tareqwaleed1996
Published © GPL3+

PID Speed Controller for DC Motor

[@version 1 ] PID loop is used in this project to control the speed of a permanent magnet DC motor.

IntermediateShowcase (no instructions)74,369
PID Speed Controller for DC Motor

Things used in this project

Hardware components

Arduino UNO
Arduino UNO
×1
Power supply 300w - 24/12 v
×1
Dc motor 24v/150w
×1
Encoder 600ppr incremental
×1
Gt2 closed loop belt
×1
INA219 I2C POWER MONITOR SENSOR
×1
Cooling fan
×2
Bluetooth hc-05
×1
LCD
×1
SERIAL I2C TO LCD
×1
Gt2 pulley 20 teeth 6mm (for encoder)
×1
Gt2 pulley 20 teeth 8mm (for motor)
×1
On –off switch
×2
Bread board 830 tie
×1
wire
×1
IRF540 Power MOSFET
×1
Push button
×1
Voltage regulator 5v
×1
Voltage regulator 9v
×1

Software apps and online services

Arduino IDE
Arduino IDE
MATLAB
MATLAB
Visual Studio 2015
Microsoft Visual Studio 2015

Hand tools and fabrication machines

digital multimeter
3D Printer (generic)
3D Printer (generic)
cnc machine

Story

Read more

Custom parts and enclosures

motor base

encoder base

2D enclosure box

Acrylic 5mm thick

Schematics

Circuit diagram

Image of Circuit diagram

Code

final code

Arduino
//when covert string into float u will get only 2 digit after float point (.) and for
// that we cant send the value of tuning serially (kp ,ki ,kd) .
// change these value here in arduino sketch .

/* cruise control project .
 * 1)encoder 600ppr 5v two channel A,B
 * 2)motor 24v/150w max speed 3600rpm 
 * 3)motor driver control by pwm .
 * 4)arduino uno .
 * 5)power supply (12v/5a) ... (24v/10a) .
 * 6)gt2 pulley 8mm bore.
 * 7)gt2 pulley 6mm bore .
 * 8)tooth belt 400mm length 6mm width .
 * 9)(x2) fan 5v .
 * 10)(x2)led.
 * 11)(x2)switch on-off 
 * 12)bluetooth module.
 * 13)lcd+i2c .
 * 14)push button .
 * 15) others .
 */
#include <Wire.h> 
#include <LiquidCrystal_I2C.h>
#include <PID_v1.h> 
#include <FreqMeasure.h>
#include <Adafruit_INA219.h>

Adafruit_INA219 ina219;

LiquidCrystal_I2C lcd(0x27, 16, 2);

// kalman filter
double K =0;                // kalman gain 
const double R=0.5 ;      // error in measurement

double Eest=0;              // error estimate 
double pre_Eest=0;          // error estimate(t-1)

double est =0;              // estimate 
double pre_est=0;           // estimate(t-1)

double sensor_meg=0;        // from analog pin 

double p1=1; 
const double Q=0.01;     //0.01;          //1e-04;       //1e-04;    // process noise [0.001 slow response]//0.01
/////////////////////////////////////////////////
// kalman filter
 
double K8 =0;                // kalman gain 
const double R8=0.5 ;      // error in measurement [data sheet of lm35 error =0.5]

double Eest8=0;              // error estimate 
double pre_Eest8=0;          // error estimate(t-1)

double est8 =0;              // estimate 
double pre_est8=0;           // estimate(t-1)

double sensor_meg8=0;        // from analog pin 

double p18=1; 
const double Q8=0.0001;       // process noise [0.001 slow response]

// for measure f:-
float rps,rpm ;
int const ppr=600; //pulse per rev.
String data;
String receive;
int sampletime=20;
int mode;
float freq_a;
int Disturbance=0;
int controller=1;
int open_loop_pwm=86;
// sensor :-
double voltage_sensor=12;
double current_sensor=0.55;
double power_sensor=25;

// motor driver :-
int in_A=6; //PWM
//int in_B=5; //PWM
int pwm =50;


// pid parameters:-
double Setpoint,Input,Output;

// from pid matlab tune :-
//double Kp=0.00548333297173391;
//double Ki=0.0423023548974992;
//double Kd=0.000177690701568258;

double Kp=0.00206812507453938;
double Ki=0.0339782106923304; 
double Kd=3.14697363162208e-05;

// define object :-
PID myPID(&Input,&Output,&Setpoint,Kp,Ki,Kd,DIRECT);

