02 - Introduction To The NI LabVIEW Control Design and Simulation Module PDF

Introduction to the NI LabVIEW Control
Design and Simulation Module

Andreas Stark
Systems Engineer
Agenda
Simulation Concepts
PID Concepts
Advanced Control Algorithms
Conclusion
Agenda
Simulation Concepts
PID Concepts
Conclusion
How to become a control expert?

Trial and Error
Time consuming
Risk
Simulation
No need of physical plant

Safe
What can you learn from simulation?

Gain insight into the system that otherwise would
be impossible or difficult due to real-world
limitations
Improve your design before beginning the
prototyping stage
Validate and tune your embedded LabVIEW
FPGA or LabVIEW Real-Time logic
What is simulation?
Use mathematical formulas to represent dynamics
of a system
Simulation Benefits
Faster, better control algorithm code
development
Understand how your control algorithm effects
the system
Evaluate impact of
Sampling rate
Sensor response time, noise, offset/gain error
Deadtime, backlash or resonance
Todays Example
NI 9505
Motor Drive Module
Ethernet
Maxon Amax
Brushed DC Motor
Demo DC Motor Control Simulation
Control System Diagram DC Motor

LabVIEW
Front Panel
Desired
Position
+-
Error
PID
Toolkit
NI 9505
Disturbance
PID
Compensator
Drive
Output
Motion
System
Measured
Position
Windows
Real-Time Hardware
FPGA Hardware
10
Encoder
Sensor
11
How to create plant models.

The old days
Write differential equations for system

Linearize the system
Convert to Laplace domain
Rearrange for transfer function or state-space model
Enter matrix equations
Today
Write differential equations for system

Type into a formula node in the LabVIEW diagram
Click RUN
Use System Identification
Use measurement data
12
Simulating a DC Motor the Old Way
Shaft
Angle
i
+
DO5
d
Tf B
dt
Ti J
B
d 2
dt 2
+
-
vR iR
L
vL L
vm
Vsup
id
di
dt
+
-
ve K e
Tm Kt i
Sum of Forces
d 2
d
0 Kt i J 2 B
dt
dt
Kirchoffs Voltage Law
di
d
vm Ri L K e
dt
dt
Rearrange to put highest order derivative terms on the left side of equation:
d 2 Kt
B d
dt 2
J
J dt
di
R
Ke d vm
i
dt
L
L dt
L
13
d
dt
The Traditional Way: Laplace Transforms

Laplace transform of motor force & voltage equations,
Vm R I L sI K e s
0 Kt I J s 2 B s
Rearranging the force equation,

Kt I
J s2 B s
Transfer function between motor terminal

voltage and shaft angle position,
Vm
K t / JL
BR K t K e
s 3 s 2 B / J R / L s
JL
14
Demo - DC Motor Simulation TF
15
Laplace Transform Approach

Benefits
Wide array of analytical techniques available (bode plots, root

locus, stability analysis, )
Challenges
Transformation is labor intensive

System must be linear otherwise a linear approximation must
be made
Transfer functions are solved for one input and one output
must redo algebra to solve for other variables.
Difficult to monitor other system states during simulation
Abstract. After transformation, the system model is less

human readable
16
Simulating a DC Motor the Modern Way
Shaft
Angle
i
+
DO5
d
Tf B
dt
Ti J
B
d 2
dt 2
+
-
vR iR
L
vL L
vm
Vsup
id
di
dt
+
-
ve K e
Tm Kt i
Sum of Forces
d 2
d
0 Kt i J 2 B
dt
dt
Kirchoffs Voltage Law
di
d
vm Ri L K e
dt
dt
Rearrange to put highest order derivative terms on the left side of equation:
d 2 Kt
B d
dt 2
J
J dt
di
R
Ke d vm
i
dt
L
L dt
L
17
d
dt
Demo - DC Motor Simulation - Textual
18
LabVIEW Simulation Module with Formula Node

Easier: If you can find the equations in a textbook, you
can simulate the system
More intuitive: You can analyze the differential
equations to gain insight into the system and discover
novel control techniques
More informative: You can instrument the system
with no physical limitations on time, accuracy or which
variables can be measured
More accurate: Both linear and non-linear behavior can
be accurately simulated
19
System Identification Definition

If prototype hardware exists, system identification can
be used as first step in model-based control design
process
Create a mathematical model of dynamic system using
measured stimulus and response data
Techniques similar to curve-fitting
Inputs
(stimulus signals)
Dynamic
System
Outputs
(response signals)
20
Demonstration System Identification
21
Comparing Simulated & Real World Results

