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MODELING, POSITION AND VISCOSITY CONTROL OF INTELLIGENT PNEUMATIC ACTUATOR TEH CHUAN ENN A project report submitted in partial fulfilment of the requirements for the award of degree of Master of Engineering (Electrical - Mechatronics and Automatic Control) Faculty of Electrical Engineering Universiti Teknologi Malaysia 22 JANUARY 2013
Transcript

MODELING, POSITION AND VISCOSITY CONTROL OF INTELLIGENT PNEUMATIC ACTUATOR

TEH CHUAN ENN

A project report submitted in partial fulfilment

of the requirements for the award of degree of

Master of Engineering (Electrical - Mechatronics and Automatic Control)

Faculty of Electrical Engineering

Universiti Teknologi Malaysia

22 JANUARY 2013

iii

Specially dedicated to

my beloved parent, siblings, and friends who always give spiritual support to me

iv

ACKNOWLEGDEMENT

First of all, I would like to express my highy appreciation to my supervisor,

Dr. Ahmad ‘Athif Mohd Faudzi for his advices and guidance throughout the whole

project. He is a great, friendly and excellent mentor, and always shares his valuable

experiences to inspire me for completing this project. I also would like to thanks to

his willingness to spend time for conducting several favorable meetings, so that I can

grab opportunities to obtain knowledge from these meetings. Secondly, I would like

to address my gratitude to my fellow postgraduate students who are also researching

their projects under similar field. Specially thank to Khairuddin bin Osman, who are

currently still going on in his PhD research. I would like to express my sincere

appreciation to his technically support and help towards achieving this success.

Besides, I would like to thanks to the authority of Faculty of Electrical (FKE) for

providing such a good environment and facilities to complete this project. Last but

not least, I would like to convey my deepest thanks to my family members,

especially my parent who always encourage and give concern to me in completing

my master degree in University Technology Malaysia (UTM).

v

ABSTRACT

Intelligent pneumatic actuator (IPA) is a new developed actuator which

integrates actuator, and others new features such as microcontroller and various

micro sensors. This type of actuator has the capability to communicate with

computer to give better control, higher position and force accuracy. In prior to that,

several experimental setup for the stiffness and viscosity control had been done using

conventional PI controller. The previous experimental results showed that these

control algorithms were feasible for the real IPA system. In this project, the work

focuses more on the reverse engineering method, which is from existing real IPA

system which had been developed by Dr. Ahmad ‘Athif Mohd Faudzi, to simulation

analysis for the validation of other controllers. The objectives of this project are to

develop a simulation model to represent the real IPA system, and design other

controllers to be applied in this developed simulation model. For the simulation

model, nonlinear mathematical modeling based on fundamental physical derivation

is presented. Open-loop and closed-loop simulation works are done to confirm this

model based on this derivation. Closed-loop IPA system is divided into two main

control algorithms, which are position control for position tracking control and

viscosity control for force tracking control. Several controllers which are related to

the fuzzy logic are designed and applied to these control algorithms. The simulation

results from these controllers are then validated and compared with result of using

conventional PI controller. The comparison is made by analyzing their performances

based on control theory. Lastly, due to the nonlinearities problem exist in nonlinear

mathematical model, linearization method is proposed to obtain a new linear model

to ease the controller design and analysis. For the future research, it is recommended

to implement all the proposed controllers to the real-time IPA system.

vi

ABSTRAK

Aktuator pneumatik pintar (IPA) adalah aktuator baru yang menggabungkan

aktuator, dan ciri-ciri baru lain seperti pengendali mikro dan pelbagai sensor mikro.

Aktuator jenis ini mempunyai keupayaan untuk berkomunikasi dengan komputer

untuk memberi kawalan yang lebih baik, serta kedudukan dan daya yang tepat.

Sebelum itu, beberapa setup eksperimen berdasarkan kekukuhan dan kelikatan

dengan menggunakan pengawal PI konvensional, telah dijalankan. Keputusan

daripada setup eksperimen itu menunjukan bahawa algoritma kawalan itu boleh

dilaksanakan untuk sistem IPA yand sebenar. Dalam projek ini, kerja-kerja adalah

ditumpu kepada kaedah kejuruteraan undur, bermaksud daripada sistem IPA yang

sebenar kepada simulasi analisis untuk pegesahan pengawal lain. Tujuan-tujuan bagi

projek ini adalah untuk membuat satu model simulasi bagi mewakili sistem IPA

sebenar, serta mereka pengawal lain untuk diaplikasikan dalam model simulasi ini.

