Complex Engineering Problem for Power Electronics (EE-313)

Project Title:
Variable Speed DC Motor With Speed Monitoring,powered using 3 Phase AC Supply

Abstract:
This project focuses on the design and implementation of a comprehensive system that utilizes a three-phase power supply to
drive a variable-speed DC motor while simultaneously monitoring its speed. The integration of a three-phase power supply, a DC
motor controller, and speed monitoring mechanisms offers an advanced solution for industrial and automation applications.

The three-phase power supply provides a stable and efficient source of power, ensuring the consistent operation of the DC motor.
A rectifier converts the three-phase AC voltage to a DC voltage, which powers the motor. The speed control of the DC motor is
achieved through a microcontroller enabling precise and dynamic speed adjustments.

In addition to motor control, the project incorporates a feedback system for real-time speed monitoring. An optical sensor is
employed to capture the motor's rotational speed. This information is then processed by a microcontroller, allowing for
continuous monitoring and control adjustments to maintain the desired speed.

The project's outcomes highlight the benefits of a three-phase power supply in combination with speed monitoring for industrial
applications where motor speed precision and reliability are crucial. Such systems find relevance in conveyor systems, CNC
machinery, and robotics, where precise speed control is a fundamental requirement for efficient and safe operation.

Task Identification

Literature Review
METHODS OF SPEED CONTROL OF A DIRECT CURRENT MOTOR:
Speed control of a DC (Direct Current) motor is essential for various applications where precise control over the
motor's rotational speed is required. There are several methods to achieve this control, each with its own advantages
and disadvantages. Following are some common methods of DC motor speed control:

1. Armature Voltage Control:

i) Method:
The voltage applied to the motor's armature (the rotor) is varied to control the motor's speed. This is typically
done using a rheostat (variable resistor) connected in series with the armature.
ii) Advantages:
(1) Simple and cost-effective method.
(2) Provides a wide range of speed control.
iii) Disadvantages:
(1) High power loss in the rheostat due to the voltage drop.
(2) Inefficient, as the power dissipation in the resistor can be significant.
(3) Limited to low-power applications due to the heat generated in the resistor.

2. Field Flux Control:

i) Method:
The field winding's current is varied to control the motor's speed. By changing the magnetic field strength, the
motor speed can be adjusted.
ii) Advantages:
(1) Offers better efficiency than armature voltage control.
(2) Suitable for medium-power applications.
iii) Disadvantages:
(1) Less range of speed control compared to armature voltage control.
 (2) Requires a separate field winding and a complex control system.

3. Armature Resistance Control:

i) Method:
Instead of controlling the voltage, this method controls the armature current by varying the armature winding's
resistance.
ii) Advantages:
(1) Provides a good balance between efficiency and control range.
(2) Suitable for medium-power applications.
iii) Disadvantages:
(1) Still has some power loss in the variable resistor.
(2) Limited control range compared to more advanced methods.

4. Chopper Control:

i) Method:
A chopper is used to chop the supply voltage to the motor, controlling the effective voltage applied to the
armature. Pulse Width Modulation (PWM) is often used in chopper control.
ii) Advantages:
(1) Efficient control method with minimal power loss.
(2) Suitable for both low and high-power applications.
(3) Provides precise speed control.
iii) Disadvantages:
(1) More complex and costly than earlier methods.
(2) Requires a feedback system for accurate control.

The choice of method for DC motor speed control depends on the specific application's requirements, such as power,
efficiency, and cost. While simpler methods like armature voltage control may be sufficient for low-power
applications, more advanced techniques like FOC are necessary for high-performance and precise control. It's essential
to consider the trade-offs between efficiency, cost, and complexity when selecting the appropriate speed control
method for a given application.

