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EN7908
INSTRUCTIONS
https://moodle.polytechnic.bh/moodle/mod/assign/view.php?id=151854
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Learning outcomes (LOs)
On successful completion of this test the student will be able to:
4) Critically analyse the effectiveness of a feedback control system for a practical
engineering application.
Question
Topic LOs
number
Q1 Block Diagrams 4
Q2 Second Order Systems 4
Q3 Poles and Zeros 4
Q4 Time Response 4
Q5 PID Control 4
Feedback
• Plagiarized work will receive the appropriate penalty as set out in Bahrain
Polytechnic Policy. (A-AB-003 Academic Integrity and Honesty);
• You are responsible for the complete submission of your assessment(s);
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• This work may be submitted to Turnitin and if so, it will be stored in the Turnitin
database for comparison purposes.
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Centrifugal Casting
Centrifugal casting is the casting of metal in a rapidly revolving mold. They are
used to produce duplexed mill rolls, cylinder liners, bronze or copper alloy
tubes, brake drums, discs, bottle molds, flywheels, etc. Centrifugal casting is a
cost-effective means of providing complex shapes with reduced machining
requirements and lower manufacturing costs as compared to forgings and
fabrications. In the centrifugal casting process, molten metal is poured into a
preheated, spinning die. The die may be oriented either on a vertical or
horizontal axis depending on the configuration of the desired part.
Figure 1 depicts a vertical centrifugal casting machine. The mold rotates at
certain speed by an electric motor. By spinning a mold while molten metal is
poured into the die, centrifugal force acts to distribute the molten metal in the
mold with a magnitude approaching 100 times the force of gravity. Once the
casting has solidified, the part is removed from the die and residual impurities
are machined away, resulting in a defect-free structure without cavities.
.
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Electrical Subsystem
The electrical subsystem contains a rotating circuit called the armature, which
is wound on a rotor and represented by its resistance and inductance. A
magnetic field is developed by a stationary electromagnet called the fixed
field. The armature, through which current 𝑖𝑎 (𝑡) flows, passes through this
magnetic field at right angles to the magnetic field. Which in turn produces a
resulting torque that turns the rotor.
Current flows to the rotor armature through slip rings, and thus a force on
each conductor in the armature is generated. Since the conductors in the rotor
initially rotate through the stationary fixed field, this causes a relative rate of
change of flux and it also rotates due to the torque generated from the
interaction of the armature current and the stator magnetic field. Since the
rotor is not part of the electrical circuit but due to its rotation within the fixed
stator field it results in the generation of the back emf 𝑣𝑏 (𝑡) across the
armature. The induced back emf (Faraday’s law) 𝑣𝑏 (𝑡) will oppose this
motion (Lenz’s law), hence the requirement for the armature voltage 𝑒𝑎 (𝑡).
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Rotational Mechanical Subsystem
The DC motor contains a rotor which has a moment of inertia 𝐽𝑎 and a
rotational viscous damping 𝐷𝑎 at the armature, and the spinning die along
with the flywheel (The load) will have moment of inertia 𝐽𝐿 and a rotational
viscous damping 𝐷𝐿 . We shall assume that the shafts are rigid, and that the
moment of inertia is a constant and rotating along a fixed axis. The motor
drives the load through the gear trains 𝑁1 and 𝑁2 . The angular displacements
and torques for the armature and the spinning die are denoted as 𝜃𝑎 (𝑡), 𝜃𝐿 (𝑡),
𝑇𝑎 (𝑡) and 𝑇𝐿 (𝑡) respectively.
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The Gear Trains
The motor drives the load through the gear trains
Figure 6 – Backlash
In this case, we shall idealize the behaviour of gears and assume that there is
no backlash. An input gear with radius 𝑟1 and 𝑁1 teeth is rotated through angle
𝜃𝑎 (𝑡) due to the armature torque, 𝑇𝑎 (𝑡) . Conversely, the output gear with
radius 𝑟2 and 𝑁2 teeth responds by rotating through angle 𝜃𝐿 (𝑡) and
delivering the load torque, 𝑇𝐿 (𝑡). Let us now find the relationship between the
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rotation of Gear 1, 𝜃𝑎 (𝑡) and Gear 2, 𝜃𝐿 (𝑡). As the gears turn, the distance
traveled along each gear’s circumference is the same.
𝑟1 𝜃𝑎 (𝑡) = 𝑟2 𝜃𝐿 (𝑡)
Or
𝜃𝐿 (𝑡) 𝑟1 𝑁1
= =
𝜃𝑎 (𝑡) 𝑟2 𝑁2
Since the ratio of the number of teeth along the circumference is in the same
proportion as the ratio of the radii. We can conclude that the ratio of the
angular displacement of the gears is inversely proportional to the ratio of the
number of teeth.