Model matematik tidak linear berdasarkan terbitan fizikal asas dibentangkan bagi

model simulasi ini. Kerja-kerja untuk simulasi gelung terbuka dan gelung tertutup

dilakukan untuk mengesahkan model ini adalah betul. Kemudian sistem IPA gelung

tertutup boleh dibahagikan kepada dua algoritma kawalan utama, iaitu kawalan

kedudukan untuk mengawal kedudukan dan kawalan kelikatan untuk mengawal

daya. Beberapa pengawal yang berdasarkan fuzzy logik direka and digunakan untuk

kedua-dua algoritma kawalan itu. Selepas itu, semua keputusan daripada simulasi

dibandingkan dengan hasil daripada menggunakan pengawal PI konventional.

Perbandingan itu dibuat dengan menganalisis prestasi mereka berdasarkan teori

kawalan. Akhir sekali, disebabkan masalah tidak lelurus wujud dalam model

matematik tidak linear, maka kaedah ‘pelinearan’ dicadangkan untuk mendapatkan

model linear yang baru. Bagi penyelidikan masa depan, pengawal-pengawal baru

yang direka boleh diimplikasikan kepada sistem IPA yang sebenar.

vii

TABLE OF CONTENTS

CHAPTER TITLE PAGE

DECLARATION OF THESIS ii

DEDICATION iii

ACKNOWLEDGEMENT iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENTS vii

LIST OF TABLES xi

LIST OF FIGURES xii

LIST OF SYMBOLS AND ABBREVIATIONS xvi

LIST OF AXPENDICES xvii

1 INTRODUCTION

1.1 Overview of the project 1

1.2 Problem Statements 4

1.3 Objectives 4

1.4 Scope of Works 5

2 LITERATURE REVIEW

2.1 Introduction 6

2.2 Terminology: Viscosity 6

2.3 Earlier Model (Prototype) of Intelligent 8

Pneumatic Actuator

viii

2.4 Control Algorithm based on the Previous 9

Experimental Setup

2.5 Fuzzy Logic Speed Control of an Inductor 11

Motor

2.6 Fuzzy Control of the Compressor Speed in a 12

Refrigeration Plant

2.7 Fuzzy and Neural Controllers for a Pneumatic 13

Actuator

2.8 Speed Control of Separately Excited DC Motor 14

using Self Tuned Fuzzy PID Controller

2.9 A Comparative Analysis of PI, Fuzzy Logic 15

and ANFIS Speed Control of Permanent

Magnet Synchronous Motor

2.10 Non-linear Modeling and Cascade Control of 16

an Industrial Pneumatic Actuator System

2.11 Summary 17

3 METHODOLOGY

3.1 Overview 18

3.2 Flow Chart of Methodology 19

3.3 Modeling and Control Approaches 20

3.4 Structure of Intelligent Pneumatic Actuator 21

3.5 Operation of the IPA System 22

3.6 Nonlinear Mathematical Modeling 24

3.6.1 Piston-Load Dynamic Model 25

3.6.2 Modeling of the Cylinder Chambers 27

3.6.3 Valve Model 28

3.7 Development of the IPA Simulation Model 30

3.7.1 Position Control (Closed-loop) 31

3.7.2 Viscosity Control (Closed-loop) 31

3.8 Controller Design 32

3.8.1 Fuzzy Logic Controller 33

3.8.1.1 Fuzzy Logic Controller Design 37

ix

3.8.2 Adaptive Neuro-Fuzzy Inference System 40

(ANFIS) Controller

3.8.2.1 ANFIS Controller Design 44

3.8.3 ANFIS Cascade Controller 47

3.8.4 Self-tuning Fuzzy PI Controller 48

3.8.4.1 Self-tuning Fuzzy PI Controller Design 49

3.9 Linearization 51

3.10 Summary 54

4 RESULTS AND DISCUSSIONS

4.1 Introduction 55

4.2 Open-loop Response of Nonlinear 56

Mathematical Model

4.3 Closed-loop Response of Nonlinear 58

Mathematical Model

4.3.1 Position Control (Nonlinear Mathematical 58

Model)

4.3.1.1 Conventional PI Controller (Position 59

Control)

4.3.1.2 Fuzzy Logic Controller (Position 62

Control)

4.3.1.3 ANFIS Controller (Position Control) 64

4.3.1.4 ANFIS Cascade Controller (Position 65

Control)

4.3.1.5 Self-tuning Fuzzy PI Controller 68

(Position Control)

