APPEND COVER PAGE OF THE REPORT HERE

WITHOUT HEADER AND FOOTER TO T COVER PAGE

 Internship Title 2022 - 23

1
Vision of the Department
To emerge as one of the finest Electrical & Electronics Engineering Departments facilitating the
development of competent professionals, contributing to the betterment of society.

Mission of the Department

Create a motivating environment for learning Electrical Sciences through teaching, research,
effective use of state of the art facilities and outreach activities.

Program Educational Objectives

Graduates of the program of Electrical and Electronics Engineering will,

Have successful professional careers in Electrical Sciences, and Information

PEO1*
Technology enabled areas and be able to pursue higher education.

Demonstrate ability to work in multidisciplinary teams and engage in lifelong

PEO2
learning.

PEO3 Exhibit concern for environment and sustainable development.

Program Outcomes
After the successful completion of the Program, the graduate will be able to,

Apply knowledge of mathematics, science and engineering principles to the

PO1**
solution of engineering problems in electrical and IT enabled areas.

Identify and solve complex engineering problems using first principles of

PO2
mathematics and engineering sciences.

Design system components and solve complex engineering problems that meet
PO3
specific societal and environmental needs.

PO4 Conduct experiments, analyze, and interpret data to provide valid conclusion

Apply appropriate modern engineering tools to complex engineering activities

PO5
with an understanding of the limitations.

Demonstrate understanding of societal health, safety, legal and consequent

PO6
responsibilities relevant to the professional engineering practice.

Understand the impact of engineering solutions in a societal context and

PO7
demonstrate the knowledge of and need for sustainable development.

PO8 Understand social issues and ethical principles of electrical engineering practice.

Function effectively as an individual and as a member or leader in diverse teams

PO9
to accomplish a common goal.

Communicate effectively with diverse audiences and be able to prepare effective

PO10
reports and design documentation.

PO11 Demonstrate knowledge and understanding of engineering and management

EEE, BMSIT&MPage 1
 Internship Title 2022 - 23

2
principles and apply these as a member and leader in a team to manage projects
in multi-disciplinary environments.

Recognize the need to engage in independent and lifelong learning in the

PO12
context of technological change.

Program Specific Outcomes

After the successful completion of the Program, the graduate will be able to

PSO1 Analyze and design electrical power systems

PSO2 Analyze and design electrical machines

PSO3 Analyze and design power electronic controllers for industrial drives

PSO4 Analyze and design analog and digital electronic systems

EEE, BMSIT&MPage 2
 Internship Title 2022 - 23

INTERNSHIP CERTIFICATE

EEE, BMSIT&MPage 3
 Internship Title 2022 - 23

CONTENTS Page. No
1. Chapter – 1 : About the Company
2. Chapter – 2 : About the department
3. Chapter – 3 : Technical Report
4. Chapter – 4: Learning Outcomes of the Internship
5. Chapter – 5: Conclusion

EEE, BMSIT&MPage 4
 Internship Title 2022 - 23

5
chapter 1

Decibels Lab Pvt ltd

• Decibels lab is a Bangalore based startup working in the field of Autonomous

vehicles. The company aims towards providing engineering solutions in
design and development of Autonomous vehicle systems such as UAVs &
automotives.

• It is an incubated startup at Tihan IIT Hyderabad.

• The research and development team is working on developing a FRUGAL
ADAS Product for autonomous vehicles.

EEE, BMSIT&MPage 5
 Internship Title 2022 - 23

6
chapter 2
About the department

CONTROL SYSTEMS DESIGN & TESTING

• This department is responsible for developing and testing control systems

deployed into Autonomous vehicles like quadcopters , Fixed wing planes ,
plant control systems and Automotives.

• The department also works in the domain of capacity building of control

engineers for other control theory intensive industries .

EEE, BMSIT&MPage 6
 Internship Title 2022 - 23

7
chapter 3
Technical details
Role in the department as an intern
• My role in Decibels lab is of design intern in the control systems department.

• My role usually deals with designing mathematical models of Control

systems involved in a drone that are responsible for flight dynamics control
and generating relevant simulations in Scilab and LabVIEW to test response
parameters of the systems and push the design forward for Code generation.

