CLOSED-LOOP MOTOR SPEED SENSOR & CONTROLLER 318-355 Spring 2003, Team #3 CLOSED-LOOP MOTOR SPEED SENSOR & CONTROLLER STAFF Greg Carlsson, BSEE Rich Dehnel, BSEE Michael Host, BSEE Dave Jasinski, BSEE Kentucky Pommerening, BSEE Jarrod Widmann, BSEE AND BSCS

Kentucky D. Pommerening Jarrod D. Widmann 318-355 Spring 2003, Team #3 Page 2 CLOSED-LOOP MOTOR SPEED SENSOR & CONTROLLER Team Page Gregory P. Carlsson Richard G. Dehnel Michael R. Host David L. Jasinski Kentucky D. Pommerening Jarrod D. Widmann

CLOSED-LOOP MOTOR SPEED SENSOR & CONTROLLER 318-355 Spring 2003, Team #3 Page 3 CLOSED-LOOP MOTOR SPEED SENSOR & CONTROLLER Project Abstract Precision AC motor control is currently an expensive option requiring a $200+ encoder and supporting circuitry. This project aims to design a cost effective alternative with a flexible interface which can be implemented in nearly any industrial AC motor application to provide closed-loop control. Cost, reliability, accuracy, and safety are key aspects in the scope of this project.

CLOSED-LOOP MOTOR SPEED SENSOR & CONTROLLER 318-355 Spring 2003, Team #3 Page 4 CLOSED-LOOP MOTOR SPEED SENSOR & CONTROLLER Product Description The input to the Closed Loop Motor Speed Sensor and Controller will be generated by an optical sensing device which detects the shaft speed of a motor. This signal will be sent to a micro-controller which compares the input signal to a pre-programmed reference value. The signal will then be manipulated in the digital domain to provide an analog feedback signal to the motor controller. A user interface will be developed to enter the reference value to the micro and display the actual motor shaft speed. A power supply will need to be developed to supply the various circuits.

CLOSED-LOOP MOTOR SPEED SENSOR & CONTROLLER 318-355 Spring 2003, Team #3 Page 5 CLOSED-LOOP MOTOR SPEED SENSOR & CONTROLLER Product Feature Set The desired features for our product included: Accurate control of desired speed level Analog output switch-able between 0-10VDC and 4-20mA. This signal will be used as a control signal to an AC motor drive, or as a monitor signal to a chart recorder or data logger. Instantaneous under/over speed indicator Audible under/over speed alarm for sustained out-of-range conditions. Form C relay triggered for same alarm. Programmable scaling factor for display output Constantly displayed set-point and actual speed values. Internal over-temperature alarm

Product Performance Requirements 318-355 Spring 2003, Team #3 Page 6 CLOSED-LOOP MOTOR SPEED SENSOR & CONTROLLER Product Performance Requirements 0.4% accuracy – actual versus displayed speed of motor shaft Less than 2.5W power consumption User interface keypad will be chosen for industrial environment The user display will be viewable from 5 feet Under-speed and over-speed indicators on user interface Audio alarm for sustained under-speed and over-speed conditions Form-C relay output for alarm conditions Over-current and over-voltage protection on input power Shaft speeds to 1800 RPM Compatibility with AC motor drives and PLCs containing analog inputs. Mounting by DIN rail or panel screws. Installation with basic hand tools.

Product Standard Requirements 318-355 Spring 2003, Team #3 Page 7 CLOSED-LOOP MOTOR SPEED SENSOR & CONTROLLER Product Standard Requirements

Implementation Block Diagram 318-355 Spring 2003, Team #3 Page 8 CLOSED-LOOP MOTOR SPEED SENSOR & CONTROLLER Implementation Block Diagram

Allocation of Standard Requirements 318-355 Spring 2003, Team #3 Page 9 CLOSED-LOOP MOTOR SPEED SENSOR & CONTROLLER Allocation of Standard Requirements

Association of Performance Requirements 318-355 Spring 2003, Team #3 Page 10 CLOSED-LOOP MOTOR SPEED SENSOR & CONTROLLER Association of Performance Requirements Thank You!