4.3.1.6 Comparison of Controllers applied for 70

Position Control

4.3.2 Viscosity Control (Nonlinear Mathematical 71

Model)

4.4 Linearization 76

4.4.1 Linear Differential Equation (Taylor Series 76

Expansion)

x

4.4.2 Linear Transfer Function (Control and 81

Estimation Tools Manager)

4.5 3D Animation for IPA System 85

4.6 Summary 86

5 CONCLUSION AND FUTURE WORK

5.1 Conclusion 87

5.2 Future Work 89

REFERENCES 90

Appendices A - B 94 - 101

xi

LIST OF TABLES

TABLE NO. TITLE PAGE

2.1 Specifications of the prototype of intelligent cylinder 9

2.2 Specification of parameter settings for each experiment 10

3.1 Important parameters of the IPA system 24

3.2 Upstream and downstream pressures according to the process 29

of cylinder chamber

3.3 Criteria for designing fuzzy logic controller for IPA system 39

3.4 Fuzzy rules matrix for fuzzy controller design 40

3.5 ANFIS editor training criteria 46

3.6 Fuzzy rule matrix of the fuzzy PI controller 51

4.1 Performance of step response using conventional PI controller 60

4.2 Performance of step response using fuzzy logic controller 63

4.3 Performance of step response using ANFIS controller 64

4.4 Performance of step response using ANFIS cascade controller 66

4.5 Performance of step response using self-tuning fuzzy PI 69

controller

4.6 Performances of step response using different kinds of 71

controllers

4.7 Comparison of RMSE (m) values for sine wave tracking 71

4.8 Output forces (N) for different value of velocity and viscosity 75

parameter

xii

LIST OF FIGURES

FIGURE NO. TITLE PAGE

1.1 Basic structure of a pneumatic actuator 2

1.2 New LA36 intelligent pneumatic actuator from LINAK 3

1.3 Intelligent pneumatic actuator 3

2.1 A mass-spring-damper system 7

2.2 Damping effect when external force is being applied to an 8

object

2.3 Comparison between Intelligent cylinder and commercial 8

cylinder

2.4 Structure of previous experiment setup 9

2.5 A unified control block diagram 10

2.6 Control scheme for an induction motor voltage-source inverter 11

drive

2.7 Fuzzy controller block diagram 12

2.8 Vapor compression experimental plant 12

2.9 Comparison of energy consumption using both the fuzzy 13

control and thermostatic control

2.10 Fuzzy force - position feedback system 14

2.11 Separately excited DC motor model 14

2.12 Speed vs time response of fuzzy tuned PID controlled DC 15

motor

2.13 d-axis equivalent circuits of the sinusoidal PMSM brushless 15

machine

2.14 Step response for fuzzy logic and ANFIS controller 16

xiii

2.15 Closed loop system with cascade controller 17

3.1 Flow chart for the modeling and control approaches 19

3.2 Organization K-chart for whole project 20

3.3 Structure of new intelligent pneumatic actuator 21

3.4 Simplify diagram of the IPA structure 22

3.5 Schematic diagram and valve connection of the intelligent 23

pneumatic actuator

3.6 Translational mechanical systems and their relationships 25

3.7 Model of IPA plant 30

3.8 Position control simulation model 31

3.9 Viscosity control simulation model 32

3.10 Components of the fuzzy logic controller 34

3.11 Process of fuzzification 35

3.12 Computation of the centroid defuzzification method 36

3.13 Operations of fuzzy controller 37

3.14 Flow chart of the design procedure of a fuzzy logic control 37

system

3.15 MATLAB graphical tool for designing fuzzy logic controller 38

3.16 Membership function of error (e) 39

3.17 Membership function of control signal (u) 39

3.18 A typical architecture of an ANFIS model 41

3.19 Flow chart of training procedure of ANFIS 43

3.20 Graphical user interface of ANFIS editor 44

3.21 Collection of input output training data 45

3.22 Input and output training data for ANFIS system 45

3.23 Result from training data 46

3.24 Generated membership functions for input variable through 46

ANFIS editor

3.25 Simulation model using ANFIS cascade controller 48

3.26 Structure of self-tuning fuzzy PI controller 49

3.27 Structure of fuzzy logic for fuzzy PI controller 50

3.28 Membership function of input푒 50

3.29 Membership function of input ∆푒 50

xiv

3.30 Membership function of output퐾 50

3.31 Membership function of input퐾 50

3.32 Some examples of graph showing nonlinearities problem 52

3.33 Graphs showing comparison of (a) linear equation and (b) 53

nonlinear equation

3.34 GUI of Control and Estimation Tools Manager 54

4.1 Simulink block diagram for nonlinear mathematical IPA 56

model

4.2 Open-loop step response 57

4.3 Open-loop sine wave response 57

4.4 Simulink block diagram for position control 58

4.5 Step response for position tracking using conventional PI 59

controller