We will also assume the gears are lossless, i.e. they do not dissipate or store
energy, the energy into Gear 1 equals the energy out of Gear 2. In other words,
the gears have negligible inertia and damping. Since the translational energy
of force times displacement becomes the rotational energy of torque times
angular displacement then,
𝑇𝑎 (𝑡)𝜃𝑎 (𝑡) = 𝑇𝐿 (𝑡)𝜃𝐿 (𝑡)
In this case, the torques are directly proportional to the ratio of the number of
gear teeth.
𝑇𝐿 𝜃𝑎 (𝑡) 𝑁2
= =
𝑇𝑎 𝜃𝐿 (𝑡) 𝑁1
Rotational Mechanical Impedance Equivalence
Rotational mechanical impedances can be reflected through gear trains by
multiplying the mechanical impedance by the gear ratio squared. where the
impedance to be reflected is attached to the source shaft and is being reflected
to the destination shaft or vice versa.
We shall represent 𝜃𝐿 (𝑡) as an equivalent system at 𝜃𝑎 (𝑡) without the gears. In
other words, the mechanical impedances be reflected from the output to the
input, thereby eliminating the gears. Assuming that all the spinning die inertia
and damping values are known, then 𝐽𝐿 and 𝐷𝐿 can be reflected back to the
armature as some equivalent inertia and damping to be added to 𝐽𝑎 and 𝐷𝑎 ,
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respectively. Hence the load torque 𝑇𝐿 can be reflected to the armature shaft
𝑁
by multiplying it by 1 , from which we write the equation of motion as
𝑁2
𝑁1 𝑁2 𝑁1 𝑑 2 𝑁2 𝑁1 𝑑
𝑇𝐿 (𝑡 ) ( ) = [( ) 𝐽𝑎 + 𝐽𝐿 ( )] 2 {𝜃𝐿 (𝑡 )} + [( ) 𝐷𝑎 + 𝐷𝐿 ( )] {𝜃𝐿 (𝑡 )}
𝑁2 𝑁1 𝑁2 𝑑𝑡 𝑁1 𝑁2 𝑑𝑡
Now convert 𝜃𝐿 (𝑡) into an equivalent 𝜃𝑎 (𝑡), and 𝑇𝐿 (𝑡) to an equivalent 𝑇𝑎 (𝑡)
so that it will look as if it were written at the input. We have
𝑁1 𝑁1
𝜃𝐿 (𝑡) = 𝜃𝑎 (𝑡) and 𝑇𝐿 (𝑡) ( ) = 𝑇𝑎 (𝑡)
𝑁2 𝑁2
𝑁2 𝑁1 𝑁1 𝑑 2 𝑁2 𝑁1 𝑁1 𝑑
𝑇𝑎 (𝑡 ) = [( ) 𝐽𝑎 + 𝐽𝐿 ( )] { 𝜃𝑎 ( 𝑡 )} + [( ) 𝐷𝑎 + 𝐷𝐿 ( )] {𝜃 (𝑡)}
𝑁1 𝑁2 𝑁2 𝑑𝑡 2 𝑁1 𝑁2 𝑁2 𝑑𝑡 𝑎
Hence
𝑁1 2 𝑑 2 𝑁1 2 𝑑
𝑇𝑎 (𝑡) = [𝐽𝑎 + 𝐽𝐿 ( ) ] 2 {𝜃𝑎 (𝑡)} + [𝐷𝑎 + 𝐷𝐿 ( ) ] {𝜃𝑎 (𝑡)}
𝑁2 𝑑𝑡 𝑁2 𝑑𝑡
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The Overall Model
We need to develop a relationship between 𝜃𝑎 (𝑡) and the armature current
𝑖𝑎 (𝑡), substituting the armature torque in equation (6) in equation (7) and
rearranging
