1. Introduction
- an introduction to real world modeling and/or control issues, such as uncertainties, saturation, noise, sensor/actuator dynamics, etc.;
- a demonstration or validation of analytic and theoretical concepts;
- a way of providing facility with instrumentation and measurement tools;
- activities for problem solving and team learning;
- a motivational activity;
- a way to develop professional practices, including maintaining engineering notebooks and report writing.
- A remote lab is a real plant that can be accessed through the Internet. Students remotely operate and control a real plant through an experimentation interface.
- A virtual lab is similar to the previous one, but it replaces the physical system with a mathematical model.
- open-source/open-hardware tools;
- rapid prototyping technologies. We have witnessed the rise of 3D printing or single board computers, technologies that fit like a glove to our purposes.
- the rapid dynamics makes it specially suitable for experiences with a control lab;
- due to the system nature, the design can be optimized and, with some precision tradeoff, kept affordable both in cost and construction efforts;
- the realistic physics of the system are complex and the system is better modeled through an identification process. However, a simple physics model approximation can also be used and compared with the behavior of both the real system and the model obtained through the identification process.
2. The System
- Design of the experience;
- Design and construction of the plant;
- Design and construction of the server software;
- Creation of the graphical user interface (GUI).
- a methacrylate tube;
- a small and light object;
- 3D printed parts;
- a single-board computer (Beaglebone Black);
- an infrared distance measuring sensor (PIR);
- a PC fan;
- some discrete electronic components and a printed circuit board (PCB);
- a webcam.
2.1. Hardware
- All boards ship with the Debian GNU/Linux image. This image comes with pre-installed software tools and, in particular, it provides the Node.js runtime and the Cloud9 IDE (Integrated Development Environment). In addition, the bonescript library (included in the Node.js installation) provides an Arduino-like application programming interface (API) to access the GPIO, so any person with previous experience in Arduino finds a soft learning curve.
- The GPIO provides analog inputs that can be used to acquire the sensor measures, and PWM outputs to control the fan and the servo of the air levitation system.
- The board has on-board embedded Multi-Media Controller (eMMC) memory, eliminating the need of an external SD card memory.
- There is an active development community. The Beaglebone boards have good hardware/software support and it is easy to find documentation, guides, etc.
2.2. Sensors
- Fix:
- -
- measurement range ( cm < h < cm);
- -
- measurement interval ( cm).
- Repeat, for each height (steps of 1 cm):
- -
- put the ball fixed at a known level;
- -
- record the sensor voltage for t seconds;
- -
- calculate the mean voltage value and store .
2.3. CAD Software
2.4. Design and Construction of the Server Software
- The hardware interface is implemented in Node.js by the object BoardInterface, which provides a common interface to access the boards, and the boards objects actually implementing the low-level communication. At the moment, only the Beaglebone Black and Arduino boards have been implemented, but there will be support for other boards in the future. These objects provide several methods to work with the hardware.
- The datalogging is implemented by the Node.js singleton object Datalogger, which gathers the important data and sends it to the database server. Currently, the data can be logged to a local file or sent to an InfluxDB server.
- The communication is implemented in Node.js by the object JsonRpcServer, which provides basic functionality to create a JSON-RPC 2.0 server, and RIPServer, which makes use of the former to implements the API of the Remote Interoperability Protocol (RIP). These approach can also be used to easily define new protocols or adapt to other implementations.
- The control subsystem is implemented by the object RealTimeLoop, which defines the controller implementation.
2.4.1. Hardware Interface
2.4.2. Datalogging
2.4.3. Communication
2.4.4. Control
2.5. Discussion
- Commercial academic platforms are very expensive and sometimes can be less flexible. However, they are usually complemented with a curricula of activities, technical support, etc. Building your own system can be cost-effective and the final product is prone to be enhanced or adapted to experiences different from originally thought.
