INDIAN INSTITUTE OF TECHNOLOGY

BOMBAY

DEPARTMENT OF AEROSPACE ENGINEERING

Control Systems Laboratory - AE 427

INDUSTRIAL EMULATOR

GROUP 5

Name Roll Number

Swarit Sood 180010056
Panshikar Anay Rajan 18D180020
P.Raghav Rajeev 170010056
Atharva Gurudatta Telange 180010014

Instructors :
Prof. Arnab Maity
Prof. Shashi Ranjan Kumar
Experiment 1 Industrial Emulator

Contents
1 Objectives 2

2 Theory 2
2.1 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 System Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Rigid Body PD and PID Control . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Gain measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4.2 Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Inertia Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5.2 Result Plots and Calculations: . . . . . . . . . . . . . . . . . . . . . . 7

3 Experiment 2 8
3.1 Effect of kd and kp independently . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1.1 Procedure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1.2 Result Plots and Calculations: . . . . . . . . . . . . . . . . . . . . . . 9
3.1.3 Discussion: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 PD Control Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.2 Result Plots and Calculations: . . . . . . . . . . . . . . . . . . . . . . 12
3.2.3 Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3 Adding Integral Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3.2 Result Plots and Calculations: . . . . . . . . . . . . . . . . . . . . . . 16
3.3.3 Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 Tracking Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4.2 Result Plots and Calculations: . . . . . . . . . . . . . . . . . . . . . . 19
3.4.3 Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.5 Frequency Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.5.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.5.2 Result Plots and Calculations . . . . . . . . . . . . . . . . . . . . . . 24
3.5.3 Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4 Conclusion 29

AE 427 1 Group 5
Experiment 1 Industrial Emulator

1 Objectives
1. Study and understand the various components of the industrial emulator.
2. Identify the system parameters - Gain and Inertia.
3. Observe the impact of linear control strategies by designing P, D, PD and PID con-
trollers for the system.
4. Check the Tracking and Frequency Response of the system under different control
schemes.

2 Theory
The Industrial Emulator is a device which is used for the study of industrial control
systems. It has configurable features similar to industrial plants and can emulate-
• Drive and load Inertias
• Gear ratio changes
• Drive Flexibility
• Coupled / discrete vibration with actuator at the drive input and sensor collocated or
noncollocated

2.1 System Overview

The experimental control system is comprised of three subsystems:
1. Electromechanical Plant- It consists of the emulator mechanism, its actuator and
sensors. The drive and load disks can be coupled with different gear ratios by using
a stiff or a flexible belt. The moment of inertia of source and load can be varied by
placing brass weights of different masses on the disks.

Figure 1: Industrial Emulator Plant

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Experiment 1 Industrial Emulator

2. Real-time Controller Unit- This contains the digital signal processor(DSP) based
real-time controller, servo/actuator interfaces, servo amplifiers, and auxiliary power
supplies. The DSP is capable of executing control laws at high sampling rates allow-
ing the implementation to be modeled as continuous or discrete time. The controller
also interprets trajectory commands and supports such functions as data acquisition,
trajectory generation, and system health and safety checks. A logic gate array per-
forms motor commutation and encoder pulse decoding. Two auxiliary digital-to-analog
converters (DACs) provide real-time analog signal measurement. This controller is rep-
resentative of modern industrial control implementation.

3. Executive Program- This is a PC program for the DOS operating system. This
menu-driven program is the user’s interface to the system and supports controller
specification, trajectory definition, data acquisition, plotting, system execution com-
mands and more. Controllers may assume a broad range of selectable block diagram
topologies and dynamic order. The interface supports an assortment of features which
provide a friendly yet powerful experimental environment.

Figure 2: Controller Unit and PC Program

Figure 3: Experimental Control System

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Experiment 1 Industrial Emulator

2.2 System Identification

In the first section of the experiment, inertia, gain and damping of the various system
components are found indirectly by measuring their effect on system response characteristics.
In these tests, we will keep a proportional plus rate feedback loop about the drive feedback
encoder. Below is the picture of the block diagram of the controller.

Figure 4: Controller Configuration for Identification of a Plant

And the below table gives the identification of various test cases.

Figure 5: Test Cases for mentioned configurations

2.3 Rigid Body PD and PID Control

In the following experiment, we are demonstrating the concepts related to PD controller
(proportional + derivative) and subsequently the effects of adding the integral action to the
PD controller - thus becoming the PID Controller. Such a controller has varied applications
in many fields such as automobiles, aircrafts, gripper tools, machines, etc. The block dia-
gram is shown in Figure 4.
The closed loop transfer function is given by:

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Experiment 1 Industrial Emulator

khw


θ(s) J
(kd s + kp )
c(s) = = 3 khw


r(s) s + J
(kd s2 + kp s + ki )
Also, the other formulae used are shown in the calculation section.