1 𝑑2 𝑑
𝑖𝑎 (𝑡) = [𝐽 2 {𝜃𝑎 (𝑡)} + 𝐷 {𝜃𝑎 (𝑡)}] (8)
𝐾𝑡 𝑑𝑡 𝑑𝑡
Combining the resultant armature current in equation (8) with the Kirchhoff’s
law shown in equation (5) around the armature circuit gives
𝑅𝑎 𝑑 2 𝑑 𝐿𝑎 𝑑 3 𝑑2
𝑒𝑎 (𝑡) = [𝐽 {𝜃 (𝑡)} + 𝐷 {𝜃𝑎 (𝑡)}] + [𝐽 3 {𝜃𝑎 (𝑡)} + 𝐷 2 {𝜃𝑎 (𝑡)}]
𝐾𝑡 𝑑𝑡 2 𝑎 𝑑𝑡 𝐾𝑡 𝑑𝑡 𝑑𝑡
𝑑
+ 𝐾𝑏 {𝜃𝑎 (𝑡)}
𝑑𝑡
Rearranging gives
𝐿𝑎 𝐽 𝑑 3 𝐿𝑎 𝐷 𝑅𝑎 𝐽 𝑑 2 𝑅𝑎 𝑑
𝑒𝑎 (𝑡) = [ ] 3 {𝜃𝑎 (𝑡)} + [ + ] 2 {𝜃𝑎 (𝑡)} + [ 𝐷 + 𝐾𝑏 ] {𝜃𝑎 (𝑡)}
𝐾𝑡 𝑑𝑡 𝐾𝑡 𝐾𝑡 𝑑𝑡 𝐾𝑡 𝑑𝑡
The angular velocity of the motor at the armature can be defined as
𝑑
𝜔𝑎 (𝑡) = {𝜃 (𝑡)}
𝑑𝑡 𝑎
Hence, this will simplify to a second order differential equation representing
ωa (t) as the output and ea (t) as the input
1 𝑑2 𝑑
𝑒𝑎 (𝑡) = [𝐿𝑎 𝐽 2 {𝜔𝑎 (𝑡)} + [𝐿𝑎 𝐷 + 𝑅𝑎 𝐽] {𝜔𝑎 (𝑡)} + [𝑅𝑎 𝐷 + 𝐾𝑡 𝐾𝑏 ]𝜔𝑎 (𝑡)]
𝐾𝑡 𝑑𝑡 𝑑𝑡
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Rearranging yields the following input output relationship
𝐾𝑡
̅𝑎 (𝑠) =
𝜔 𝐸̅ (𝑠)
𝐿𝑎 𝐽𝑠 2 + (𝐷𝐿𝑎 + 𝐽𝑅𝑎 )𝑠 + (𝐷𝑅𝑎 + 𝐾𝑡 𝐾𝑏 ) 𝑎
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Tasks
Q1) The block diagram depicting the vertical casting process described
above is shown in figure Q1. By solving sub-question a) to d), simplify the
block diagram to show that the closed loop transfer function between the
input signal 𝐸̅𝑎 (𝑠) and the output signal 𝜔
̅𝑎 (𝑠) is
3.3
̅𝑎 (𝑠) =
𝜔 𝐸̅ (𝑠)
𝑠 2 + 1.46𝑠 + 7.13 𝑎
Where
1 1
̅𝑎 (𝑠) = 𝐺𝐸𝜔 (𝑠)𝐸̅𝑎 (𝑠);
𝜔 𝐹(𝑠) = ; 𝐺(𝑠) = ;
𝑠𝐿𝑎 + 𝑅𝑎 𝐽𝑠 + 𝐷
Figure Q1
a) Simplify the forward path of the block diagram to show that the
transfer function between 𝜔̅𝑎 (𝑠) and 𝑉̅ (𝑠) is
𝐾𝑡
̅𝑎 (𝑠) =
𝜔 ∙ 𝑉̅ (𝑠)
(𝑠𝐿𝑎 + 𝑅𝑎 )(𝐽𝑠 + 𝐷)
Figure Q1a
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b) Using the shortcut rule show that the closed loop transfer function
between 𝐸̅𝑎 (𝑠) and 𝜔
̅𝑎 (𝑠) is
𝐾𝑡 /𝐿𝑎 𝐽
̅𝑎 (𝑠) =
𝜔 𝐸̅ (𝑠)
2 𝐷𝐿𝑎 + 𝐽𝑅𝑎 𝐷𝑅𝑎 + 𝐾𝑡 𝐾𝑏 𝑎
𝑠 +( 𝑠+(
𝐿𝑎 𝐽 ) 𝐿𝑎 𝐽 )
𝐾𝑡
(𝑠𝐿𝑎 + 𝑅𝑎 )(𝐽𝑠 + 𝐷)
Figure Q1b
Q3) Verify the stability of the system by carrying out the following
a) By substituting a unit impulse signal for the input 𝐸̅𝑎 (𝑠) and by
completing the square, write down the signal 𝜔 ̅𝑎 (𝑠).
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Q5) Consider the following feedback loop arrangement outlined in Figure Q5.
