MAGLEV: Magnetic Levitation Plant User Manual
Contents
1. con photodarlington The position sensor is embedded inside the ball pedestal and provides linear position readings over the complete ball vertical travel Its output measurement is processed through a signal conditioning board and made available as 0 to 5V DC signal Its measurement sensitivity is given in Table 3 below Warning It is to be noted that the phototransistor measurement is sensitive to its environmental light conditions To that effect two lights represented by components 6 in Figure 2 are present in the chamber interior to provide repeatable and constant light conditions However as de tailed in a following section a calibration of the sensor offset and gain potentiometers components 7 and 8 respectively is required to keep consistent measurements in changing light environments As a consequence the user should also avoid disturbing the light conditions inside the MAGLEV chamber by for example grasping the ball with his her whole hand inside chamber Document Number 525 Revision 03 Page 4 MAGLEV User Manual 2 3 MAGLEV System Wiring Schematic The schematic depicted in Figure 4 below presents a wiring diagram of the MAGLEV ca ble connectors in association with the system electrical components namely the electro magnet coil current sense resistor interior lights and photodarlington ELP PCB MGLV ELP SNSK FATE ELP SCKT MDIN 6 Ser ELP RES 1IROQ Figure 4 MAGLEV System Wiring2. Figures 9 10 and 11 below show respectively the MultiQ PCI Terminal Board the MAGLEV plant back and the Universal Power Module UPM 2405 all connected with the necessary cabling to interface to and use the MAGLEV plant Figure 9 MultiQ PCI Terminal Board Connections EEE a SEES cy Current nr Coil 86 sense dd Nm ha gj Sensor Upm ea0s 12O vac OnLy Figure 10 Back MAGLEV Connections Figure 11 Universal Power Module UPM2405 The Quanser UPM 2405 is capable of providing the required power to the MAGLEV coil Document Number 525 Revision 03 Page 9 MAGLEV User Manual AN However it should be used in conjunction with a To Load cable of gain 5 i e 4 pin DIN to 6 pin DIN cable as described in Table 4 above Together with the power supply for the amplifier all Quanser power modules are equipped with a l ampere 12 volt regulated DC power supply for signal conditioning of external analog sensors The connectors are also fully compatible with our quick connect system enabling you to switch from one experiment to another quickly and efficiently 4 3 Typical Connections For The MAGLEV System 4 3 1 Wiring Of The Electromagnet Power Line The power line wiring of the MAGLEV electromagnet consists of two connections as described below 1 Connect the From Digital To Analog Cable Cable 1 The From Digital To Analog cable is the 5 pin DIN to RCA cable described in Tabl
3. manual ie EE KD ea Offset Gain both offset and gain potentiometers of the Figure I MAGLEV Specialty Plant ball position sensor are readily available for proper calibration current sense resistor is also included in the design in order to provide for coil current measurement if necessary Document Number 525 Revision 03 Page 1 MAGLEV User Manual 1 2 MAGLEV Control Challenge As illustrated in Figure 1 above the purpose of the magnetic levitation experiment is to design a control system that levitates a one inch solid steel ball in air from the post using an electromagnet The controller can then track the ball position to a desired trajectory The system is supplied with a feedback controller tuned through pole placement but of course you may design any other controller you wish The complete mathematical model ling and system parameters are provided to streamline the implementation of the control theory of your choice 2 MAGLEV Component Description 2 1 Component Nomenclature As a quick nomenclature Table 1 below provides a list of all the principal elements composing the MAGLEV Specialty system Every element is located and identified through a unique identification ID number on the MAGLEV plant represented in Figures 2 and 3 below Description Description MAGLEV Overall Enclosure 2 Solenoid Coil Coil Steel Core 4 Pedestal and Position Sensor Solid Stainless Steel Ball 6 Inter