4.6 Multistep response for position tracking using conventional PI 59

controller

4.7 Sine wave response for position tracking using conventional 60

PI controller

4.8 Input and piston speed response 61

4.9 Change of pressure of chamber 1 versus time 61

4.10 Mass flow rate versus time 62

4.11 The structure of the fuzzy logic controller 62

4.12 Step response for position tracking using fuzzy logic 63

controller

4.13 Step response for position tracking using ANFIS controller 64

4.14 Simulink block diagram of closed-loop system using ANFIS 65

cascade controller

4.15 Step response for position tracking using ANFIS cascade 65

controller

4.16 Multistep response for position tracking using ANFIS cascade 66

controller

4.17 Square wave response for position tracking using ANFIS 67

cascade controller

xv

4.18 Sine wave response for position tracking using ANFIS 67

cascade controller

4.19 Simulink block diagram of fuzzy PI controller 68

4.20 Tuning process of PI controller’s parameters 68

4.21 Step response for position tracking using self-tuning fuzzy PI 69

controller

4.22 Step responses for position tracking using different types of 70

controllers

4.23 Simulink block diagram for the viscosity control 72

4.24 Sinusoidal wave responses for force tracking 73

4.25 Force reference with output force versus time, based on four 74

different value of viscosity coefficient

4.26 Force reference with output force versus time, based on four 74

different value of velocity

4.27 Viscosity plot for intelligent pneumatic actuator 75

4.28 Simulation result of the position control using conventional PI 77

controller

4.29 Simulation graph for spool displacement form time 0 s to 78

0.377 s

4.30 Position tracking of 0.1 m step responses for the linear and 80

nonlinear system

4.31 Steps in linearizing the nonlinear system 81

4.32 Pole-zero map of the linear transfer function 82

4.33 Bode diagram of the linear transfer function 83

4.34 Simulink block diagram for position control using linear 83

transfer function

4.35 Position tracking of 0.1m step responses for the linear systems 84

(mathematical model and transfer function)

4.36 Complete 3D animation for the IPA system 85

xvi

LIST OF SYMBOLS AND ABBREVIATIONS

3D - Three dimension

ANFIS - Adaptive neuro-fuzzy inference system

CAD - Computer-aided design

CAM - Computer-aided manufacturing

DC - Direct current FIS - Fuzzy inference system

FLC - Fuzzy logic controller

GUI - Graphical user interface

IC - Integrated circuit

IPA - Intelligent pneumatic actuator

LED - Light emitting diode

MIMO - Multi input multi output

MISO - Multi input single output

PASS - Pneumatic Actuator Seating System

PI - Proportional-integral

PSoC - Programmable system on chip PSPM - Permanent magnet synchronous motor

PWM - Pulse-width modulation

RMSE - Root mean square error

SI - System identification

VRML - Virtual reality modeling language

xvii

LIST OF APPENDICES

APPENDIX TITLE PAGE

A Gantt chart for MEM 1813 – Research Project 94

Proposal

Gantt chart for MEM 1825 – Master Project 94

B1 IPA complete parameter 95

B2 Complete Simulink block diagram for position 96

control (conventional PI)

B3 Complete Simulink block diagram for viscosity 97

control (conventional PI)

B4 Complete Simulink block diagram + Simulink 3D 98

Animation™

B5 Design of IPA 3D Model using V-realm Builder 2.0 99

B6 MATLAB coding for Linearization using Taylor series 100

expansion

CHAPTER 1

INTRODUCTION

1.1 Overview of the project

In the new era of technology world, actuators were invented and applied in

various fields. There are many types of actuators: electromagnetic, electrostatic,

piezoelectric, pneumatic and hydraulic actuators. These actuators not only used for

automation applications in many industries, they are also being used in others

applications such as home applications, micro machines, medical applications, in

special environments and in physical human-machine applications.

One of the popular types of actuators is pneumatic actuators. Terminology of

pneumatics came from a Greek word pnein, meaning to blow or breath. Pneumatics

is a kind of technology involves the study and application of pressurized gas to

generate mechanical motion. Recently, pneumatic system has been widely

implemented in various kinds of applications such as industrial manipulators and

robotics fields. Pneumatic cylinder or actuator plays vital roles in the pneumatic

system. Since many years ago, pneumatic system was extensively used in lots of

machines in factories to help or assist operations. A pneumatic actuator mainly

consists of a piston, a cylinder, and valves as shown in Figure 1.1.