METHODS OF CONVERSION OF THREE PHASE AC TO VARIABLE DC SUPPLY:

Converting three-phase AC (Alternating Current) to variable DC (Direct Current) involves various methods, and the
choice depends on the specific application requirements and the level of control needed. Here are some common
methods for converting three-phase AC to variable DC:

1. Phase-Controlled Rectifiers (SCR or Thyristor Rectifiers):

i) Method:
A controlled rectifier circuit using thyristors (SCRs) is employed. By controlling the firing angle of the
thyristors, you can regulate the output DC voltage.

ii) Advantages:
(1) Suitable for high-power applications.
(2) Provides variable DC voltage with a good level of control.
iii) Disadvantages:
(1) Can introduce harmonics in the AC supply, requiring additional filtering.
(2) Less efficient at partial load conditions.

2. Pulse-Width Modulated (PWM) Inverters:

i) Method:
A three-phase PWM inverter is used to convert the three-phase AC into variable DC. By controlling the
 width of the output pulses, you can regulate the DC voltage.
ii) Advantages:
(1) High efficiency and precise control.
(2) Suitable for a wide range of applications.
(3) Low harmonic distortion.
iii) Disadvantages:
(1) More complex and costly compared to SCR rectifiers.
(2) Requires a control system for precise voltage regulation.

METHOD USED IS THE FOLLOWING

3)Uncontrolled Rectifier

Using uncontrolled rectification with a microcontroller to control voltage is a more complex task because uncontrolled
rectification inherently produces a fixed or semi-fixed DC voltage output. However, you can achieve a form of voltage
control by altering the duty cycle of a chopper circuit (a type of DC-DC converter) that is connected to the output of
the rectifier. Following are the steps:

1. Uncontrolled Rectifier Circuit:

Start with a standard uncontrolled rectifier circuit, such as a diode bridge rectifier. This circuit converts the
incoming AC voltage to pulsating DC voltage.

2. Voltage Sensing and Microcontroller Monitoring:

Use voltage dividers or potential transformers to step down the DC voltage to a level that is safe for the
microcontroller's analog input. Connect the sensed voltage to the microcontroller's analog input pin.

3. Chopper Circuit:
Connect a chopper circuit to the output of the uncontrolled rectifier. A chopper is a DC-DC converter that can vary
the DC voltage by controlling the duty cycle of its switching device (e.g., a MOSFET or IGBT). The chopper will
allow you to control the average DC voltage by periodically connecting and disconnecting the DC voltage source to
the load.

4. Microcontroller Control:
Write a control algorithm in the microcontroller that adjusts the chopper's duty cycle based on the sensed DC
voltage. You can program the microcontroller to achieve the desired average voltage by increasing or decreasing the
duty cycle as needed.

5. Feedback Control Loop:

Implement a feedback control loop in the microcontroller. The microcontroller continuously monitors the DC
voltage using the analog input and adjusts the chopper's duty cycle to maintain the desired voltage level. This
feedback loop ensures that the voltage stays within the specified range.

6. Output Filtering (Optional):

Depending on the application, you might need output filtering to reduce voltage ripple or other disturbances in the
DC voltage.

7. Testing and Calibration:

Thoroughly test and calibrate the system to ensure that the microcontroller effectively controls the output voltage
within the desired range. Make sure to account for the chopper's switching frequency and its impact on the output
voltage.

8. Safety and Protection Mechanisms:

Implement safety and protection features in the microcontroller code, such as overvoltage or overcurrent protection,
to prevent damage to the load or the circuit.

It's important to note that this method is relatively complex and may not provide the same level of precision and
stability as fully controlled rectification methods like PWM inverters. The voltage control in this setup depends on the
speed and accuracy of the microcontroller's control loop, as well as the characteristics of the chopper circuit.
Additionally, it introduces switching losses in the chopper, which may affect the overall efficiency.

This method is typically suitable for applications where relatively coarse voltage control is acceptable and where the
advantages of uncontrolled rectification (simplicity and cost-effectiveness) outweigh the disadvantages. For
applications requiring highly precise voltage control, more advanced rectification and control methods are usually
preferred.