• Creating documentation of the systems created with results and parameters

and reporting it to the internship mentor .

During the 4 week period of internship , my group was tasked with two problem
statements as follows :

Problem statement 1 : Analyse the dynamic parameters associated with a high

speed vehicle and design a model for vehicle resistive forces acting on the frame
of moving vehicle & obtain plot of net Aerodynamic Force in newtons,

Problem statement 2: Analyze the data sheet and speed requirement of BLDC
motor to be used in a quadcopter and design a model of PID control based speed
control system and report the plots obtained.

problem statement 1
EEE, BMSIT&MPage 7
 Internship Title 2022 - 23

8
Modelling of Vehicle Resistive forces acting on a fast moving vehicle

Dynamic parameters of high speed vehicle

1) Drive cycle
A driving cycle is a series of data points representing the speed of a
vehicle versus time. Driving cycles are produced by
different countries and organizations to assess the performance of
vehicles in various ways, as for example fuel
consumption, Battery Capacity, Battery Discharge current and polluting
emissions.

drive cycle data

2) Wheel speed

EEE, BMSIT&MPage 8
 Internship Title 2022 - 23

9
Wheel speed is the speed of the wheel in rpm.
Nw= V∗60/2∗ 𝑝i ∗𝑅w

where,
Nw= Wheel Speed [rpm]
V = Vehicle Speed [mps]
Rw = Radius of the wheel [m]

3) Gross vehicle mass (GVM):

Gross vehicle mass is the total mass of the vehicle including the driver.
GVM = Kerb mass of the vehicle+Driver mass
Where,
Kerb mass of the vehicle=The total mass of a vehicle with standard
equipment and all necessary operating consumables such as motor oil,
transmission oil,coolant, air conditioning refrigerant, and sometimes a full tank
of fuel,while not loaded with either passengers or cargo.

Driver mass = The total mass of the driver

4)Gross Vehicle Weight

Gross Vehicle Weight is the total weight of the vehicle including the driver and
the vehicle.
GVW =GVM∗g
Where,
GVM = Gross vehicle mass
g = acceleration due to gravity

5)Rolling resistance force

EEE, BMSIT&MPage 9
 Internship Title 2022 - 23

10

Rolling resistance, sometimes called rolling friction or rolling drag, is the force
resisting the motion when a body (such
as a ball, tire, or wheel) rolls on a surface.
Rolling resistance force is the product of gross vehicle weight and the
rolling resistance
coefficient.
The coefficient of rolling resistance, which has the dimension of length, is
approximately
equal to the value of the rolling resistance force times the radius of the wheel
divided by the wheel load.
The coefficient rolling resistance value depends on the wheel and road material.

Rolling coefficient data

Fr = GVW ∗ Crf

Where,
Fr = Rolling resistance force [N]
GVW = Gross vehicle weight [N]
Crf = coefficient of rolling friction

6)Grade Resistance Force:

EEE, BMSIT&MPage 10
 Internship Title 2022 - 23

11
Gradient resistance force is the force acting on the vehicle when the vehicle is
climbing an inclined surface.

Fgr = GVW * sin (theta)

Where,
Fgr= Gradient force [N]
theta= Angle of inclination with respect to the horizontal [Degrees]

Grade data

7) Aerodynamic Force

EEE, BMSIT&MPage 11
 Internship Title 2022 - 23

12
It is a resistive force acting on the vehicle,because of its frontal area, density of
air, geometry of car & cars velocity.

When the area of the vehicle is not present the aerodynamic force can be
calculated by a process called coast down process.