- As mentioned before, the construction process itself is interesting from a didactic point of view. It can be proposed as an academic activity, if not from the scratch, dividing into smaller tasks or with some guidelines so students can address the activity.
3. The Lab
3.1. EjsS
3.2. The Virtual/Remote Lab GUI
- Save into File: Used to save graphs and numeric data in a .m file for later analysis.
- Control Manual/Automatic: This drop-down list allows modifying the mode in which the experiment runs: open loop or in a closed loop with a controller.
- Language: To select between English and Spanish.
- Linear/Non-linear: Each of these modes can be selected, corresponding to a linear and nonlinear mathematical model in the virtual laboratory.
4. Experiences
- The activities document contains some guidelines in order to reach the objectives of the lab. Using this guide, the knowledge about systems, control and analysis, the user can obtain fundamental parameters of the system structure or dynamics, information about the best controller configuration, etc.
- The user manual facilitates the understanding of the laboratory application’s GUI. It contains information about the available interactions with the interface and a description of the main structure of the views, graphs and menus.
4.1. Activities with the Lab
- PD/PI/PID Tuning: In Section 4, we said that the user can select an automatic mode, where the system runs into a closed loop. This loop is established for controlling the position of the levitating object inside the tube, which is done by changing the control signal to the fan by means of a PID controller. Using the PID tab in the bottom control panel of the application, the user can modify the proportional, integral and derivative parameters of such controller (, , ). The main goal is to be able to tune these parameters so that the output of the system satisfies some required specifications: response time, overshoot, etc. This activity is available in both the remote and the virtual laboratories.
- Disturbances Analysis: The virtual and remote labs allow for introducing disturbances in the system. A useful way to obtain this behavior is changing the wind flux outside the fan. In the virtual version, the flux is modified including a random signal in the velocity of the fan. In the real version, this response is obtained using a servo-mechanism similar to a plane flap. The 3D printed flap is designed to divide the base under the fan in two different parts, changing then the local airflow and the flux inside the tube. This possibility of enabling flux disturbances is available in both versions of the lab. In the virtual one, the user can activate the random signal and see how the system response changes. The remote version allows to introduce a single disturbance by changing the angle of the flap using a slider, Figure 6.
- System Identification: The system identification is a complex activity in this lab; therefore, the user needs to obtain information from the numeric data gathered in different lab sessions using the virtual and the remote laboratory. In this regard, the students can obtain data files from the GUI with the numeric responses of the system. Then, using a mathematical software program, the students can obtain useful information about the order, poles and zeros of the system.
- -
- From the simulated version, the user can obtain an initial approach. The virtual laboratory presents two models (discussed in Appendix A): the linear and the nonlinear ones. Using the acquired data in both models, students can obtain information of the system.
- -
- From the remote lab, and with the knowledge about the virtual air levitation system, the user can try to obtain more information about the real plant in the remote laboratory, where the system identification is not easy.
- Object Properties Analysis: The model depends on some parameters like the density of air or the mass and area of the levitating object. In the document of activities, students are encouraged to obtain information about the changes produced in the dynamics when they modify the physical properties of the object in the virtual lab. This activity can be only performed in the simulated version where the physical properties of the object can be easily changed.