Assume that disturbances 𝑑̅ (𝑠) enter the system as shown in the diagram. It is
assumed that the reference input 𝑟̅ (𝑠) is normally held constant, and the
response characteristics to disturbances are a very important consideration for
the casting process. A PID controller is placed at the forward path
𝐾𝑖 3.3
𝐶(𝑠) = 𝐾𝑝 + + 𝑠𝐾𝑑 ; 𝐺𝐸𝜔 (𝑠) = 2 ; 𝐻(𝑠) = 1
𝑠 𝑠 + 1.46𝑠 + 7.13
𝑑̅ (𝑠)
𝑟̅ (𝑠) ̅𝑎 (𝑠)
𝜔
𝐺𝐸𝜔 (𝑠)
Figure Q5
a) In the absence of the reference input, i.e. 𝑟̅ (𝑠) = 0, analytically derive the
closed-loop transfer function between 𝜔 ̅𝑎 (𝑠) and 𝑑̅ (𝑠).
b) The performance specification for the closed loop system requires that
the unit step disturbance response be such that the settling time to be 1
to 2 seconds and the system’s transient response has reasonable
damping. We may interpret the specification as 𝜁 = 0.8 and 𝜔𝑛 =
4 rads/sec for the dominant closed-loop poles. We may choose the third
pole at 𝑠 = – 10 so that the effect of this real pole on the response will be
negligible.
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c) Design a Proportional Integral Derivative Controller (PID) that satisfies
the requirements in b).
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RULES
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PLAGIARISM & COLLUSION
Departments are able to give advice about the appropriate use and correct
acknowledgements of other sources in your own work.
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Useful MATLAB commands
Command Description
axis Set the scale of the current plot, see also plot, figure
gtext Add a piece of text to the current plot, see also text
imag Returns the imaginary part of a complex number, see also real
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input Prompt for user input
real Returns the real part of a complex number, see also imag
subplot Divide the plot window up into pieces, see also plot, figure
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tfdata Access to transfer function data, see also ssdata
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TABLE OF FORMULAS
Initial Value Theorem
lim 𝑦(𝑡) = lim 𝑠𝑦̅(𝑠)
𝑡→0 𝑠→∞
Delay time 𝑻𝒅 : Time required for the response to reach half the steady state,
i.e.
𝑦(𝑇𝑑 ) = 0.5𝐾𝐴
Rise time 𝑻𝒓 : Time required for the response to rise from 10% to 90% or 5%
to 95% of the steady state KA.
1 𝜔𝑑
𝑦(𝑇𝑟 ) = tan−1 ( )
𝜔𝑑 −𝜁𝜔𝑛
Peak time 𝑻𝒑 : Time required to reach the first peak of the maximum
overshoot
𝜋
𝑇𝑝 =
𝜔𝑑
Maximum Overshoot 𝑶𝒎𝒂𝒙 : The maximum peak value of the response
measured from the steady state value KA. This measure indicates the relative
stability of the system.
𝜁
𝑦(𝑇𝑝 ) − 𝑦𝑠𝑠 −𝜋(
2
)
𝑂𝑚𝑎𝑥 = = 𝑒 √1−𝜁
𝑦𝑠𝑠
Settling time 𝑻𝒔 : Time required for the response to reach within either 2% or
5% of the steady state value KA.
4 3
𝑇𝑠 = (2% criterion) or 𝑇𝑠 = (5% criterion)
𝜁𝜔𝑛 𝜁𝜔𝑛
𝜔𝑑 = 𝜔𝑛 √1 − 𝜁 2
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TABLE OF LAPLACE TRANSFORMS
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LAPLACE TRANSFORMS THEOREMS
Pass Levels
Competent (C) Not Yet Competent (NYC)
• Correct MATLAB commands are • Most of the code written have incorrect
used. MATLAB command and result
• Correct answers are shown. • Incorrect answers are shown.
• Correct mathematical derivation is • Wrong MATLAB syntax.
shown • Error strewn code.
• MATLAB syntax is in the right order. • Incorrect graph is shown with no axis or
• Correct graph is shown with clear title labels.
axis labels. • Incorrect calculations and procedures.
• Correct calculations and • Incorrect use of formulae.
procedures. • Incorrect mathematical derivations.
• Correct use of formulae.
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Question 1
Competent (C)/ Not yet
Part Feedback
Competent (NYC)
a
b
c
d
Question 2
Competent (C)/ Not yet
Part Feedback
Competent (NYC)
a
b
c
d
Question 3
Competent (C)/ Not yet
Part Feedback
Competent (NYC)
a
b
c
d
Question 4
Competent (C)/ Not yet
Part Feedback
Competent (NYC)
a
b
c
d
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Question 5
Competent (C)/ Not yet
Part Feedback
Competent (NYC)
a
b
c
d
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