2.4 Gain measurement

2.4.1 Procedure
1. Configure as test case 1 given in Figure 5.

2. Calculate total moment of inertia at drive disk with given information: brass weight
diameter = 4.95 cm, thickness of drive plate = 0.47 cm, diameter of drive disk = 13.21
cm, ρaluminium = 2.71 g/cm3 , Jmotor = 3.810−5 kg.m2 .

Jtotal = Jmotor + Jdrivedisk + Jmass

3. With the controller powered up, enter the control algorithm box under the Set-up menu
and set Ts = 0.002652s. In ‘Trajectory’ select ‘step’. Select Open Loop Step and input
a step size of 2.0 volts, a duration of 200 ms and 2 repetitions.

4. Go to ‘Set up Data Acquisition’ in the Data menu and select encoder 1 as data to
acquire and specify data sampling every 5 servo cycles1 (i.e. every 5 Ts’s).

5. Select OK to exit. This sets up the system to accelerate the drive disk with 2.0 V input
to the servo amplifier for 200 ms forward, then 200 ms at zero, then 200 ms backward
while acquiring Encoder 1 position data

6. Select Execute from the command menu and select Run.

7. Plot velocity response of encoder with respect to time. Measure velocity and time
difference through the linear section of the curve and calculate acceleration.

8. Calculate ka kt ke and determine khw using below given expression:

2V ∗ ka kt ke = Jtest ∗ acceleration

khw = kc ka kt ke ks
where Jtest is the total inertia at the disk calculated initially

2.4.2 Calculation
Thickness of the driver plate (t) = 0.47 cm
Diameter of the disk (d) = 13.21 cm
Density of aluminium (ρaluminium ) = 2.71 g/cc

d2
mplate = ρaluminium ∗ π ∗ ∗ t = 0.175 kg
4

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Experiment 1 Industrial Emulator

1 0.13212
Jplate = ∗ 0.175 ∗ = 3.8 ∗ 10−4 kg.m2
2 4
Jmass = 4 ∗ 0.500 ∗ 0.052 = 0.005 kg.m2
Given Jmotor = 3.8 ∗ 10−5 kg.m2 ,

Jtotal = Jmotor + Jplate + Jmass = 5.42 ∗ 10−3 kg.m2

Figure 6: Encoder Velocity vs Time

DAC gain, kc = 10V/32768 DAC counts

Controller software gain, ks = 32 (controller input counts/ encoder or ref. input(counts)
Acceleration measured in the linear region from t=0 to t=0.186,

acceleration = 162166 counts/s2

2V ∗ ka kt ke = Jtest ∗ acceleration
ka kt ke = 439.35
khw = kc ka kt ke ks
khw = 4.29 kg.m2 /s2

2.5 Inertia Measurement

2.5.1 Procedure
1. Place the mechanism in the test case 3 configuration

2. In control algorithm give Ts = 0.002652 s and continuous time control. Select PI With
Velocity Feedback and give kp = 0.5 and kd = 0.001. Implement the Algorithm.

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3. Select Step Trajectory with step size of 1000 counts, duration of 1000 ms and 1 repe-
tition.

4. Select Encoder1 and Commanded Position for Data Acquisition. Select data sampling
every servo cycle(1).

5. Execute and Run. Plot the response for encoder 1 Position.

6. Calculate damping ratio from the plot. For small ζ this expression becomes
1 x0
ζ= ln
2πn xn

7. Divide number of cycles, i.e., n, by time taken to complete them (tn - t0 ) to find
damped frequency. Convert the resulting frequency in Hz to radians/sec. This damped
frequency, ωd is relate to natural frequency ωd by
ωd
ωn = p
1 − ζ2

8. For lightly damped systems it becomes ωn ≈ ωd

9. Use the calculated value of khw and ωn for calculating Jdd by using the following
expression and compare this value with the value calculated in beginning of the previous
experiment. r
kp kh w
ωn =
J

2.5.2 Result Plots and Calculations:

For n = 4, we get,
For x0 = 1911, we have t0 = 0.04 and for x4 = 1445, we have t4 = 0.321s
1 x0
ζ= ln = 0.011122
2πn xn
tn − t0
T = = 0.07025
n
2π
ωd = = 89.44036
T
ωd
ωn = p = 89.44589
1 − ζ2
We can also see here that ωn ≈ ωd as ζ is small.