2

Figure 1.1: Basic structure of a pneumatic actuator. [31]

Intelligent actuator was initially developed by P. Strickland et al. [1] where

this research focused on the development of the actuators and highlighted new

approach of designing servo systems. The development consists of control and fault

tolerant software, communication links, microcontroller, sensor system and actuator.

By having the assistant from a CAD/CAM facility, ‘SERVOCAM’, they managed to

construct intelligent servo systems for robotic systems and the results shows that the

approach is feasible. Development of an intelligent pneumatic cylinder and its

application to pneumatic servo mechanism was then presented by K. Suzumori et al.

[2] where this research contributed to develop intelligent cylinder that can control

position and speed. Micro functional elements such as optical encoder, micro

pneumatic control valves and a micro-processor were started to be utilized to achieve

high control performance.

Intelligent Pneumatic Actuator (IPA) is a new type of developed actuator

which represents the upgraded version of earlier actuator model. Many researchers

and industrial technicians are interesting in applying these new pneumatic actuators

due to their advantages over others actuator model. The positive advantages of

pneumatic actuators are low in cost, high-power-to-weight ratio, light, easier to

maintenance, and have a simpler structure design if compared to other types of

actuators. Moreover, pneumatics actuators are less sensitive to temperature changes

and substance contamination. Figure 1.2 shows one example of intelligent pneumatic

actuator.

Piston

Cylinder

3

Figure 1.2: New LA36 intelligent pneumatic actuator from LINAK. [32]

Intelligent pneumatic actuator have been developed by A.A.Mohd Faudzi et

al. [3] where in this research, IPA was developed and applied to Pneumatic Actuator

Seating System (PASS) as an application. The appearance of the IPA is shown in

Figure 1.3. Intelligent pneumatic actuator integrates microprocessors and some micro

sensors to give better control and thus can achieve higher position and force accuracy.

The movement of the stroke inside the chamber of actuator is controlled by on/off

valve. The benefit of intelligent pneumatic actuator is it can provide accurate position

tracking, deal with different value of stiffness and damping function, and movement

of piston can be controlled by regulating the air pressure of only one chamber inside

the cylinder.

Figure 1.3: Intelligent pneumatic actuator. [3]

4

1.2 Problem Statements

The new intelligent pneumatic actuator (IPA) which had been developed by

A.A.Mohd Faudzi [3], was used on chair type human-machine interaction tool,

Pneumatic Actuated Seating System (PASS). Sufficient information was required on

this human-machine interaction chair in order to obtain how position, stiffness and

viscous coefficient can affect the contour shape, spring and damping characteristics.

Thus, several previous experimental setups have been conducted for these control

algorithms. Based on his research, real IPA closed loop system was controlled by

using conventional PI controller for position and viscosity control. However, this

IPA system is not yet controlled with other controllers to achieve higher control

performances. Therefore, better controllers need to be designed, for the purpose of

giving high control performances and minimizing the errors. In this study, to ease the

controllers design, the works are done in MATLAB simulation. On the other hand,

previous mathematical modeling of pneumatic actuator which had been derived from

other researchers was a nonlinear system; therefore a new linear model is needed for

controller design.

1.3 Objectives

The objectives for this project are:

1. To develop the nonlinear modeling of the Intelligent Pneumatic Actuator.

2. To design controllers (using fuzzy logic) for the position and viscosity control

of IPA.

3. To do the simulation analysis through MATLAB Simulink and compare

results with other controllers.

4. Obtain the linear model of IPA by using linearization technique.

5

1.4 Scope of Works

Basically, the scope of works for this project is shown as following:

1. Study and understand the nonlinear mathematical modeling of the IPA.

2. Do the modeling from the nonlinear mathematical equations to represent IPA

plant by using MATLAB Simulink.

2. Design various kinds of controllers for position and viscosity control for the

nonlinear model.

3. Obtain result using Simulink MATLAB, and compare result from

conventional PI controller.

4. Linearize the current nonlinear model into linear system using theory of

Taylor Series Expansion.

90

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93

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[31] Pneumatic Actuator (http://www.stoneleigh-eng.com/pneumatic_actuators.html)

[32] Actuator to Linear Actuator - LA36 (http://www.projectlink.com.au/actuator-

to-linear-actuator-la36-)


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