MEASUREMENT OF SPEED OF A DC MOTOR USING MICROCONTROLLER:

Measuring the speed of a DC motor with a microcontroller can be achieved using various methods. One common and
straightforward approach is to use a quadrature encoder, which provides precise information about the motor's speed
and direction. Here's how you can measure the speed of a DC motor using a microcontroller with a quadrature
encoder:

Materials Needed:
1. DC motor with an encoder (quadrature encoder)
2. Microcontroller (e.g., Arduino, Raspberry Pi, or any microcontroller with appropriate input/output capabilities)
3. Motor driver (H-bridge or other motor control circuit)
4. Power supply for the motor
5. Connecting wires
6. Breadboard or custom PCB for circuit connections (if needed)

Steps:

1. Motor and Encoder Connection:

a. Connect the DC motor to the motor driver circuit, ensuring it is powered and controlled by the microcontroller.
b. Connect the quadrature encoder to the motor shaft. The encoder typically has two output channels, A and B,
which provide pulses as the motor shaft rotates. Connect these channels to the microcontroller's digital input
pins.

2. Microcontroller Programming:
a. Write a program for the microcontroller to read the encoder's A and B channels. Use interrupts or polling to
monitor the changes in the encoder's output.
b. Measure the time between encoder pulses to calculate the motor's speed. This time interval will be used to
determine the RPM (revolutions per minute).

3. Calculating Motor Speed:

The number of encoder pulses (both rising and falling edges) that occur in a specific time interval will give you the
counts per minute (CPM).

RPM can be calculated using the formula:

`RPM = (CPM / Encoder PPR) * 60`
where PPR (Pulses Per Revolution) is the number of encoder pulses per motor shaft revolution.

4. Display or Utilize the Speed Information:

a. Display the motor speed on an LCD, LED display, or send it to a computer for monitoring.
b. You can also use the speed information to control the motor's behavior or for feedback in a closed-loop control
system.

5. Calibration and Testing:

a. Ensure your system is calibrated correctly by comparing the measured RPM to the actual motor speed (e.g.,
using a handheld tachometer).
b. Test the system under various loads and conditions to ensure accurate speed measurements.
 6. Considerations:
a. Make sure to handle encoder channel phase shifts correctly (quadrature decoding).
b. Implement debouncing to eliminate false encoder pulse readings.
c. Select a microcontroller with a sufficient number of interrupt-capable digital pins and processing power for
your application.

This method provides accurate speed measurements of the DC motor using a quadrature encoder. The microcontroller
continuously monitors the encoder output and calculates the motor's speed in real-time. You can use this information
for various applications, including feedback control, monitoring, and automation.

List of Tasks needed to be completed to fulfill the Problem Statement requirements

1) Planning and Research
2) Gathering material
3) Block Diagram
4) Circuit Diagram
5) Stimulation
6) Hardware Design

Resource Identification
Human Resource (Project Team)

S.No. Name Roll No. Section Current skill-set seemingly valuable for project
completion (only tangible/demonstrable skills)
1 Sameed Ansar Ahmed* 168 D Familiar with Aurdino
2 Muhammad Ibaad Ur Rehmaan 125 D No skill set currently
3 Mohammad Anas Tungekar 161 D Circuit Implementation
4 Salman Asif 166 D Familiar with multisim
5 Syed Qaim Rizvi 157 D Circuit design and components

Human Resource Skill Gap

Sameed:Get more familiar with coding for arduino
Anas:Learn basics of arduino
Salman:Get familiar with basics of arduino
Ibaad:learn circuit design and improve circuit implementation skills
Qaim:Get familiar with basics of arduino
Hardware Resource Identification

S. No. Hardware Component/Equipment Name Where/How to acquire

1 Diodes Spark Electronics
2 DC Motor With Optical Encoder Daraz
3 Aurdino Daraz
4 Veroboard Sparks Electronic
5 Connecting wires Sparks Electronic
6 Three phase Transformer PE lab
7 Two/three pin connectors Sparks Electronic
8 Soldering Kit Sparks Electronic

Software Resource Identification

S. No. Software Name Where/How to acquire

1 Multisim www.multisim.com
2 TinkerCad www.tinkercad.com
 3 Google Docs online available

Project Objectives
Objective: Develop a hardware system that integrates a DC motor with an optical encoder and a microcontroller to accurately
measure the motor's speed.

