Hydraulic Car Final Presentation

Team Members

Fang Li
Drive Train Modeling/Controls

Nate Lappin
Lift sensors and controls

Grant Miller
Safety System
PAVE 2

Team Members (cont.)

Ashish Karamchandani
Electrical System/Wiring

Andrew Cromwell
Electrical System/Wiring

PAVE

Team Members (cont.)

Nikhil Bajaj
HCM Programming

Rajiv Perera
Netburner/PC Programming

Neil Dantam
Team Leader
PAVE 4

Hydraulics Overview

Objectives
Main Objective: Navigate 100 m track Controlled wirelessly with user joysticks
100 m

Networking Objectives: Hydraulic Control Module (HCM) communication with actuators HCM communication with NetBurner Laptop communication with NetBurner and joystick

40 m

Objectives
Drive Objective Drive and Steer with one (preferred) or two joysticks Turning radius meets track requirements Lift Maintain 0 Control arm angle Safety User Emergency Stop (E-Stop) button at laptop joystick Controls to zero, engine kill Software initiated E-Stop Redundant E-Stop buttons
100 m

40 m

Drive Transmission Control

Fang Li

Overview of System

Drive Plant Simulation

Close loop step response

Results
Actual response of the controlled systems shows inconsistency in wheel velocity. Possible reason:

Inaccuracy

of the plant model(assumptions, estimates, etc, ) Part, mechanism defects.

Alternative solution

Try proportional controller

Works,

the vehicle was able to drive

Problems, does not turn on ground with high friction at low speed Reasons:
Too

much distance between the front and back axle. Engine not powerful enough

Pressure analysis

Pressure analysis

Lift
Nate Lappin

Lift System
Control arm attached to frame via pin 2 joints Linkage Kinematics Symbol CA Lh l Quantity -15 3 15 20 in 3.2 in

Mechanical Specifications

Description Control arm angle range Vehicle lift (clearance) Piston Stroke

Lift System
Hydraulic Circuit

Lift Pump: Pressure Compensated Parker PV023 Valve: Proportional Directional Parker D1FH Cylinder: 4in Stroke, 2 in Bore

Lift System
Control Arm Angle Feedback
Potentiometers mounted above control arm pin joints Driven by timing belt and pulley attached to control arm pin

Control Arm Angle Feedback Lift System

Lift System
Control Arm Angle Feedback
High belt tension to ensure sensitive translation of control arm rotation to potentiometer Design allows adjustable belt tension Gear ratio implemented to increase sensitivity Symbol p,tot G Quantity 270 60/11 Description Potentiometer total range Gear ratio

Lift System
Potentiometer Mount Lift Pump mounting Previously mounted to frame Engine shaking altered belt tension, caused slipping New design mounted to auxiliary mechanical output port on engine front Weight reduction, aesthetically professional application

Spring 2008 Modifications

Old Pump Mount

New Mounting Bracket New Lift Pump Mount Implementation

Lift System
Spring 2008 Modifications
Brass bushings added to frame/CA pin interface Harder steel (Chro-Moly 4142 ) used for pins Brass bushing acts as bearing, prevent wear

Safety System
Grant Miller

Safety Diagram
Battery Regulated Power Supply

E-stop Buttons

Safety Relays

HCMs

Fuel Cutoff Switch Drive Valves

Lift Valves

Visuals

Electrical System
Ashish Karamchandani Andrew Crowell

Work Involved
Design and fabricate mounts for electrical system and components Voltage regulation Isolate vibration of sensitive components Enhance safety for battery Set engine rpm to optimize position on torque-speed curve for maximum power Plan and wire the electrical, control and communication components

Work Started

Work finished

Control System
Nikhil Bajaj Rajiv Perera

Overview

RemoteControl UI

NetBurner
Receive joystick input Receive feedback from wheels Compute new wheel speed

Send

new wheel speed to HCM

Send feedback to UI Monitor for communication loss Handle a loss of communication

HCM (Hydraulic Control Modules)

4 on the car Responsible for direct control drive motor and lift actuation Have programmed-in safety features
Handles

loss of communication by killing actuation outputs Have engine kill capability

HCM (Hydraulic Control Modules)

HCM Functions In Depth:

Monitor

for reference signals and communication from the NetBurnerif you dont get any for 200 ms, panic Take appropriate actions during panic mode

Kill outputs and zero control parameters Wait for reset signal from Netburner

Physical Data Decode quadrature signal and calculate RPM Read in lift potentiometer data Report data on CAN bus Control lift and wheels Lift up and down Wheel speed

Results
Neil Dantam

Results
Main Objective: Not able to navigate track Wireless joystick control successful Networking Objectives: All Communication and networking objectives met Joystick Laptop Netburner HCM Actuators 100 m Drive and Lift: Forward and reverse steering successful Not able to meet 20m turning radius. Actual radius ~60 m at max engine with high Kp Lift cylinders can be set to extreme positions by user, no feedback control implemented Safety: All user, software, and redundant E-Stop systems successfully implemented

40 m

Future Recommendations
Skid Steer: Need Decreased Turning Radius More power in prime mover Add turbo to current engine: 30% more power New Engine Decrease rolling radius Hard rubber tires Decrease wheel base length, increase width Implement conventional automotive steering Lift System: Good performance at start up. Low pressure at steady state, undesirable noise Lower maximum displacement setting

Appendix

Design Criteria
1) The Error between the reference and the actual output to be zero when the controllers are in place. 2) Attenuate any noise at least 500 times. 3) Attenuate disturbance at least 200 times.

Design Strategy

Obtain the transfer function of the plant

No Reference Trajectory Filter, sensor can be considered unity Identify the system type and controller based on this. Zero and pole placement and/or frequency domain analysis

Drive Transmission Control

LTI Model for Hydraulic Transmission

Drive Transmission Control

LTI Model for Hydraulic Transmission

Drive Transmission Control

Plant Transfer Function

Controller Design

Step response with 100rpm reference

Step Response 108 106 104 102 100

Amplitude

98 96 94 92 90 0.45 0.5 0.55 0.6 0.65 0.7 Time (sec) 0.75 0.8 0.85 0.9 0.95

Frequency response system ID

Idea:
Excite

the system with a series of sine waves with different frequencies. Make bode plot Identify the system based on natural frequency, roll-off rate.

Frequency Response
Frequency Response 45 40

35

Amplitude (db)

30

25

20

15 -1 10

10

10 w (rad/s)

10

Lift

Lift System
Hydraulic Component Specifications
Lift Pump: Pressure Compensated Parker PV023 Symbol Quantity Description pp 65 bar Set constant pressure

Vp
Qp

23 cm /rev
27.6 L/min

Max pump displacement

Max flow @ 1200 RPM

Valve: Proportional Directional Parker D1FH Symbol Quantity Description QL,max 20 L/min Max valve flow pv,max Qpump 35 bar 27.6 L/min Pressure drop at max flow Max flow @ 1200 RPM

Cylinder Symbol dc
dr

Quantity 2 in 1.125

Description Cylinder Diameter Rod Diameter

3.2 in

Stroke

Electrical System

Hall Effect sensor

Hall Effect sensor

Wheel

l i f t

Router

l i f t POT

Wheel

Netburner

POT 12/12 VDC Regulator HCM Wheel

Hall Effect sensor

Smart connect Safety syste m

HCM

HCM

HCM

POT

POT l i f t
Driv e front left Driv e back left Driv e back right Driv e front right

l i f t

Wheel

Hall Effect sensor

Thermal Image

HCM Control Overview

HCM PID Control