Fa = Rho*A*Cd*v^2 / 2
where,
Fa = Aerodynamic Force [N]
rho= Density of air [Kg/m^3]
A = Frontal area [m^2]

Cd = Coefficient of Drag

v = Vehicle Speed [m/s]

EEE, BMSIT&MPage 12
 Internship Title 2022 - 23

13

8) Acceleration Force

Acceleration force is the force that helps the vehicle to reach a predefined speed
form rest in a specified period of
time.
Facc = GVM*a
Where,
Facc = Acceleration Force [N]
GVM = Gross Vehicle Mass [kg]
a = acceleration [m/s]

9)Total tractive effort

Total tractive effort is the total force that the vehicle needs to provide to the
wheel in order to move the vehicle. The total tractive effort value does not
represent for a single wheel, but it represents the total force that needs to be
provided to move the vehicle.
TTE = Fr + Fgr + Fa + Facc
Where,
TTE = Total tractive effort [N]
Fr = Rolling resistance force [N]
Fgr = Gradient force [N]
Fa = Aerodynamic force [N]
Facc = Acceleration force [N]

10) Wheel Torque:

The torque that is required on the wheel to produce the required drive
characteristics.
Tw = TTE * Rw
Where,
Tw = Torque of the wheel [Nm]
TTE = Total tractive effort [N]

EEE, BMSIT&MPage 13
 Internship Title 2022 - 23

14
Rw = Radius of the wheel [m]
MODEL PREFIX INPUT DATA:

Scilab Xcos based mathematical model

EEE, BMSIT&MPage 14
 Internship Title 2022 - 23

15

Aerodynamic force plot

EEE, BMSIT&MPage 15
 Internship Title 2022 - 23

16
Problem statement 2
Modelling of PID controller based electronic speed control system for
quadcopter rotors
DRONE

⮚ A drone is an emerging technology that is widely used in various cases, such

as military, surveillance and public safety. The drones or Unmanned Aerial
Vehicles (UAV) are available as military grade class technology but cast an
expensive model, especially in a surveillance case.

⮚ Powered by Li-Po battery , an aerial vehicle that does not carry a human
operator, uses aerodynamic forces to provide vehicle lift, can fly
autonomously or be piloted remotely, expendable or recoverable and can
carry a lethal or non-lethal payload.

⮚ Drones can access difficult-to-reach areas, such as remote and tight spots in
a hostile region.

⮚ With the development and application of unmanned systems and

autonomous control technology,Drones have greatly expanded its
operational modes and capabilities on account of its characteristics of
stability, highly flying capabilities and strong penetration capability.

⮚ A Quadcopter is a classification of drone with four arms and four rotors to

support aerial flight . They are the most common design when it comes to
drone design topologies.

EEE, BMSIT&MPage 16
 Internship Title 2022 - 23

17

DYNAMICS OF A DRONE

⮚ ROTTLE : Vertical lift created by drone propulsion systems to hover the

drone, increase or decrease the height of the drone.

⮚ YAW: Rotational movement about the vertical axis, parameter for controlling
the steer motion of the drone.

⮚ PITCH: Rotational movement about the Z-axis , parameter for controlling the
forward and backward motion of the drone.

⮚ ROLL: Rotational movement around the horizontal axis, parameters for

EEE, BMSIT&MPage 17
 Internship Title 2022 - 23

18
controlling the sideways motion of the drone.

PID CONTROLLER

PID stands for Proportional-Integral-Derivative. These three controllers are

combined in such a way that it produces a control signal.
Approximately 95% of the closed-loop operations of the industrial
automation sector use PID controllers.
As a feedback controller, it delivers the control output at desired levels.
Before microprocessors were invented, PID control was implemented by the
analog electronic components. But today all PID controllers are processed
by the microprocessors.
Programmable logic controllers also have the inbuilt PID controller
instructions. Due to the flexibility and reliability of the PID controllers,
these are traditionally used in process control applications.

EEE, BMSIT&MPage 18
 Internship Title 2022 - 23

19
WORKING OF A PID CONTROLLER
The PID controller maintains the output such that there is zero error
between the process variable and setpoint/ desired output by closed-loop
operations. PID uses three basic control behaviors :
P- Controller
Proportional or P- controller gives an output that is proportional to current
error e (t). It compares the desired or set point with the actual value or
feedback process value. The resulting error is multiplied with a proportional
constant to get the output. If the error value is zero, then this controller
output is zero.
This controller requires biasing or manual reset when used alone. This is
because it never reaches the steady-state condition. It provides stable
operation but always maintains the steady-state error. The speed of the
response is increased when the proportional constant Kp increases.