4. Schematic Document Number 525 Revision 03 Page 5 MAGLEV User Manual 3 MAGLEV Model Parameters Table 3 below lists and characterizes the main parameters e g mechanical and electrical specifications convertion factors constants associated with the MAGLEV specialty plant Some of these parameters can be used for mathematical modelling of the MAGLEV system as well as to obtain the steel ball s Equation Of Motion EOM Description Maximum Continuous Coil Current 3 Coil Inductance 412 5 Coil Resistance 10 Number Of Turns in the Coil Wire 2450 Coil Length 0 0825 Coil Steel Core Radius 0 008 Electromagnet Force Constant 6 5308E 005 Current Sense Resistance l Steel Ball Radius 1 27E 002 Steel Ball Mass 0 068 Steel Ball Travel 0 014 Gravitational Constant on Earth 9 81 Magnetic Permeability Constant 47 E 007 Ball Position Sensor Sensitivity 2 83 E 003 Assuming a User Calibrated Sensor Measurement Range from 0 to 4 95 V Table 3 MAGLEV System Model Paremeters Document Number 525 Revision 03 Page 6 MAGLEV User Manual 4 Wiring Procedure For The MAGLEV This section describes the standard wiring procedure for the MAGLEV specialty plant The following hardware accompanying the MAGLEV is assumed Power Amplifier Quanser UPM 2405 or equivalent Data Acquisition Card Quanser Q8 MultiQ PCI MultiQ 3 or one of the National Instruments E Series cards or equivalent 4 1 Cable Nomenclature Ta
5. Specialty Plants QUANSER INNOVA TE EDB DUGATE Levitation Plant C Magneti MAGLEV User Manual MAGLEV User Manual Table of Contents Da NV LY ESSE UGA esae E itor poet A E E A ES l l t MAOLE V Systemi DESC DH ON avse aA l NNN MN 2 MAGEN r 2 2 le C OmMDOne MY NOMICIIC AMIN ed 2 Dudes MIP 4 22 Overall Fnclosure Component Ti EE 4 2 2 2 Electromagnet Coil Component 42 J rornnnnrrnnrrnnnnnnnnnrnnrrnnnnnnnrrnnnnvnnnnnenrrnnnnnnnnnene 4 2 2 3 Pedestal Position Sensor Component H4 J rrrnrrrnnnnnnnnrrnnnrnnnnnnnnnrrnnrrnnnnnnnnrrnvnnnnn 4 2 3 MAGLEV System Wiring Schematic rrnnoonnooooooonnnnnnrnnnnnnnrrrnrnnnnnnnnnnnnnnnnnnennnnnnnnnnnr 5 MON MUM 6 21 Wiring Proced re For The MAGLEV scat cressaesncasrrspie neine au ieo Ena E EEN E NEE 7 AECE INOS Od UL a E E erate ees E T A nates 7 HNL 9 4 3 Typical Connections For The MAGLEV System rrrrrrrnnnnnnrnnnrrnrrrvrnnnnnnrrnnnnnnnnnnnnnr 10 4 3 1 Wiring Of The Electromagnet Power LIne rrrrnrnnnrnnnrnnnnnnnnrnrrsrrrsrnrssrsrssssrsssn 10 4 3 2 Wiring Of The Electromagnet Feedback Sensors rrrrrrnnnnrnnrnrrrnnrrrrrrnnnnnnnnnnr 10 2 MAGLEV VS ALY canteen ener ovens E N cueicescersiesaieewae 12 PATNA 13 JE NN 13 5 2 Calibration PTO CE UUM Goose veosactnesivaesdsadeseseaavdeanesasiashine essatedvessast cbieniasntasncteenondneceseeesna 14 LNR Ne 14 5 2 2 Zero Offset Potentiometer Calibration At Voltage Zero rrrrnrnn
6. Z Substitution Name Description The corresponding controller file interfaces to the Quanser s MultiQ 3 board The corresponding controller file interfaces to the Quanser s MultiQ PCI board The corresponding controller file interfaces to the Quanser s Q8 board The corresponding controller file interfaces to the National Instruments E Series boards Table 6 ZZ Substitution Names 5 2 Calibration Procedure The calibration procedure detailed in the following subsections is to calibrate the two potentiometers namely Offset and Gain shown in Figure 2 above as components 7 and 8 respectively The Offset and Gain potentiometers are part of the signal conditioning circuitry of the photodarlington used as a position sensor for the steel ball In order to run the calibration procedure first ensure that the MAGLEV system is wired as previously described Then power up the UPM2405 The two lights inside the chamber should go on The calibration should be carried out under normal external light conditions at the location where you are planning to use the apparatus You may also use a level to level the MAGLEV rig so that both electromagnet axis and gravity force acting on the steel ball are aligned You are now ready to proceed 5 2 1 WinCon Calibration Project To load the WinCon calibration project run WinCon and open the project titled q cal maglev ZZ wcp where ZZ stands for either for mq3 mqp q8 or nie d