Real-World
Simulated
22
Agenda
Simulation Concepts
PID Concepts
Basic PID Algorithms
Loop Rate
PID tuning

Conclusion
23
What is PID Control
Set Point (SP) Desired control point

Output (OP) Controller output
Process Variable (PV) Plant/process output
Error = SP - PV
error
OP
SP
PV
25
PID Parameters
Proportional
Drive to setpoint
Error 0, OP 0
Steady-state error
Integral
Eliminate steady-state error
OP proportional to error
Derivative
Increase response rate

OP proportional to change of error rate
26
Proportional-Integral-Derivative (PID)
Proportional
The further the system is from the set point, the larger the
actuator output to drive it to the set point
Integral
The longer the system has been off from the set point, the
larger the actuator output to drive it to the set point
Derivative
The faster the system is changing, the larger the actuator

output to drive it to the set point
27
Demo DC Motor Control
28
How to program PID
PID VIs
Simulation VI
Function Blocks
PID FPGA VIs
Textual Math Scripts
Ready to Run
Custom
30
Algorithm Compatibility Chart

PID VIs
Function
Blocks
Windows
Yes
No
Yes
Yes
Yes
Real Time
Yes
Yes
Yes
Yes
Yes
FPGA
No
No
Yes
No
No
PID and
Fuzzy Logic
Toolkit
LabVIEW RT
PID and
Fuzzy Logic
Toolkit
Control
Design and
Simulation
Mathscript
RT
Included
with Product
FPGA PID VI Simulation VI Textual Math

Scripts
31
PID and Fuzzy Logic Toolkit - Features

Saturation
Integral Antiwindup
Bumpless Transfers
Autotuning
Gain Scheduling
Filtering
32
PID Toolkit Features Explained

Output Range Limits
Protects the motor
Integrator Antiwindup
Better performance in the presence of control

saturation
Bumpless Manual Control
Avoid abrupt changes to motor, increase life
33
Demonstration Integral Antiwindup
34
How fast should the loop rate be

Perception that faster is
better
Too fast might be
challenge to implement
Tuning challenges
Use Frequency
Response to find out
35
Frequency Response
Gain Crossover Frequency
Frequency (Hz)
Input
System (Plant)
Output
36
What can you learn from the frequency response?

Loop Rate Requirements
How fast the control system need to be
Rule of thumb
The control loop should be at least ten times faster than the gain
crossover frequency of the system (minimum 2X faster)
Crossover frequency = 40 Hz
Suggested Loop rate = 400 Hz
CAUTION: Increasing the control algorithm gain increases the crossover frequency
37
Demo: Frequency Response Demo
38
Real World Control Challenges

Systems with a fast response
Use a fast control system and fast I/O modules
Ensure determinism and avoid jitter
FPGA-based control systems are ideal !
39
PID Tuning and Loop Rates

Increasing the P gain makes your system faster.
Result: You may need a faster control loop rate.
40
Conclusions
The performance and stability of the system
depends on the frequency response of the
system AND the control algorithm
Systems that change quickly or have complex
behavior require faster control loop rates
Increasing the gain of the control algorithm may
mean you need to run the control system faster
41
Other PID Tuning tools

Manual
Open Loop Ziegler-Nichols
Closed Loop Ziegler-Nichols
Automatic
Autotuning
Frequency Based (Analytical PID)
Time Based (Optimization)
44
Demo Analytical PID
45
Conclusions
P gain is the most important factor in PID tuning
I gain gets rid of steady-state error
D gain is rarely used and may cause problems if
feedback signal is noisy
If you increase the gain, you may have to
increase the loop rate
If you see a system tuned with a gain of less than 1,

running the control loops faster may improve
performance and reliability
46
Agenda
Simulation Concepts
PID concepts
Advanced PID Algorithms
Conclusion
47
Upgrade Your PID

Disturbances
Nonlinear
Time Variant
Known
Profiles
Feedforward
Gain Scheduling
Adaptive PID
Model Predictive
Control
48
Feed forward
49
Gain Scheduling
PID 3
PID 2
PID 1
50
Control Design Techniques

Adaptive Control
Self-Tuning
Parameter or Structure of the
Controller modifies with changes
on the plant
Set Point
+-
Controller
Configurator
Plant
Estimator
Controller
System
(Plant)
51
Adaptive PID - Example
52

Modern Control
State-Space Feedback Controller Design

Ackermann / Pole Placement
Optimal or Linear Quadratic Regulator (LQR)
Stochastic Systems and Linear Quadratic Gaussian (LQG)
Set Point
+-
PID
Servo
System
(Plant)
+-
Estimator
Regulator
u=-k.x
States
53

Optimal Control and Predictive Control
Parameter of the Controller are optimized for the specific operation.