I-Controller
Due to the limitation of the p-controller where there always exists an offset
between the process variable and setpoint, an I-controller is needed, which
provides necessary action to eliminate the steady-state error. It integrates
the error over a period of time until the error value reaches zero. It holds the
value to the final control device at which error becomes zero.

Integral control decreases its output when a negative error takes place. It
limits the speed of response and affects the stability of the system.
mathematically, it adds a pole at origin to the plant control system transfer
function which leads the root locus trace to shift towards the right side thus
decreasing the stability margin. The speed of the response is increased by
decreasing integral gain, Ki.

EEE, BMSIT&MPage 19
 Internship Title 2022 - 23

20

D-Controller
The I-controller doesn’t have the capability to predict the future behavior of
error. So it reacts normally once the setpoint is changed. D-controller
overcomes this problem by anticipating the future behavior of the error. Its
output depends on the rate of change of error with respect to time, multiplied
by derivative constant. It gives the kick start for the output thereby increasing
system response.

From a mathematical standpoint , it is observed that the D controller adds a

zero to the transfer function of the plant control transfer function , thus ,
improving its stability by increasing its stability margin by shifting the root
locus trace towards the left side of the plane .

A pid control topology employs all three controller types as discussed above
and result in a brand new controller that can be tuned to carry out stable
control function

Circuit implementation of PID controller

In modern industries ,PLCs are used like PID controllers in most of the
industrial control applications. The arrangement of PID blocks can be done
within PACs or PLCs to give superior choices for an exact PLC control.
These controllers are smarter as well as powerful as compared with separate
controllers. Each PLC includes the PID block within the software
programming.

A programmable logic controller (PLC) or programmable controller is an

industrial computer that has been ruggedized and adapted for the control of
manufacturing processes, such as assembly lines, machines, robotic devices,
or any activity that requires high reliability, ease of programming, and process
fault diagnosis.

EEE, BMSIT&MPage 20
 Internship Title 2022 - 23

21
TUNING METHODS FOR PID CONTROLLER

Before the working of the PID controller takes place, it must be tuned to suit the
dynamics of the process to be controlled. Designers give the default values for
P, I, and D terms, and these values couldn’t give the desired performance and
sometimes leads to instability and slow control performances. Different types of
tuning methods are developed to tune the PID controllers and require much
attention from the operator to select the best values of proportional, integral, and
derivative gains.

1)Trial and Error Method: It is a simple method of PID controller tuning.

While the system or controller is working, we can tune the controller. In this
method, first, we have to set Ki and Kd values to zero and increase the
proportional term (Kp) until the system reaches oscillating behavior. Once it is
oscillating, adjust Ki (Integral term) so that oscillations stop and finally adjust D
to get a fast response.

2)Ziegler-Nichols method: Zeigler-Nichols proposed closed-loop methods for

tuning the PID controller. Those are the continuous cycling method and damped
oscillation method. Procedures for both methods are the same but oscillation
behavior is different. In this, first, we have to set the p-controller constant, Kp to
a particular value while Ki and Kd values are zero. Proportional gain is
increased till the system oscillates at a constant amplitude. After that the gains
of I & D blocks are set accordingly to get a desired control response.

BLDC ( BRUSHLESS DC ) MOTOR

EEE, BMSIT&MPage 21
 Internship Title 2022 - 23

22

A brushless DC electric motor (BLDC), also known as an electronically

commutated motor, is a synchronous motor using a direct current (DC) electric
power supply. It uses an electronic controller to switch DC currents to the motor
windings producing magnetic fields which effectively rotate in space and which
the permanent magnet rotor follows. The controller adjusts the phase and
amplitude of the DC current pulses to control the speed and torque of the motor.
This control system is an alternative to the mechanical commutator (brushes)
used in many conventional electric motors.

The construction of a brushless motor system is typically similar to a permanent

magnet synchronous motor (PMSM), but can also be a switched reluctance
motor, or an induction (asynchronous) motor. They may also use neodymium
magnets and be outrunners (the stator is surrounded by the rotor), inrunners (the
rotor is surrounded by the stator), or axial (the rotor and stator are flat and
parallel).