// to apps 
String send_to(double s,double i, double e,double o,double ff,double kalman,double v_s,double c_s,double p_s){
String d = (String)s+";"
          +(String)i+";"
          +(String)e+";"
          +(String)o+";"
          +(String)ff+";"
          +(String)kalman+";"
          +(String)v_s+";"
          +(String)c_s+";"
          +(String)p_s
          ;
return d;
d="";
}

void setup() {
  lcd.begin();
  lcd.print("cruise sys");
  delay(2000);
  lcd.clear();
  pinMode(in_A,OUTPUT);
  //pinMode(in_B,OUTPUT);
  pinMode(8,INPUT_PULLUP); // must pull up to 5v to work .
  Serial.begin(9600);
  FreqMeasure.begin();
  myPID.SetMode(AUTOMATIC); //start calculation.
  myPID.SetOutputLimits(0,255);
  myPID.SetSampleTime(sampletime);
  //myPID.SetSampleTime(20); // matlab. 
  Setpoint=2000; // 12v =1800 almost.
  /////////////////////////////////////////////////////////////////////////////////
    uint32_t currentFrequency;
  // Initialize the INA219.
  // By default the initialization will use the largest range (32V, 2A).  However
  // you can call a setCalibration function to change this range (see comments).
  ina219.begin();
  // To use a slightly lower 32V, 1A range (higher precision on amps):
  //ina219.setCalibration_32V_1A();
  // Or to use a lower 16V, 400mA range (higher precision on volts and amps):
  //ina219.setCalibration_16V_400mA();

}

void right_move(){
  analogWrite(in_A,pwm);
  //digitalWrite(in_B,LOW); 
}

float get_speed(){
      if(FreqMeasure.available()) {
       // if there is data coming do something : 
      float f = FreqMeasure.countToFrequency(FreqMeasure.read());
      freq_a=f;
      
      //convert F to rps :
      rps=f/ppr;
      //convert rps to rpm :
      rpm=rps*60;
      // condition limit :
      if(rpm<0){rpm=0; }
      if(rpm>3600){rpm=3600; }
      
      // effect of disturbance :
      if(rpm>=500){
      rpm=rpm-Disturbance ;
      }
      return rpm;
      }
}

void display_lcd(){
lcd.setCursor(0,0);
lcd.print("S:");
lcd.setCursor(8,0);
lcd.print("I:");
lcd.setCursor(0,1);
lcd.print("E:");
lcd.setCursor(8,1);
lcd.print("o:");

lcd_clear();

// print to lcd after clear :
lcd.setCursor(2,0);
lcd.print((int)Setpoint);
lcd.setCursor(10,0);
lcd.print((int)Input);
lcd.setCursor(2,1);
int e=Setpoint-Input;
lcd.print((int)e);
lcd.setCursor(10,1);
lcd.print((int)Output);
// must have delay above 300ms.

}
void lcd_clear(){

for(int i=2;i<8;i++){ 
  lcd.setCursor(i,0); 
  lcd.print(" "); 
  lcd.setCursor(i,1); 
  lcd.print(" ");
}
for(int i=10;i<16;i++){ 
  lcd.setCursor(i,0); 
  lcd.print(" "); 
  lcd.setCursor(i,1); 
  lcd.print(" "); 
}

}

void parsing (String q){
  String a; // sp
  String b; // sample time
  String c; // mode operation
  String d; // disturbance 

  String a1;
  String b1;
  a=q.substring(0,q.indexOf(";"));
  b=q.substring(q.indexOf(";")+1 , q.indexOf(","));
  c=q.substring(q.indexOf(",")+1 , q.indexOf("&") );
  d=q.substring(q.indexOf("&")+1 , q.indexOf("@") );
  //
  a1=q.substring(q.indexOf("@")+1 , q.indexOf("%") );
  b1=q.substring(q.indexOf("%")+1);

controller=a1.toInt();
typeOfControl(controller);

open_loop_pwm= b1.toInt();

 Disturbance=d.toInt();
 //Output=Output-Disturbance;
 
 Setpoint=a.toInt();
 
 sampletime=b.toInt();
 myPID.SetSampleTime(sampletime);
 
 mode=c.toInt();
 if(mode==1){
  myPID.SetMode(AUTOMATIC);
 }
 else if (mode==0){
  myPID.SetMode(MANUAL);
  Output=open_loop_pwm;
 }

}

void typeOfControl(int x)
{
 
if (x==1){ // pid 
Kp=0.00548333297173391;
Ki=0.0423023548974992; 
Kd=0.000177690701568258;    
  }
  
else if (x==2){ //pi
Kp=0.00284752617249473;
Ki=0.035555779556629; 
Kd=0;    
  }
  
else if (x==3){ //p
Kp=0.0280057653779624;
Ki=0; 
Kd=0;    
  }
  
else if (x==4){ // i
Kp=0;
Ki=0.0187518091153096; 
Kd=0;    
  }
  
else if (x==5){ // oscillator
Kp=0.16;
Ki=0; 
Kd=0;   
  } 
  
myPID.SetTunings(Kp,Ki,Kd);
  
}

void loop()
{ 
unsigned long real_ms=millis();//calculate real time ms ;
// do it later not now.
 