7. ble 4 below provides a description of the standard cables used in the wiring of the MAGLEV Cable Designation Description 5 pin DIN This cable connects an analog to output of the data acquisition ter RCA minal board to the power module for proper power amplification 4 pin DIN This cable connects the output of to the power module after amplifi 6 pin DIN cation to the desired actuator e g electromagnet One end of this cable contains a resistor that sets the amplification gain When carrying a label show ya ing 5 at both ends the cable Figure 6 To Load Cable Of Gain 5 has that particular amplification gain Document Number 525 Revision 03 Page 7 MAGLEV User Manual Designation 6 pin mini DIN to 6 pin mini DIN Figure 7 From Analog Sensors Cable Figure 8 To Analog To Digital Cable Table 4 Cable Nomenclature Description This cable carries analog signals from one or two plant sensors to the UPM where the signals can be either monitored and or used by an analog controller The ca ble also carries a 12VDC line from the UPM in order to power a sensor and or signal condition ing circuitry This cable carries the analog sig nals previously taken from the plant sensors unchanged from the UPM to the Digital To Ana log input channels on the data acquisition terminal board Document Number 525 Revision 03 Page 8 MAGLEV User Manual 4 2 Hardware Requirements
8. e 4 The From Analog Sensors cable is the 6 pin mini DIN to 6 pin mini DIN cable described in Table 4 and shown in Figure 7 First connect one end of the cable to the Sensor Connector located at the back of the MAGLEV and which is shown as component 10 in Figure 3 Then connect the cable s other end to the UPM socket labelled S1 amp S2 which is contained inside the UPM From Analog Sensors front panel These connections are illustrated by cable 4 in Figures 10 and 11 above 2 Connect the From Analog Sensors Cable Cable 5 The From Analog Sensors cable is the 6 pin mini DIN to 6 pin mini DIN cable described in Table 4 and shown in Figure 7 First connect one end of the cable to the Current Sense Connector located at the back of the MAGLEV and which is shown as component 11 in Figure 3 Then connect the cable s other end to the UPM socket labelled S3 which is contained inside the UPM From Analog Sensors front panel These connections are illustrated by cable 5 in Figures 10 and 11 above 3 Connect the To Analog To Digital Cable Cable 3 The To Analog To Digital cable is the 5 pin DIN to 4xRCA cable described in Table 4 and shown in Figure 8 First connect the cable 5 pin DIN connector to the UPM socket labelled To A D as illustrated by cable 3 in Figure 11 above The other end of the cable is split into four RCA connectors each one labelled with a single digit ranging from one to four This numbering c
9. e 4 and shown in Figure 5 Connect the RCA end of this cable to the Analog Output 0 i e DAC 0 of your data acquisition card terminal board and its 5 pin DIN connector to the socket labelled From D A on the UPM2405 These two connections are illustrated by cable 1 in Figures 9 and 11 above 2 Connect the To Load Cable Of Gain 5 Cable 2 The To Load cable of gain 5 is the 4 pin DIN to 6 pin DIN cable described in Table 4 and shown in Figure 6 First connect the cable 4 pin DIN connector to the MAGLEV Coil Connector which is shown as component 9 in Figure 3 Then connect the cable 6 pin DIN connector to the UPM socket labelled To Load The connection to the UPM is illustrated by cable 2 in Figure 11 above 4 3 2 Wiring Of The Electromagnet Feedback Sensors The MAGLEV system contains two feedback sensors One is a small current sense resistor in series with the coil The other is a photodarlington embedded in the chamber pedestal and providing the ball position signal Both current sensor and photodarlington are wired to one 6 pin mini DIN socket each as seen in the wiring schematic in Figure 4 Pictures of the same 6 pin mini DIN socket are available in Figure 3 where they are represented as components 11 and 10 respectively To connect these two analog sensors follow the steps described below Document Number 525 Revision 03 Page 10 MAGLEV User Manual 1 Connect the From Analog Sensors Cable Cabl
