Dynamometer for Testing
Frequency Inverter Performance
Andres Calle Otero, Alexander Sawyer, Christian Ratliff
Team 1603
Sponsored by Lenze
Advanced Power Electronics and Electric Drives Lab (APEDL)
ECE Department and Center for Clean Energy Engineering
11/13/2015
11/12/2015
Copyright © 2015 – Advanced Power Electronics & Electric Drives Lab (APEDL)
1
Outline
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11/12/2015
Project Overview
Solution
GUI
HMI/PLC
Communication
Deliverables
Budget
Schedule
Copyright © 2015 – Advanced Power Electronics & Electric Drives Lab (APEDL)
2
Overview
• What is Lenze?
• What do they want?
11/12/2015
Copyright © 2015 – Advanced Power Electronics & Electric Drives Lab (APEDL)
3
Overview: Test Setup
4
Overview: Objectives
• Primary:
• Secondary:
• Tertiary:
5
Overview: Desires
6
Solution: Ideal
User
HMI w/ Program
HMI Visual Basic GUI
with Modbus Communication
User Interaction
Advantages
•
•
•
•
•
•
Communication
(ModBus)
Touchscreen
Possibly all Lenze product
No need for PLC
More direct communication
Use of Modbus reduces complexity
Visual Basic is supported
Disadvantages
•
Switcher
Drive Control
And
Sensor Feedback
(Ethernet)
Motor Inverter
The use of the HMI adds complexity
Drive Control
And
Sensor Feedback
(Ethernet)
Test Motor
Dynometer
Dynometer Inverter
7
Solution: Alternative
User
Computer w/ Program
Computer GUI with DAQ and
Analog/Digital Communication
User Interaction
Communication
(ModBus)
Advantages
Drive Control
And
Sensor Feedback
(A/D)
PLC w/ A/D inputs and
DAQ
outputs
Drive Control
And
Sensor Feedback
(A/D)
•
•
•
•
No need for Ethernet Switch
Can use standard drive A/D ports
Computer supports wide variety of GUI
options
External current sensing feasible
Disadvantages
•
•
Motor Inverter
Test Motor
Dynometer
More hardware is needed
Less Lenze components and no HMI
Dynometer Inverter
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Other Feasible Solutions
User
Computer w/ Program
Computer GUI with PLC Control and
Analog/Digital Communication
User Interaction
Communication
(ModBus)
Advantages
Drive Control
And
Sensor Feedback
(A/D)
PLC w/ A/D inputs and
outputs
Drive Control
And
Sensor Feedback
(A/D)
•
•
•
No need for Ethernet Switch
Can use standard drive A/D ports
Computer supports wide variety of GUI
options
Disadvantages
•
•
Motor Inverter
Test Motor
Dynometer
May need external signal conditioning
components
PLC needs more A/D inputs and outputs
making it more costly
Dynometer Inverter
9
Other Feasible Solutions
User
Computer w/ Program
Computer GUI with PLC Control and
Modbus Communication
User Interaction
Communication
(ModBus)
Advantages
•
PLC w/ Ethernet
•
Modbus
Computer supports wide variety of GUI
options
Use of Modbus protocol throughout the
design reduces design complexity
Disadvantages
•
Switcher
Drive Control
And
Sensor Feedback
(Ethernet)
Motor Inverter
Communication rate between the
computer and drives is slower
Drive Control
And
Sensor Feedback
(Ethernet)
Test Motor
Dynometer
Dynometer Inverter
10
Other Feasible Solutions
User
Computer w/ Program
Computer GUI
with Modbus Communication
User Interaction
Advantages
•
Communication
(ModBus)
•
•
•
Computer supports wide variety of GUI
options
No need for PLC
More direct communication
Modbus reduces complexity
Disadvantages
•
Switcher
Drive Control
And
Sensor Feedback
(Ethernet)
Motor Inverter
Drive Control
And
Sensor Feedback
(Ethernet)
Test Motor
Dynometer
More extensive communication programming
computer
Dynometer Inverter
11
Other Feasible Solutions
User
HMI w/ Program
User Interaction
HMI GUI with PLC Control and
Modbus Communication
Communication
(ModBus)
Advantages
PLC w/ Ethernet
•
•
•
Touchscreen
Possibly all Lenze product
Use of Modbus reduces complexity
Modbus
Disadvantages
•
•
HMI does not support as may GUI options
Communication rate between the
HMI and drives is slower
Switcher
Drive Control
And
Sensor Feedback
(Ethernet)
Motor Inverter
Drive Control
And
Sensor Feedback
(Ethernet)
Test Motor
Dynometer
Dynometer Inverter
12
GUI Programs
4/9/2014
Copyright © 2014 – Advanced Power Electronics & Electric Drives Lab (APEDL)
13
Visual Basic Pros
• Visual Basic 6.0 is free to
download.
