Doha Dec. 2009 1Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Electrical Energy Education and Research

Energy Curriculum

“From Matlab Simulink to Practical Results in Minutes”

Jens Onno Krah

Prof. Dr.-Ing.

Cologne University of Applied Sciences

www.fh-koeln.de jens_onno.krah@fh-koeln.de

Doha Dec. 2009 2Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Introduction: Jens Onno Krah 1

1988 – 1993 Ph.D. – team of Prof. Holtz

1993 – 1996 Post Doc at University Wuppertal

Prof. Joachim HoltzJ. Holtz, J. O. Krah: Adaptive Optimal Pulsewidth

Modulation for the Line-Side Converter of Electric

Locomotives. IEEE Transactions on Power

Electronics (1992), pp. 205-211.

Doha Dec. 2009 3Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Introduction: Jens Onno Krah 2

1996 – 1997 R&D Manager: Seidel Servo Drives

1998 – 2000 R&D Manager: Kollmorgen

2000 – 2004 R&D Manager: Danaher Motion

Danaher Servo Drive

ServoStar 300 Permanent Magnet Motor

Advanced Kollmorgen Motor

Doha Dec. 2009 4Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Introduction: Jens Onno Krah 3

Since 2004: Professor for control theory at the Cologne University

Research: Motor control & digital signal processing with FPGA

Team: 7 Eng. , 2 Master thesis and 14 diploma thesis

8000 eng. Students

~ 90 % Bachelor (diploma)

~ 10 % Master

~ 1 % PH. D. (in Co.)

Engineering Research Center

Cologne University of Applied Sciences

Doha Dec. 2009 5Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

www.google.de

Cologne

Doha Dec. 2009 6Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Doha Dec. 2009 7Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Germany: Students are striking7

Diploma -> Bachelor & Master

Doha Dec. 2009 8Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

All complex projects are more or less build

by using modular building Blocs (like LEGO)

Integrating Students in Research … break down in small blocks.

Doha Dec. 2009 9Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Building Bloc 1: Computing Algorithms

+ Well known by every student

+ Excellent – floating point – computing power per $

– PC (was) not real time

(Industrial)

Personal

Computer= +

( ) ( )

Doha Dec. 2009 10Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Building Bloc 2: System Modulation and Simulation

+ Fast design entry

+ Excellent simulation

+ Most eng. students learn during their education

+ Real time workshop (with FPU)

– Interface to hardware (was) expensive

Doha Dec. 2009 11Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Building Bloc 3: IGBT Inverter

+ One control card from < 1 kW … > 1 MW

+ 3 ~ closed loop hall current measurement

+ High volume manufacturer

+ Every student can install and set up

– Power stage (was) not free programmable

VLT AutomationDrive

Doha Dec. 2009 12Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Building Bloc 4: the Ethernet Fieldbus

+ Most common Real Time Ethernet for Motion Control

+ Extremely fast (50µs) due to the summing frame structure

+ The EtherCAT slave devices read the data addressed to them while the frame

passes through the node

+ Similarly, input data is inserted while the telegram passes through

+ up to 180 Mbit per second (full duplex fast Ethernet)

Slave Device

EtherCAT Slave

Controller

Slave Device

EtherCAT Slave

Controller

Doha Dec. 2009 13Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Building Bloc 5: I/O Bus Terminal

+ The Beckhoff I/O system supports about 400 Bus Terminals

+ Extremely fast (50µs) due to the EtherCAT interface

+ The Beckhoff Bus Terminals have been tried and tested in a wide range of

sectors worldwide, from machine construction to building management.

+ Beckhoff Bus Terminal technology makes design, wiring and maintenance of

equipment very cost-effective.

• Analog I/O

• Digital I/O

• Encoder interface

• Communication

• …

Doha Dec. 2009 14Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Building Bloc 6: Field Programmable Gate Array (FPGA)

+ Extremely fast due to parallel computing (VHDL)

+ Processing of feedback units: Encoder / Resolver

+ 6 ~ Pulse Width Modulation (PWM)

+ 3–Level Inverter (Wind power – PV)

+ Fieldbus connectivity – EtherCAT IP

+ Handling of SD ADC

– Not much internal RAM

VHDL+

-

Doha Dec. 2009 15Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Building Bloc 7: TwinCAT PC → real-time controller

+ TwinCAT turns almost any compatible PC

into a real-time controller

+ open: utilizes compatible PC hardware

+ embedded IEC 61131-3 software PLC,

software NC and software CNC in

Windows NT/2000/XP/Vista, Windows 7,

NT/ XP Embedded, CE

+ programming and run-time systems

optionally together on one PC or separated

+ data communication with user interfaces and other programs by means of open

Microsoft standards (OPC, OCX, DLL, etc.)