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Experiment 1 Industrial Emulator

Below is the plot:

Figure 7: Step response to PI with Velocity Feedback

3 Experiment 2
3.1 Effect of kd and kp independently
3.1.1 Procedure:
1. Configure in test case 2
q
kp khw kd khw
2. From the equations - ωn = J
and η = 2Jωn
= √kd khw , find kp so that the
2 Jkp khw
system behaves like a 2 Hz spring-inertia oscillator.

3. Setup encoder 1 for Data Acquisition. Set up a closed-loop step of 0 counts, dwell time
= 5000 ms, and 1 rep (Trajectory in the Command menu). This puts the controller
board in a mode for acquiring 10 sec of data on command while the control system
will maintain regulation.

4. Enter the Control Algorithm box under Set-up and set Ts = 0.000884 s and select
Continuous Time Control. Select PI with Velocity Feedback and Set-up Algorithm.
Enter the kp value determined above for 2 Hz oscillation (kd and ki = 0), and select
OK. Implement the Algorithm.

5. Enter Execute under Command. Prepare to manually rotate the drive disk roughly
60 deg. Select Run, rotate about 60 deg. and release disk. Do not hold the rotated
disk position for longer than 1-2 seconds as this may cause the motor drive thermal
protection to open the control loop.

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6. Plot encoder 1 output. Determine the frequency of oscillation. What will happen when
proportional gain, kp , is doubled? Repeat Steps 4 and 5 and verify your prediction.

7. Determine the value of the derivative gain, kd , to achieve kd khw = 0.05 N-m/(rad/s) .
Repeat Step 4 and 5, except set Ts = 0.006188 s and input the above value for kd and
set kp & ki = 0.

3.1.2 Result Plots and Calculations:

Four weights (m=200 g) are placed at r = 5 cm and for 2 Hz oscillation:

Jmass = 4 ∗ 0.2 ∗ 0.5 = 0.002

Jtotal = 0.002 + 0.00038 + 0.000038 = 2.42 ∗ 10−3 kg.m2

ωn = 2 ∗ 2 ∗ π = 12.57Hz
r
kp khw
For P control, ωn =
Jtotal
For D control, kd khw = 0.05

Case1: kp only:
kp = 0.089, kd and ki = 0

Figure 8: Step response for P control (kp = 0.089)

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Experiment 1 Industrial Emulator

Figure 9: Simulink Step response for P control (kp = 0.089)

Case2: Doubled kp :
kp = 0.178, kd and ki = 0

Figure 10: Step response for P control (kp = 0.178)

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Experiment 1 Industrial Emulator

Figure 11: Simulink Step response for P control (kp = 0.178)

Case3: kd only:
kd = 0.01165, kp and ki = 0

Figure 12: Step response for D control (kd = 0.01165)

3.1.3 Discussion:
1. As we saw, natural frequency is proportional to square root of proportional gain.
Increase in proportional gain results in higher frequency and shorter time to reach the
peak.

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Experiment 1 Industrial Emulator

2. Introduction of derivative controller reduces the settling time but doesn’t reach its
commanded position

3.2 PD Control Design

3.2.1 Procedure
q
kp khw kd khw
1. From equations - ωn = J
and η = 2Jωn
= √kd khw , find kp and kd for a
2 Jkp khw
system having a natural frequency of 4 Hz and three damping cases (i) ζ = 0.2 (under
damped), (ii) ζ = 1 (critically damped) and (iii) ζ = 2 (over damped).

2. Implement the controller for a input step for a 2000 count step size and 1500 ms dwell
time and 1 rep.

3. Execute and plot the command position and encoder position

4. Repeat steps 2 & 3 for critically damped and over damped cases and save the plots for
later reference and comparison.

3.2.2 Result Plots and Calculations:

Below are the plots for the above steps executed with the Simulink plots:
Case 1: Under-damped PD Controller
Values : ζ = 0.1 kp = 0.3560770612 kd = 0.00566714244

Figure 13: PD Control Under Damped obtained via MATLAB

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Experiment 1 Industrial Emulator

Figure 14: PD Control Under Damped obtained via Simulink

Case 2: Critically-damped PD Controller

Values : ζ = 1 kp = 0.3560770612 kd = 0.0283357122

Figure 15: PD Control Critically Damped obtained via MATLAB

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Experiment 1 Industrial Emulator

Figure 16: PD Control Critically Damped obtained via Simulink

Case 3: Over-damped PD Controller

Values : ζ = 2 kp = 0.3560770612 kd = 0.0566714244

Figure 17: PD Control Over Damped obtained via MATLAB

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Experiment 1 Industrial Emulator

Figure 18: PD Control Over Damped obtained via Simulink

3.2.3 Discussion
1. In the under-damped case, the position reaches quickly to the command position and
then it oscillates about it and again goes down as step changes and oscillates about it
as shown clearly in the plot.