Objective:Write code for the microcontroller that monitors the encoder's output, calculates the motor's speed in real-time, and
provides accurate speed measurements.

Objective: Design a user-friendly interface for displaying the measured motor speed in a human-readable format. Consider
options for visualization, such as LCD displays, LEDs etc

Objective: Convert three phaseAC supply to variable DC

Objective:Design a circuit diagram to display how three phase supply is used to power variable dc motor.

Project Deliverables
Functional Speed Measurement System:
A working hardware system compromising of a three phase bridge rectifier, a DC motor, an optical encoder, and a
microcontroller.The system accurately measures and displays the speed of the DC motor in real-time.The system demonstrates
robust performance.
User-Friendly Interface and Data Visualization:
An aesthetically pleasing user interface for displaying the measured motor speed.
The ability to visualize the speed data on a designated output medium, such as an LCD display or LED etc.
Three Phase Bridge rectifier:
A three phase bridge rectifier using six diodes, with high efficiency of converting ac voltage to dc voltage.
Circuit diagram:
Circuit diagram blueprinting the whole system.

Resource Allocation and Time Scheduling

Human Resource Allocation
Planning and Research by Sameed and Anas
Gathering material by Sameed and Anas
Block Diagram by Ibaad and Salman
Circuit Diagram by Ibaad and Anas
Stimulation by Sameed and Salman
Hardware Design by everyone

Hardware/Software Resource Allocation

Objectives Software Hardware

Develop Hardware system for varying Nil Micro controller

Speed of DC motor DC motor with optical encoder

Coding for micro controller to adjust Arduino coding interface nil

speed
 User friendly display Arduino coding interface LED Display

Three Phase AC to DC Nil Three phase AC supply and 6 diodes

Circuit Diagram Multisim Nil

Time Scheduling

Budgeting and Bill Of Materials (BOM)

Estimated BOM

S.No. Equipment/Component Name Estimated Cost Reference of Cost Estimate

(PKR)
1 Diodes (6) 60 Spark Electronics
2 DC Motor With Optical Encoder 380 Daraz

Total Cost: 440

 Budget Funding
Self Sponsored

Risk Assessment and Mitigation

Risk Assessment
Motor Compatibility:
When the DC motor is operated within the intended speed and torque range. There is a risk of overloading the motor which
can result in overheating and damage to the DC motor.
Component Reliability:
There is a possibility that parts may prematurely break as the result of the strain of frequent conversions, which could affect
the system's operational reliability.
Component Procurement Delays:
There is a chance that the project's schedule will be impacted by delays in acquiring necessary components.
Supplier Reliability:
Unreliable suppliers may sell us with inefficient or broken pieces of equipment
Voltage Fluctuations:
Voltage fluctuations in three phase AC supply may impact motor performance and the quality of DC power.

Risk Mitigation
01. Motor Compatibility can be rectified by checking it in great detail before its implementation.
02. Buying components from reliable suppliers will ensure we have fewer reliability issues
03. Component Procurement Delays can be mitigated through backup suppliers and strategies to deal with procurement
delays.
04. In order to keep voltage levels steady, we will use power supply from area where voltage fluctuations are low

References
Chatgpt, Daraz

Submission at the time of Evaluation

1) Original source file for Gantt Chart
2) Proof of survey of market/online-vendors for BOM
3) Partial/complete set of equipment bought for the project

Extent of Achievement
Skill(s) to be assessed
<50% 50%-65% 65%-80% 80%-100%
Resource Unable to Partial Partial identification Complete
identification and identify and identification or Partial allocation identification and
allocation allocate and allocation allocation
Task identification Unable to Partial Partial identification Complete
and scheduling identify and identification or Poor scheduling identification and
schedule and poor proper scheduling
 scheduling
Bill of Materials No BOM and Incomplete Complete BOM and Complete BOM
(BOM) and budgeting budgeting BOM and budgeting with errors and budgeting
budgeting with no errors
Risk assessment and Unable to Identifies risks Partial risk Comprehensive
management identify risks correctly but identification and risk assessment
and unable to unable to partial mitigation and mitigation
propose propose plan proposed plan presented
mitigation mitigation plan
plan