• Capable of object oriented
programming.
• Free MODBUS toolkit.
• Links directly to MS Excel:
beneficial for creating nice
looking graphs.
• Can run on Windows CE.
• Lenze team can continue
software support for free
14
Visual Basic Cons
• CANopen communication is not
well supported.
• Our team does not have
experience with this program.
• No longer supported by
Microsoft
15
LabVIEW Pros
• Well supported by NI
• Free MODBUS library
• Our team has experience with
this program.
• Possibility of HMI support
• NI DAQs are very easy to
implement
16
LabVIEW Cons
• CANopen library cost $162
• LabVIEW is no longer
supported for Windows CE.
• Lenze team would need to
purchase LabVIEW licenses to
continue support of the
program
17
LabVIEW GUI: Basic Tests
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LabVIEW GUI: Basic Tests
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LabVIEW GUI: Basic Tests
20
LabVIEW GUI: Periodic
Tests
21
LabVIEW GUI: Periodic
Tests
22
LabVIEW GUI: Periodic
Tests
23
LabVIEW GUI: Real Time
Tests
24
HMI
• Lenze HMIs are p500 and
p300
• Operating system is
Windows CE
• Equipped for MODBUS
communication
• Designed for PLC control.
• Potentially could control the
drives directly from GUI
program
25
PLC
• The PLC is a well supported
control for the drives and
can communicate with the
Lenze HMI.
• Possibly redundant, and
unneeded.
• Adds complexity, but may
prove necessary if MODBUS
or CAN does not work.
26
MODBUS
• Modbus only requires
Ethernet ports
• Supported by free libraries.
• Well documented
• Lower communication rate.
• Dependent on Ethernet cable
27
CANopen
• Faster communication rate
• Requires a CANopen reader
card or dongle
• Libraries cost money
• Less supported than
MODBUS in most cases
28
Analog/Digital
• Requires the use of a data
acquisition module (DAQ)
• Fast communication
• Will integrate well with
additional external sensors
such as per phase current
sensors.
• Requires less software
development
29
Torque Estimation
• Motor Stator Flux
•
𝒅𝝋𝒔
𝒅𝒕
= 𝑽𝒔 − 𝑹𝒔𝒊𝒔
• Torque Calculation:
• 𝑻𝒆 =
𝟑
𝒑(𝒊𝒔 ×
𝟐
𝝍𝒔)
𝝍𝒔 = flux
𝑽𝒔 = voltage
𝑹𝒔= resistance
𝒊𝒔 = current
𝑻𝒆 = torque
𝒑 = pole pairs
30
Deliverables
Minimum Deliverables
Target Deliverables
Computer A/D Control of i500 and EVS
9329 Drives
HMI/MODBUS Control of i500 and EVS
9329 Drives
Torque Estimation from Drive Sampled
Data
Torque Estimation from Drive Sampled
Data
Speed from Resolver Data (Servo Motor)
Compare Commanded Torque from Servo
Real Time Load Manipulation
Speed from Resolver Data (Servo Motor)
Output .csv data for external processing
Real Time Load Manipulation
User Defined Load Profile Inputs
Output .csv data for external processing
Embedded Figure Generation
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Budget - Ideal
Item
Cost
P500 HMI
TBD
Power
Cable
Sub-Total
Vendor
1
TBD
CFI
$12.25
2
$24.50
Grainger
CAT 5
Cable
$7.80
2
$15.60
Amazon
Twist-Locks
$34.00
2
$68.00
Hubbell
USB Cable
$4.99
1
$4.99
Amazon
Total
Quantity
$113.09
32
Budget – A/D Circuit & DAQ
Item
Cost
Quantity
Sub-Total
Vendor
NI DAQ
$329.00
1
$329.00
NI
USB Cable
$4.99
1
$4.99
Amazon
Resistors Kit $7.99
2
$15.98
Mouser
Op-Amps
10
$7.00
Mouser
Vector Board $6.46
4
$25.84
Mouser
Wire
10
$2.90
Mouser
$0.70
$0.29
Total
$385.71
• Total: $385.71+ 10% for shipping and taxes
• Total:$113.09 + 10% for shipping and taxes
Will be considerably higher with HMI.