Np
min J xT Qx u T Ru 2 xT Nudt
0
Constraints
Optimizer
Set Point
System
(Plant)
+-
PID Control
54
Model Predictive Control Vs PID
55
Agenda
Simulation Concepts
PID concepts
Advanced PID Algorithms
Conclusion
57
Easily Deploy to Hardware the NI Way
Many modelsOne approach
58
Questions?
To find
Code used on the demonstration
Technical documentation
Follow up whitepapers
Go to
www.ni.com\info
and enter the code
devdays2010ctrl
59
Additional Resources
60
Deadtime
The interval of time between initiation of an input change or
stimulus and the start of the resulting response
Deadtime
61
Dead time
Deadtime is a delay between when a process
variable changes, and when that change can be
observed.
Examples:
Temperature sensor is placed far away from a cold water

fluid inlet valve
Delay caused by the flow of fluid through pipes

Will not measure a change in temperature immediately if the
valve is opened or closed
Deadtime can also be caused by a System (Plant) or

Output Actuator that is slow to respond to the
Compensator command.
Valve that is slow to open or close
Thermocouple sensor: Response time depends on thermal

mass
I/O module: Filters that remove 50/60 Hz noise slow the
response
Every sensor and I/O module causes some delay in

the measurement
62
Backlash
Example: Motor spins but gate doesnt begin to
open for some time due to a sloppy mechanical
system.
63
Resonance or Vibration
Avoid exciting the system at the resonant
frequency
Gain can be reduced at the problem frequency using

a notch filter or low pass filter
Use a custom control algorithms such as a leadlag controller

Convolve algorithm
MFA algorithm
64
Linear systems vs non-linear systems

Linear system
Steady state response of the system is linearly

proportional to the stimulus
Gain
Offset
Y mX b
Steady State Response
Constant Stimulus
65
Linear system
Differential equation describing system response (y)

has constant multiplier coefficients
The function (y) or its derivatives (y, y) are not raised to

some power or embedded in another function (such as sin
y)
y 7y 0
First order linear, no stimulus
y 2 y 8 y sin 2 x
Second order linear
'
''
'
y x 1 y sin 4 x
''
Second order nonlinear
66

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Introduction to the NI LabVIEW Control

Design and Simulation Module

How to become a control expert?

No need of physical plant

What can you learn from simulation?

Demo DC Motor Control Simulation

Control System Diagram DC Motor

How to create plant models.

Write differential equations for system

Write differential equations for system

Use System Identification

Use measurement data

Simulating a DC Motor the Old Way

Kirchoffs Voltage Law

The Traditional Way: Laplace Transforms

Rearranging the force equation,

Transfer function between motor terminal

Demo - DC Motor Simulation TF

Laplace Transform Approach

Wide array of analytical techniques available (bode plots, root

Transformation is labor intensive

Abstract. After transformation, the system model is less

Simulating a DC Motor the Modern Way

Kirchoffs Voltage Law

Demo - DC Motor Simulation - Textual

LabVIEW Simulation Module with Formula Node

System Identification Definition

Demonstration System Identification

Comparing Simulated & Real World Results

Advanced Control Algorithms

What is PID Control

Set Point (SP) Desired control point

Increase response rate

The faster the system is changing, the larger the actuator

Demo DC Motor Control

How to program PID

PID FPGA VIs

Textual Math Scripts

Algorithm Compatibility Chart

FPGA PID VI Simulation VI Textual Math

PID and Fuzzy Logic Toolkit - Features

PID Toolkit Features Explained

Protects the motor

Better performance in the presence of control

Bumpless Manual Control

Avoid abrupt changes to motor, increase life

Demonstration Integral Antiwindup

How fast should the loop rate be

What can you learn from the frequency response?

How fast the control system need to be

Demo: Frequency Response Demo

Real World Control Challenges

FPGA-based control systems are ideal !

PID Tuning and Loop Rates

Result: You may need a faster control loop rate.

Other PID Tuning tools

Demo Analytical PID

If you see a system tuned with a gain of less than 1,

Upgrade Your PID