The advantages of a brushless motor over brushed motors are high power-to-
weight ratio, high speed, nearly instantaneous control of speed (rpm) and torque,
high efficiency, and low maintenance. Brushless motors find applications in
such places as computer peripherals (disk drives, printers), hand-held power
tools, and vehicles ranging from model aircraft to automobiles

Quadcopter rated BLDC motor

EEE, BMSIT&MPage 22
 Internship Title 2022 - 23

23

A2212 1000KV BLDC MOTOR

EEE, BMSIT&MPage 23
 Internship Title 2022 - 23

24
A2212 (BLDC) BRUSHLESS DC MOTOR

A2212 (BLDC) BRUSHLESS DC MOTOR is a high speed brushless motor

designed specifically for Quadcopters, Drones or toy planes. The motor is
OUTRUNNER type where the outside case rotates while inside stays fixed. It is
one of the most popular models in the market because of its low cost. It is
preferred for small drones and planes. The model is available at different speeds
and should be chosen appropriately.

Features and Specifications

● Operating voltage: 7.2V to 12V (2 to 3 Li-poly or 6 to 10 NiCad cells)

● No load current:0.5Amp
● Maximum current:13Amp for 60Sec
● Maximum Watts:150 Watt
● Weight of motor:50-60 grams
● Maximum operating temperature: + 80°C
● Complete speed control because of three phase connection.
● Long life as there are no moving contacts.

Scilab Xcos based mathematical model

EEE, BMSIT&MPage 24
 Internship Title 2022 - 23

25

Electronic speed control model with PID

Reference velocity = 1500 rpm

EEE, BMSIT&MPage 25
 Internship Title 2022 - 23

26

Internal design of PID controller block

Gains of respective block:

Kp:100
Ki: 10
Kd:1

EEE, BMSIT&MPage 26
 Internship Title 2022 - 23

27

Interior design of BLDC motor model

Interior design of electrical system block

EEE, BMSIT&MPage 27
 Internship Title 2022 - 23

28

Interior design of torque system model

Resulting plot of output response

EEE, BMSIT&MPage 28
 Internship Title 2022 - 23

29
In response to problem statement 2 , A PID control enabled electronic speed
control system model was designed .

The BLDC motor model was based upon the market quadcopter motor standard
model A2212 .

The desired output response from the motor was to produce a rotor speed of
1500 RPM .
The PID controller was tuned to get a fast and accurate output from the BLDC
motor .

The tuned gains of PID enabled the BLDC motor to reach its 90% of final value
within 0.3 seconds as shown in the plot , thus offering a very fast response .

The system achieved a rotor speed of 1520 RPM at present Tuned gain values .
Thus , the system offered a steady state error of 1.3% .

The above output response qualifies our designed system to move forward
towards the production line as it offers a fast transient response with a stable
operation and tolerable steady state error.

EEE, BMSIT&MPage 29
 Internship Title 2022 - 23

30
Chapter 4
Learning Outcomes of the Internship
• Deep insight into the field of control engineering and its applications.
• Hands-on experience with design and development of various controllers.
• Understanding of mathematical tools used for system analysis.
• Understanding of different types of motors being used in industry for vivid
applications

• Hands-on experience in designing flight control subsystems for Unmanned

Aerial vehicles.

• Experience of working in a R&D based work environment with a diverse

workforce.

EEE, BMSIT&MPage 30
 Internship Title 2022 - 23

31
Chapter 5
Conclusion

During the 4 week period of my internship at Decibels lab as a control

system design engineer, I got to know about the world of control theory
and control engineering in detail. I spent my time working on various
control systems , designing mathematical models , studying about high end
control systems such as the flight dynamics control system of an aerial
vehicle and also got an opportunity to work on a few subsystems designs
that play a crucial part in flight control systems. This internship enabled me
to obtain more knowledge related to the topics of aerospace and working
manned and unmanned aerial vehicles. It gave me an opportunity to work
on various PID control topology based industrial control systems .The
problem statement enables us to dive deep into mathematical tools used to
determine stability and other transient and steady state parameters of a
control system.
Overall , the past 4 weeks have exponentially enhanced my engineering
skills specifically in the field of control theory and have given me an
experience of working in a design intensive industrial ecosystem.

EEE, BMSIT&MPage 31