10. epending on your system data acquisition board as detailed in Table 6 above This should download the calibration code to the WinCon Client open the calibration control panel illustrated in Figure 13 below and two DigitalMeters displaying both the measured electromagnet current L and the measured position sensor voltage V Document Number 525 Revision 03 Page 14 MAGLEV User Manual Control Panel q cal maglev mqp a gt MAGLEV Calibration Step 1 OFF Offset Potentiometer Calibration Step 2 ON Gain Potentiometer Calibration Calibration Switch gt i tr f ri i rm F j J VILLE Figure 13 WinCon Calibration Control Panel 5 2 2 Zero Offset Potentiometer Calibration At Voltage Zero If it is not yet present place the steel ball on the post inside the MAGLEV chamber The control panel pushbutton should be OFF You can now start WinCon by clicking on the green START button on the WinCon Server Window This should set the electromagnet current to zero as seen in Figure 14 You can now calibrate the offset potentiometer if necessary Using a potentiometer adjustment tool 1 e a small flat end screwdriver manually adjust the offset potentiometer screw on the MAGLEV enclosure to obtain zero Volts on the V DigitalMeter as depicted in Figure 15 Turning the offset potentiometer screw clockwise increases the voltage V and vice versa When this is achieved you can
11. ior Lights Position Sensor Offset Position Sensor Gain Potentiometer Potentiometer Coil Leads 4 Pin DIN Connector Position Sensor Cable 6 Pin Mini DIN Connector Current Sensor Cable 6 Pin Mini Inside Chamber DIN Connector Table 1 MAGLEV Component Nomenclature Document Number 525 Revision 03 Page 2 MAGLEV User Manual 2 AE Quanser Consulting ML Magnetic Levitation Sensor Offset Gain Figure 3 MAGLEV Plant Back View Figure 2 MAGLEV Plant Front View Document Number 525 Revision 03 Page 3 MAGLEV User Manual 2 2 Component Description 2 2 1 Overall Enclosure Component 1 The MAGLEV overall enclosure is made of aluminum Its external dimensions are shown in Table 2 below Description Overall Enclosure Height Overall Enclosure Width Overall Enclosure Depth Table 2 MAGLEV Overall Dimensions 2 2 2 Electromagnet Coil Component 2 The electromagnet consists of a tightly wound solenoid coil made of 2450 turns of 20 AWG magnet wire For safe operation it results that the coil continuous current should never exceed 3 A The coil inductance resistance dimensions and other specifications are shown in Table 3 below Moreover the electromagnet wiring together with the current sense re sistor can be seen in Figure 4 below 2 2 3 Pedestal Position Sensor Component 4 The light sensitive sensor measuring the steel ball vertical position consists of a NPN sili
12. n you receive it or under changing external light conditions The position voltage measured on the UPM channel S1 should be zero when the ball is resting on the black post while it should be between 4 75 Volts and 4 95 Volts when the ball is held up by or stuck to the electromagnet Such a procedure results in a precisely known conversion factor relating ball displacement to sensor output voltage 5 1 Calibration Model The Simulink model used to control the electromagnet current as required by the calibra tion procedure explained hereafter is depicted in Figure 12 below Tak q cal maglev mqp File Edit View Simulation Format Tools Help WinCon MAGLEV Calibration Offset and Gain Potentiometers PI Current Controller EA Swith Trigger 100 rep Ic des A Offset Cal Ic des Current Kop AV MAGLEV Actual Plant Ic des A Gain Cal Figure 12 Position Sensor Calibration Diagram Such a controller diagram is used to generate the calibration real time code and the associ ated WinCon project as described in the following sections The actual Simulink controller diagram files are available in the Calibration directory under the name type g_cal_ma glev ZZ mdl where the extension ZZ stands for the type of data acquisition board that the diagram interfaces to The name substitutions stood for by ZZ are listed and described in Table 6 below Document Number 525 Revision 03 Page 13 MAGLEV User Manual Z
13. nnnnnnnnnnnnnns 15 5 2 3 Gain Potentiometer Calibration At The Maximum Voltage rrrrrrrnrorooenn 16 6 Obtaining Support errrrrronnrnnnrnnrrrrrrrrrnrrrrrrrrrrsnsssssnssssrnrssnsnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnn 16 Document Number 525 Revision 03 Page I MAGLEV User Manual 1 MAGLEV Presentation 1 1 MAGLEV System Description The typical Magnetic Levitation plant i e MAGLEV is depicted in Figure 1 below while levitating in air a steel ball within its magnetic field The MAGLEV can be described by three distinct sections encased in a rectangular enclosure First the upper section contains an electromagnet made of a solenoid coil with a steel core Second the middle section consists of an inside chamber where the magnetic ball suspension actually takes place One of the electromagnet poles faces the top of a black post upon which a one inch steel ball rests The ball elevation from the post top is measured using a photo sensitive sensor embedded in the post The post is designed in such a way that when the ball rests on top of it the air gap between the ball s top hemisphere and the electromagnet pole face is 14 mm The post also provides repeatable initial conditions for control system performance evaluation Finally the bottom section of the MAGLEV apparatus houses the system s conditioning circuitry needed for example by the light intensity position sensor As detailed later in this