5. Conclusions
Acknowledgments
Author Contributions
Conflicts of Interest
Abbreviations
AD | Analog to Digital |
API | Application Programming Interface |
CAN | Controller Area Network |
CAD | Computer Aided Design |
CNC | Computer Numerical Control |
CSI | Camera Serial Interface |
DSI | Display Serial Interface |
EjsS | Easy Java/Javascript Simulations |
GPIO | General Purpose Input/Output |
GUI | Graphical User Interface |
I2C | Inter-Integrated Circuit |
IoT | Internet of Things |
IO | Input/Output |
JTAG | Joint Test Action Group |
JSON | JavaScript Object Notation |
OPC | Object-Linking and Embedding for Process Control |
PIR | Passive Infrared Sensor |
PLC | Programmable Logic Controller |
PWM | Pulse Width Modulation |
RIP | Remote Interoperability Protocol |
RISC | Reduced Instruction Set Computer |
RPC | Remote Procedure Calling |
SPI | Serial Peripheral Interface |
SSH | Secure Shell |
TSDB | Time Series Database |
UART | Universal Asynchronous Receiver-Transmitter |
USB | Universal Serial Bus |
PID | Proportional Integral Derivative |
PRBS | Pseudo Random Binary Signal |
PCB | Printed Circuit Board |
RISC | Reduced Instruction Set Computing |
VRL | Virtual and Remote Labs |
Appendix A. Model
- m is the mass of the object to levitate;
- z is the vertical position of the object in the tube;
- is the density of air;
- A is the object’s area exposed to the upwards air flow;
- is the velocity of the air inside the tube;
- g is the gravity;
- is the so-called drag coefficient.
Appendix A.1. Linearization
Appendix A.2. Identification
- The operating point is set to cm;
- The system is identified in closed loop, using a proportional controller with unit gain ();
- setting a period of ms, the system is excited with a signal and 1024 samples are registered. Two kind of signals are applied:
- Step (10 cm).
- Pseudo-random bynary signal (PRBS, ±5 cm).
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Onion Omega 2 | Raspberry Pi 3 | Beaglebone Black | Intel Galileo (Gen 2) | |
---|---|---|---|---|
Cost 1 | 20 € | 35 € | 50 € | 75 € |
SoC | 400 MHz MIPS 24 Kc Big-Endian Processor | Broadcom BCM2837 | ARM | Intel Quark SoC ×1000 |
RAM | 64 MB DDR2 (400 MHz) | 1 GB LPDDR2 (900 MHz) | 512 MB DDR3L (800 MHz) | 256 MB DDR3 (800 MHz) |
Wireless | WiFi | WiFi, Bluetooth | n/a (WiFi and Bluetooth available with USB dongle) | n/a |
GPIO | UART, SPI, I2C, PWM, digital IO | UART, SPI, I2C, PWM, digital IO | UART, SPI, I2C, CAN, PWM, digital IO, A/D inputs | UART, SPI, I2C, JTAG, PWM, digital IO |
Ports | USB, WiFi, (more options availaible with expansion boards) | HDMI, 3.5 mm analogue audio-video jack, 4× USB (Universal Serial Bus) 2.0, Ethernet, Camera Serial Interface (CSI), Display Serial Interface (DSI) | HDMI, USB, Ethernet | USB, PCIe, Ethernet |
Time | Cost | |
---|---|---|
Software | 200 h | n/a |
Structural parts design | 60 h | n/a |
Assembling | 10 h | <100 € |
Lab Software Design | 40–100 h | n/a |
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Share and Cite
Chacon, J.; Saenz, J.; Torre, L.D.l.; Diaz, J.M.; Esquembre, F. Design of a Low-Cost Air Levitation System for Teaching Control Engineering. Sensors 2017, 17, 2321. https://doi.org/10.3390/s17102321
Chacon J, Saenz J, Torre LDl, Diaz JM, Esquembre F. Design of a Low-Cost Air Levitation System for Teaching Control Engineering. Sensors. 2017; 17(10):2321. https://doi.org/10.3390/s17102321
Chicago/Turabian StyleChacon, Jesus, Jacobo Saenz, Luis De la Torre, Jose Manuel Diaz, and Francisco Esquembre. 2017. "Design of a Low-Cost Air Levitation System for Teaching Control Engineering" Sensors 17, no. 10: 2321. https://doi.org/10.3390/s17102321
APA StyleChacon, J., Saenz, J., Torre, L. D. l., Diaz, J. M., & Esquembre, F. (2017). Design of a Low-Cost Air Levitation System for Teaching Control Engineering. Sensors, 17(10), 2321. https://doi.org/10.3390/s17102321