if(Serial.available()>0){
  receive = Serial.readString();
  parsing (receive);

 }
 
right_move();
Input=get_speed();

sensor_meg=Input;
pre_Eest=p1+Q;
K=Eest/(Eest+R);
est=pre_est+K*(sensor_meg-pre_est);
Eest=(1-K)*pre_Eest;

//update kalman
pre_est=est;
p1=Eest;
Input=est;


myPID.Compute();
//Output=Output-Disturbance;
pwm=Output;

//data to serial plotter
/*
Serial.print(Setpoint);
Serial.print(" ");
Serial.print(Input);
Serial.print(" ");
Serial.println(Setpoint-Input);
*/

//show result into lcd screen
display_lcd();

// current 
  float shuntvoltage = 0;
  float busvoltage = 0;
  float current_mA = 0;
  float loadvoltage = 0;
  float power_mW = 0;

  shuntvoltage = ina219.getShuntVoltage_mV();
  busvoltage = ina219.getBusVoltage_V();
  current_mA = ina219.getCurrent_mA();
  power_mW = ina219.getPower_mW();
  loadvoltage = busvoltage + (shuntvoltage / 1000);

//
sensor_meg8=current_mA;

pre_Eest8=p18+Q8;
//
K8=Eest8/(Eest8+R8);
est8=pre_est8+K8*(sensor_meg8-pre_est8);
Eest8=(1-K8)*pre_Eest8;

//update
pre_est8=est8;
p18=Eest8;

float power_cons=busvoltage*est8;
power_cons=power_cons/1000;

// noise measurement of current sensor :
 float noise =abs( est8 - current_mA );

// send data to c#:
data=send_to(Setpoint,Input,Setpoint-Input,Output,freq_a,noise,busvoltage,est8,power_cons);
Serial.println(data); //println == as string

}

step input response

Arduino
just apply 24v to the motor terminal and copy the result that appears in the serial monitor of Arduino ide.
this is for parameter estimation of the transfer function.
// this is a step input response of the dc motor.
// we need frequency and time for parameter estimation.


#include <FreqMeasure.h>

void setup() {
  Serial.begin(57600); // for faster data transmission 
  FreqMeasure.begin(); 
}

void loop() {
  if (FreqMeasure.available()) {
      float frequency = FreqMeasure.countToFrequency(FreqMeasure.read());
      Serial.print(frequency); // measure the frequency
      Serial.print("\n");
      Serial.println(micros()); // measure the time in microseconds

    }
  }

step input data

MATLAB
this is a step input data from arduino after applied 24v to the motor.
step1: convert freqency to rps then to rpm.
step2:convert time from us to s.
step3: time start from zero.
clc;
close all;