2. In the critically-damped case, there are no oscillation in accordance with the definition.

3. In the over-damped case, the rise time increases,i.e.,it takes comparatively little more
time than the critically damped response case to reach the step further and also, there
are no oscillations.

3.3 Adding Integral Action

3.3.1 Procedure
1. Compute ki such that ki khw = 5N − m/(rad − sec). Implement a controller with this
value of ki and the critically damped kp and kd parameters from the previous steps
and plot the encoder position and command position.

2. Increase ki by a factor of two, implement the controller and plot its step response.

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Experiment 1 Industrial Emulator

3.3.2 Result Plots and Calculations:

Below are the plots for the above steps executed with the Simulink plots:
Case 1: Critically damped PID Controller with ki
Values : ζ = 1 kp = 0.3560770612 kd = 0.0283357122 ki = 1.165298679

Figure 19: Critically Damped PID Control with ki obtained via MATLAB

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Figure 20: Critically Damped PID Control with ki obtained via Simulink

Case 2: Critically damped PID Controller with 2ki

Values : ζ = 1 kp = 0.3560770612 kd = 0.0283357122 ki = 2.330597358

Figure 21: Critically Damped PID Control with 2ki obtained via MATLAB

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Experiment 1 Industrial Emulator

Figure 22: Critically Damped PID Control with 2ki obtained via Simulink

3.3.3 Discussion
1. When the integral action is added to the critically-damped case, there is a overshot in
the response when it reaches the commanded position and the comes to a steady state
as shown in the plot.

2. When ki is increased by a factor of 2, the overshoot further increases.

3.4 Tracking Response

3.4.1 Procedure
1. Set up the mechanism as done in the previous sections (Test Case 2). Using Ts =
0.00442 s implement a PI with velocity feedback controller (ki = 0) using kp and kd
for natural frequency = 4Hz and critical damping. Set up to collect data (Setup Data
Acquisition, Data menu) every 4 servo cycles and add control effort.

2. Set up a closed loop ramp trajectory with Distance = 8000 counts, Velocity = 20, 000
counts/sec, and Dwell Time = 400 ms. Execute this maneuver, collect data and plot
Commanded Position, Encoder 1 Position, and Control Effort. Save your plot.

3. Repeat steps 1 and 2 with ki khw = 3 N-m/rad-s . Repeat steps 1 and 2 using forward
path PID control (PID, under Setup Control Algorithm), first with ki = 0, then with

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Experiment 1 Industrial Emulator

ki khw = 3 N-m/rad-s.

4. (optional) Setup a closed loop parabolic trajectory with Distance = 8000 counts, Veloc-
ity = 40, 000 counts/sec, Acceleration = 300 ms and Dwell Time = 200 ms. Implement
forward path PD control using kp and kd from step 1 (ki = 0). Execute this maneuver,
collect and plot the same data as in step 2.

3.4.2 Result Plots and Calculations:

For calculating ki ,
ki ∗ khw = 3
3
ki =
khw
3
ki =
4.29
ki = 0.699
Below are the plots for the above steps executed with the Simulink plots:
Case 1: PI with velocity feedback control ki = 0

Values : kp = 0.3560770612 kd = 0.0283357122

Figure 23: Velocity feedback response with ki = 0 (MATLAB)

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Experiment 1 Industrial Emulator

Figure 24: Velocity feedback response with ki = 0 (SIMULINK)

Case 2: PI with velocity feedback control ki = 0.699

Values : kp = 0.3560770612 kd = 0.0283357122

Figure 25: Velocity feedback response with ki = 0.699 (MATLAB)

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Figure 26: Velocity feedback response with ki = 0.699 (SIMULINK)

Case 3: PID control with ki = 0

Values : kp = 0.3560770612 kd = 0.0283357122

Figure 27: PID response with ki = 0 (MATLAB)

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Figure 28: PID response with ki = 0 (SIMULINK)

Case 4: PID control with ki = 0.699

Values : kp = 0.3560770612 kd = 0.0283357122

Figure 29: PID response with ki = 0.699 (MATLAB)

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Figure 30: PID response with ki = 0.699 (SIMULINK)

3.4.3 Discussion
1. If we observe the ramp tracking characteristics there is significant following error im-
plementing critically damped PI with velocity feedback using kp and kd and ki = 0.
2. Adding integrator to the above case leads to a large overshoot but helps in reducing
the following error.
3. Forward path kd gives small error if we implement PID controller.
4. Adding integrator to the above case leads to a larger overshoot.