Extent of Achievement
Skill(s) to be assessed
<50% 50%-65% 65%-80% 80%-100%
Resource Unable to Partial Partial identification Complete
identification and identify and identification or Partial allocation identification and
allocation allocate and allocation allocation
Task identification Unable to Partial Partial identification Complete
and scheduling identify and identification or Poor scheduling identification and
schedule and poor proper scheduling
scheduling
Bill of Materials No BOM and Incomplete Complete BOM and Complete BOM
(BOM) and budgeting budgeting BOM and budgeting with errors and budgeting
budgeting with no errors
Risk assessment and Unable to Identifies risks Partial risk Comprehensive
management identify risks correctly but identification and risk assessment
and unable to unable to partial mitigation and mitigation
propose propose plan proposed plan presented
mitigation mitigation plan
plan

Extent of Achievement
Skill(s) to be assessed
<50% 50%-65% 65%-80% 80%-100%
Resource Unable to
Partial Partial identification Complete
identification and identify and
identification or Partial allocation identification and
allocation allocate
and allocation allocation
Task identification Unable to
Partial Partial identification Complete
and scheduling identify and
identification or Poor scheduling identification and
schedule
and poor proper scheduling
scheduling
Bill of Materials No BOM and Incomplete Complete BOM and Complete BOM
(BOM) and budgeting budgeting BOM and budgeting with errors and budgeting
budgeting with no errors
Risk assessment and Unable to Identifies risks Partial risk Comprehensive
management identify risks correctly but identification and risk assessment
and unable to unable to partial mitigation and mitigation
propose propose plan proposed plan presented
mitigation mitigation plan
plan

Extent of Achievement
Skill(s) to be assessed
<50% 50%-65% 65%-80% 80%-100%
Resource identification Unable to Partial Partial identification or Complete
and allocation identify and identification Partial allocation identification and
allocate and allocation allocation
Task identification and Unable to Partial Partial identification or Complete
scheduling identify and identification Poor scheduling identification and
schedule and poor proper scheduling
scheduling
Bill of Materials (BOM) No BOM and Incomplete Complete BOM and Complete BOM and
and budgeting budgeting BOM and budgeting with errors budgeting with no
budgeting errors
Risk assessment and Unable to Identifies risks Partial risk Comprehensive risk
management identify risks correctly but identification and assessment and
and unable to unable to partial mitigation plan mitigation plan
propose propose proposed presented
mitigation mitigation plan
plan

Extent of Achievement
Skill(s) to be assessed
<50% 50%-65% 65%-80% 80%-100%
Resource Unable to Partial Partial identification Complete
identification and identify and identification or Partial allocation identification and
allocation allocate and allocation allocation
Task identification Unable to Partial Partial identification Complete
and scheduling identify and identification or Poor scheduling identification and
schedule and poor proper scheduling
scheduling
Bill of Materials No BOM and Incomplete Complete BOM and Complete BOM
(BOM) and budgeting budgeting BOM and budgeting with errors and budgeting
budgeting with no errors
Risk assessment and Unable to Identifies risks Partial risk Comprehensive
management identify risks correctly but identification and risk assessment
and unable to unable to partial mitigation and mitigation
propose propose plan proposed plan presented
mitigation mitigation plan
plan
 Extent of Achievement
Skill(s) to be assessed
<50% 50%-65% 65%-80% 80%-100%
Resource identification Unable to Partial Partial identification Complete
and allocation identify and identification or Partial allocation identification and
allocate and allocation allocation
Task identification and Unable to Partial Partial identification Complete
scheduling identify and identification or Poor scheduling identification and
schedule and poor proper scheduling
scheduling
Bill of Materials (BOM) No BOM and Incomplete Complete BOM and Complete BOM
and budgeting budgeting BOM and
budgeting with errors and budgeting
budgeting with no errors
Risk assessment and Unable to Identifies risks Partial risk Comprehensive
management identify risks correctly but identification and risk assessment
and unable to unable to partial mitigation and mitigation
propose propose plan proposed plan presented
mitigation mitigation plan
plan