data=[
0.07	14866316
418.84	14868832
861.05	14869992
1129.94	14870936
1340.48	14871824
1546.64	14872728
1671.54	14873988
1825.03	14877048
1938.22	14880108
2059.73	14883168
2175.98	14886228
2287.35	14889288
2403.48	14892348
2503.91	14895408
2605.01	14898468
2723.87	14901532
2818.89	14904588
2955.85	14907656
3093.58	14910708
3668.04	14913768
4371.58	14916828
5251.07	14919888
6012.78	14922948
7098.49	14926012
7707.13	14929068
8681.50	14932128
9302.33	14935196
10575.02	14938428
11469.53	14941648
12509.77	14944880
12851.41	14948108
12618.30	14951344
14939.31	14954568
15223.60	14957808
15794.67	14961036
16597.51	14964260
17486.34	14967488
18823.53	14970720
18120.05	14973948
18890.20	14977188
19536.02	14980416
19925.28	14983648
20565.55	14986876
21447.72	14990100
21947.87	14993336
21739.13	14996568
22068.97	14999796
23809.52	15003020
24279.21	15006256
24242.42	15009488
23845.01	15012708
25723.47	15015952
26058.63	15019168
26490.07	15022400
26143.79	15025628
26711.19	15028860
27874.57	15032096
27972.03	15035320
27491.41	15038556
28318.58	15041780
28520.50	15045016
28520.50	15048248
28828.83	15051468
29197.08	15054708
30018.76	15057936
29357.80	15061168
29574.86	15064388
30828.52	15067624
30188.68	15070856
30769.23	15074088
30828.52	15077316
31067.96	15080540
31558.19	15083768
32128.51	15087008
31683.17	15090228
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33542.98	15116076
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33264.03	15125768
33542.98	15128996
33333.33	15132220
33898.30	15135456
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34632.03	15141916
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34408.60	15148376
34334.76	15151600
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34632.03	15177440
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34482.76	15183912
35714.28	15187136
36117.38	15190360
36866.36	15193596
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34934.50	15203288
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35714.28	15254960
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36529.68	15277576
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37914.69	15303408
36036.03	15306640
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35555.55	15316336
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36529.68	15326020
35714.28	15329256
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36613.27	15338948
38277.51	15342176
36529.68	15345408
36363.64	15348628
35555.55	15351860
37825.06	15355096
37647.06	15358324
36363.64	15361552
36697.25	15364788
35874.44	15368016
36446.47	15371240
36281.18	15374476
36117.38	15377704
36446.47	15380936
36281.18	15384160
36281.18	15387388
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36281.18	15406772
36529.68	15410008
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36446.47	15419692
36529.68	15422924
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36529.68	15451988
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36446.47	15464916
36613.27	15468140
36199.09	15471368
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36036.03	15477836
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36613.27	15490756
36199.09	15493988
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38004.75	15500448
36529.68	15503676
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35955.05	15632876
36446.47	15636100
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37470.73	15645796
36036.03	15649028
36866.36	15652248
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37122.97	15668404
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36446.47	15674860
37914.69	15678088
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36529.68	15684548
38740.92	15687788
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36199.09	15694240
36529.68	15697468
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38095.24	15703932
36446.47	15707164
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36613.27	15723316
36446.47	15726540
36951.50	15729776
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36281.18	15739468
36036.03	15742688
37825.06	15745928
36613.27	15749156
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36036.03	15755616
36613.27	15758848
36363.64	15762072
36199.09	15765304
36117.38	15768536
36281.18	15771760
36363.64	15774996
36781.61	15778228
36446.47	15781456
35874.44	15784680
38554.22	15787916
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36866.36	15800836
35634.74	15804064
36697.25	15807288
36613.27	15810528
36781.61	15813756
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36281.18	15820216
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35955.05	15826668
36866.36	15829908
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36446.47	15839596
36613.27	15842828
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36199.09	15852516
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36446.47	15858976
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36613.27	15865436
36951.50	15868668
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37037.03	15878352
36529.68	15881588
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37209.30	15888044
36613.27	15891272
36281.18	15894500
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36613.27	15900960
37825.06	15904192
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36529.68	15913888
38186.16	15917116
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36529.68	15923576
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37296.04	15930032
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35714.28	15946188
36446.47	15949408
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35955.05	15955868
36529.68	15959108
36613.27	15962336
37735.85	15965560
36613.27	15968796
37122.97	15972024
36951.50	15975256
36363.64	15978488
38095.24	15981716
35634.74	15984948
36281.18	15988168
36781.61	15991404
38554.22	15994632
36866.36	15997864
35955.05	16001088
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36951.50	16007556
36613.27	16010788
36613.27	16014016
35874.44	16017240
36529.68	16020476
36781.61	16023708
36281.18	16026936
36199.09	16030168
36363.64	16033392
36036.03	16036628
36613.27	16039848
35955.05	16043088
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36529.68	16052776
36281.18	16056000
37296.04	16059228
37037.03	16062472
36199.09	16065696
36446.47	16068920
36613.27	16072156
36363.64	16075388
37037.03	16078616
37037.03	16081848
35476.72	16085076
36363.64	16088300
36781.61	16091532
37558.68	16094760
36199.09	16097988
37209.30	16101228
37735.85	16104464
37037.03	16107680
37037.03	16110916
36613.27	16114148
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36866.36	23097408
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36446.47	23174928
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36866.36	23181388
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36951.50	23194300
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36529.68	23200772
36446.47	23203988
36117.38	23207228
36697.25	23210456
36781.61	23213684
36613.27	23216908
36697.25	23220148
36281.18	23223368
37037.03	23226600
36781.61	23229828
37209.30	23233068
];

% convert freqency to rps 
data(:,1)=data(:,1)./600;
rps=data(:,1);

%convert time from us to s 
data(:,2)=data(:,2)./1e6;
time=data(:,2);

%rpm 
rpm=rps(:,1).*60;

% time start from zero 
time=time-min(time);
newdata=[time,rpm];

plot(time,rpm);

results of parameters estimation.

Markdown
this is estimation values of our dc motor after applied nonlinear least square method from matlab.
from estimation of parameter of dc motor : 

B=1.5319e-04;
J=1.2130e-05;
K=0.0034;
L=0.0127;
R=0.0710;

GUI code

Markdown
download it as (.exe)
Login Form.

When opening the application, a login form will be shown and you have to enter the user name and password.

· User name: user
· Password: 1234

http://www.mediafire.com/file/jtulkoftuhqhbd0/lm35.exe/file

all libraries

Markdown
all libraries you need to import it.
#include <Wire.h> 
#include <LiquidCrystal_I2C.h>
#include <PID_v1.h> 
#include <FreqMeasure.h>
#include <Adafruit_INA219.h>
#include <FreqMeasure.h>

Credits

tareqwaleed1996

tareqwaleed1996

0 projects • 18 followers

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