3.5 Frequency Response

3.5.1 Procedure
1. Set up the mechanism as in the previous sections. Using Ts = 0.00442s implement a
PI with velocity feedback controller (ki = 0) using kp and kd and ζ = 0.1. Set up to
collect (Setup Data Acquisition, Data menu) every 4 servo cycles.
2. Set up a closed loop sine sweep trajectory with Amplitude = 500 counts, Start Fre-
quency = 0.1 Hz, End Frequency = 10 Hz and Sweep Time = 30 s. Execute this
maneuver, collect data (to keep the collected data file size from becoming large you
may wish to acquire only Encoder 1 position data) and plot, Encoder 1 Position. Save
your plot.
3. Repeat steps 1 and 2 with ζ = 1.0 and 2.0. Repeat steps 1 and 2 using forward
path PID control (PID, under Setup Control Algorithm) and ζ = 1.0. Here you will
need to reduce the sine sweep input trajectory amplitude to 250 counts to avoid drive
saturation at higher frequencies.

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4. Repeat steps 1 and 2 (kd in the reverse path) with ki khw = 10N − m/rad − s.

3.5.2 Result Plots and Calculations

Case 1: Under damped PI with velocity feedback controller
Values : ζ = 0.1, kp = 0.3560770612, kd = 0.00283357122

Figure 31: Underdamped PI control with velocity feedback obtained via MATLAB

Figure 32: Underdamped PI control with velocity feedback obtained via SIMULINK

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Case 2: Critically damped PI with velocity feedback controller

Values : ζ = 1, kp = 0.3560770612, kd = 0.0283357122

Figure 33: Critically damped PI control with velocity feedback obtained via MATLAB

Figure 34: Critically damped PI control with velocity feedback obtained via SIMULINK

Case 3: Over damped PI with velocity feedback controller

Values : ζ = 2, kp = 0.3560770612, kd = 0.0566714244

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Figure 35: Overdamped PI control with velocity feedback obtained via MATLAB

Figure 36: Overdamped PI control with velocity feedback obtained via SIMULINK

Case 4: Critical damped with forward path PID controller

Values : ζ = 1, kp = 0.3560770612, kd = 0.0283357122

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Figure 37: Critically damped with forward path PID control obtained via MATLAB

Figure 38: Critically damped with forward path PID control obtained via SIMULINK

Case 5: Critically Damped PID Control with kd in reverse path

Values : ζ = 2, kp = 0.3560770612, kd = 0.0283357122, ki = 2.330597358

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Figure 39: Sine Sweep Response for PID Controller with kd in reverse path via MATLAB

Figure 40: Sine Sweep Response for PID Controller with kd in reverse path via SIMULINK

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3.5.3 Discussion
1. The frequency response was studied for three cases- underdamped, critically damped
and overdamped.

2. Using a PI controller with velocity feedback gives a response which is in phase with
the input signal.

3. The response for underdamped case has an initial overshoot and then a reduced am-
plitude. The responses for the critically and overdamped cases have a continuous
reduction in amplitude.

4. The amplitude dies down faster as damping increases.

5. When using a forward path PID controller without ki , there is an overshoot observed
for the critically damped case. The response is again in phase with the input.

6. Finally, when we used a PID controller with kd in the reverse path and non-zero ki ,
we can see that the response decays faster as compared to the one where ki was zero.
There is also an initial overshoot observed.

4 Conclusion
1. In Experiment 1, we can find the gain and inertia measurements in a indirect way by
measuring the response of the system and studying its characteristics.

2. In Experiment 2, we studied the effects of kp , ki and kd , we saw that as kp is increased

- the frequency of oscillations increased. For kd is increased, higher resistance can be
seen. For increase in ki , we see that the overshoot increases.

3. We saw the responses for under-damped, critically-damped and over-damped cases. For
under-damped case, oscillations are seen which decay after some time. For critically-
damped case, there are no oscillations. For over-damped case, it is similar to critically
damped case just that the rise time has increased.

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