14. on by clicking on the red STOP button on the WinCon Server Window Exit WinCon without saving the modified project Digital q cal maglev mqp Ic A Digital q cal maglevr mqp Yb Y B E 5 ioj xj File Window Number File Window Number Background Colour Text Colour Text Font Background Colour Text Colour Text Font Figure 16 Gain Calibration I DigitalMeter Figure 17 Gain Calibration V DigitalMeter 6 Obtaining Support Note that a support contract may be required to obtain technical support To obtain support from Quanser go to http www quanser com and click on the Tech Support link Fill in the form with all requested software version and hardware information and a descrip tion of the problem encountered Submit the form Be sure to include your email address and a telephone number where you can be reached A qualified technical support person will contact you Document Number 525 Revision 03 Page 16
15. orresponds to the four possible analog sensor signals passing through the UPM namely S1 S2 S3 and S4 In order for the analog signals to be used in software you should then connect all four RCA connectors to the first four analog input channels of your data acquisition card terminal board Specifically connect SI to Analog Input 0 S2 to Analog Input 1 S3 to Analog Input 2 and S4 to Analog Input 3 as illustrated by cable 3 in Figure 9 above In other words the ball position is sensed using A D 0 through the UPM analog channel S1 and the coil current is sensed using A D 2 through the UPM analog channel S3 Document Number 525 Revision 03 Page 11 MAGLEV User Manual 4 3 3 MAGLEV Wiring Summary Table 5 below sums up the connections detailed in the two previous subsections Cable DAC 0 UPM To Load UPM To A D MAGLEV Sensor MAGLEV Current Table 5 MAGLEV Wiring Summary UPM From D A Control signal to the UPM MAGLEV Coil Power leads to the coil Terminal Board Position and current feedback SI to ADC 0 signals to the data acquisition S3 to ADC 2 terminal board through the UPM UPM SI amp S2 Position feedback signal to the UPM UPM S3 Current feedback signal to the UPM Document Number 525 Revision 03 Page 12 MAGLEV User Manual 5 Ball Position Sensor Calibration The photosensitive ball position sensor is calibrated at the factory but may need re adjustment whe
16. stop WinCon by clicking on the red STOP button on the WinCon Server Window Digital q cal maglev mqpiIc A E JO gt Digital q_cal_maglev_mqgp Yb Y File Window Number File Window Number Background Colour Text Colour Text Font Background Colour Text Colour Text Font Figure 14 Offset Calibration I DigitalMeter Figure 15 Offset Calibration V DigitalMeter Document Number 525 Revision 03 Page 15 MAGLEV User Manual 5 2 3 Gain Potentiometer Calibration At The Maximum Voltage If it is not yet present place the steel ball on the post inside the MAGLEV chamber Click on the control panel pushbutton to switch it to ON You can now start WinCon by clicking on the green START button on the WinCon Server Window This should set the electromagnet current to 2 0A as seen in Figure 16 This should cause the steel ball to jump up to the electromagnet core face and stay there attaining the other limit of its displacement range If the ball does not jump up you can give it a small lift You can now calibrate the gain potentiometer if necessary Using a potentiometer adjustment tool i e a small flat end screwdriver manually adjust the gain potentiometer screw on the MAGLEV enclosure to obtain anywhere between 4 75 and 4 95 Volts on the V DigitalMeter as depicted in Figure 17 Turning the potentiometer screw counter clockwise increases the voltage V and vice versa When this is achieved you can stop WinC
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