– Version 3.0: direct Matlab Simulink Interface (new)

www.beckhoff.com

Doha Dec. 2009 16Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Building a Motor Control System for University purposes - step 1

1. Take the Altera / EBV Cyclone III evaluation board (www.ebv.de)

2. Take off all parts we do not need (USB, CAN, 24 V I/O, …)

3. Add SD ADC1204 from Texas Instruments

4. Add Danfoss power stage interface

5. Design a PCB with the dimensions of the Danfoss control card

6. Add motor control VHDL IP (PWM, current measuring …)

7. Add EtherCAT (Real Time Ethernet) fieldbus IP

8. Replace the original control card of the frequency inverter

Evaluation Board from EBW FPGA based control board from University Cologne

Doha Dec. 2009 17Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Real Time Ethernet:

Resolver

`PC

Cyclone III C 40

3~

0 – 480 V

Motor

400

Vdc

Avago Avago

230-480 Vac

20

0 -

80

0 V

dc

5 / 15 Vdc

Control LogicPower Supply

Vb

us SD

Motor Current SD

IGBT Signals

Chopper

Ballast Power Stage

Power Supply

Danfoss

JTAG

EMI Filter

Feed-

back

Nio

s II / V

HD

L

Mo

tor C

on

trol

`SRAM

`Flash

`MAC

or

IP

PHY

PHY

sinc3SVMRS 485

or SDFB IP

VHDL

Motor

Control

„C“

Motor

ControlCologne – FPGA Control Board

BLAC

or IM

Doha Dec. 2009 18Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Building a Motor Control System for University purposes - step 2

Hardware Setup

1. Connect motor and drive

2. Connect fieldbus (EtherCAT)

PC: second Ethernet adapter (for example Intel Pro)

3. Connect optional Input, Output & motor feedback

PC (for example Dell) Danfoss Drive with

FPGA control board

from University Cologne

Cat 5Cat 5

Motor (with feedback)

Beckhoff I/O

Doha Dec. 2009 19Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Building a Motor Control System for University purposes - step 3

Software Setup

1. Install TwinCAT

2. Install real time Ethernet adapter driver

3. Configure the system with the TwinCAT System Manager

4. Create control loop software …

Doha Dec. 2009 20Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Building a Motor Control System for University purposes - step 4

Take advantage of the superior development environment

1. On-Line variable read and modify

2. Multi-channel software scope

3. Gflops computing power (Intel CPU)

4. Utilize Microsoft interface standards (OPC, OCX, DLL, etc.)

Doha Dec. 2009 21Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

EtherCAT

„Read I/O“

TwinCATControl

Algorithm

RT Task EtherCAT

„Write I/O“

DC Event

Sync

Read: S&H

Write: Latch

D

VHDL

PWM

EtherCAT

„Read I/O“

S&H

XFC EtherCAT Cycle Time (62.5 µs)

Distributed

Clock Offset

8 MHz

Request

Clock Burst

Encoder

Building a Motor Control System for University purposes - EtherCAT Timing

Doha Dec. 2009 22Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Building a Motor Control System for University purposes – Design flow

Real Time

Workshop

Visual C++

TwinCAT

real time Task

TwinCAT

Soft Scope

TwinCAT

IDE

Doha Dec. 2009 23Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Building a Motor Control System for University purposes – Building Blocks

Real Time

Workshop

Visual C++

TwinCAT

real time Task

TwinCAT

Soft Scope

TwinCAT

IDE

FPGA

Doha Dec. 2009 24Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Automated table soccer

(one side)

Doha Dec. 2009 25Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

8 PM motors with PC / FPGA control

Doha Dec. 2009 26Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Build by 3 undergraduate students in 6 month

Doha Dec. 2009 27Prof. Dr.-Ing. Jens Onno KrahCologne University of Applied Sciences

Conclusion:

Standard power electronics with high computing power and Matlab

Simulink tool chain interface

Motor Control is going to be free programmable with reasonable effort

High quality industrial components for reasonable cost

Utilized building blocks:

1. PC technology (Intel CPU + Windows XP)

2. Matlab Simulink

3. Danfoss frequency inverter (power electronics)

4. EtherCAT the real time Ethernet Fieldbus

5. Beckhoff I/O bus terminal technology

6. Field Programmable Gate Array (FPGA) from Altera

7. TwinCAT real time automation software system

The funding of this project was kindly provided by Altera (California),

Beckhoff Automation (Germany) and EBV Elektronik (Germany)

From Matlab Simulink to Practical Results in Minutes