33
Schedule Overview
Date
Milestone
Milestone
1/19/2016
11/5/2015
3/1/2016
11/8/2015
3/10/2016
11/6/2015
3/12/2016
11/12/2015
4/15/2016
11/20/2015
4/25/2016
Spring
Semester
Begins
Complete
Research
Complete first draft of Design
Present proposal to Lenze
Present design to Lenze
Design Proposal
Midterm Design Review
Design Review
Finish Final Design
Decide
route
Finish design
Paperwork
5/1/2016
11/14/2015
Project Submission
Thanksgiving
break begins
11/28/2015
Thanksgiving break ends
12/4/2015
Gather all necessary Components
12/11/2015
Complete test setup
12/20/2015
Winter Break Begins
Legend
Completed
Design
Milestones
UCONN
submissions
34
Questions?
35
References
[1]F. Assurance, A. Converter, F. Assurance, D. #200421, D. sensor, B. converter, 1. CS5503-AP DIP Low-Cost, 1.
#090421, 1. #200421, 5. #090421, 5. ROLLING DIGITAL MAP MEASURING READER TOOL SCALE READING TOOL
TRACER CONVERTER, 5. #090421 and L. module, 'Popular Free Measurement Converter-Buy Cheap Free
Measurement Converter lots from China Free Measurement Converter suppliers on Aliexpress.com', Aliexpress.com,
2015. [Online]. Available: http://www.aliexpress.com/popular/free-measurement-converter.html. [Accessed: 13- Nov- 2015].
[2] Lenze.com, 'Controls - Lenze in the Americas. As easy as that.', 2015. [Online]. Available: http://www.lenze.com/enus/products/controls/. [Accessed: 13- Nov- 2015].
[3] Msdn.microsoft.com, 'Visual Basic', 2015. [Online]. Available: https://msdn.microsoft.com/en-us/library/2x7h1hfk.aspx.
[Accessed: 13- Nov- 2015].
[4] Ni.com, 'LabVIEW System Design Software - National Instruments', 2015. [Online]. Available:
http://www.ni.com/labview/. [Accessed: 13- Nov- 2015].
[5] Modbus.org, 'The Modbus Organization', 2015. [Online]. Available: http://www.modbus.org/. [Accessed: 13- Nov- 2015].
[6] Canopen-solutions.com, 'CANopen – Vector's Comprehensive Tool Chain', 2015. [Online]. Available:
http://www.canopen-solutions.com/?gclid=CIKr7YO3gskCFdgagQodCK4AMg. [Accessed: 13- Nov- 2015].
[7] MESSAOUDI,, Mustapha, Habib KRAIEM,, Mouna BEN HAMED, Lassaad SBITA, and Mohamed Naceur ABDELKRIM.
"A Robust Sensorless Direct Torque Control of Induction Motor Based on MRAS and Extended Kalman Filter." Leonardo
Journal of Sciences 12 (2008): 35-56. Web. 12 Oct. 2015
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