A

Project Based Lab Report

On
DESIGN OF PID CONTROLLER FOR SPEED CONTROL OF
STEPPER MOTOR BY USING MATLAB

Submitted in partial fulfillment of the

Requirements for the award of the Degree of

Bachelor of Technology
in
MECHANICAL ENGINEERING
By
PARAMESHWAR DURGA- (150070130)
KOKATI ROHIT - (150070183)
PRAVEEN KUMAR - (150070287)
SURESH GUPTAH - (150070318)

Under the guidance of

Guide Name: RENTALA VENKATESH

Dept. of MECHANICAL Engineering,

K.L. UNIVERSITY
Greenfields, Vaddeswaram
522502, Guntur Dist.
2018-19

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 K L University
DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that this project based lab report entitled “DESIGN OF PID CONTROLLER FOT
SPEED CONTROL OF A STEPPER MOTOR BY USING MATLAB” is a bonafied work done by
PARAMESHWAR DURGA- (150070130) KOKATI ROHIT - (150070183) PRAVEEN
KUMAR - (150070287) SURESH GUPTAH - (150070318) in partial fulfilment of the
requirement for the award of degree in Bachelor of Technology in MECHANICAL
ENGINEERING during the academic year 2016-2017.

I also declare that this project based lab report is of our own effort and it has not been submitted to
any other university for the award of any degree.

Signature of the Project Guide HOD OF ME

Mr R. VENKATESH Dr. A. SRINATH

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 ABSTRACT

DESIGN OF PID CONTROLLER FOR SPEED CONTROL OF STEPPER

MOTOR BY USING MATLAB

Stepper motors are motors that convert digital information to mechanical motion. Stepper
motors rotate in distinct angular increments (steps) in response to the application of digital
pulses to an electrical drive. A stepper motor is most commonly used for position control
such as in robotics, aerospace, machine tools, printers and scanners. A major constrain that a
stepper motor faces especially at high stepping rate in a open loop control are, the speed
response of the stepper motor suffer from large overshoot, oscillatory response and long
settling time. Therefore, a closed loop control system essentially required for a good precise
operation performance. In this work a novel approach named digital PID controller is tried to
enhance the performance of the open loop control system in order to control permanent
magnet stepper motor (PMSM) speed by using MATLAB. In addition to this, a micro
stepping technique with sine and cosine waveforms is also used to drive the PMSM instead of
discrete pulses. Hence the proposed control algorithm gives a better performance than that of
the open loop even when the system is subjected to a sudden load disturbance.

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INTRODUCTION:

Permanent magnet stepper motors (PMSM), in comparison with STEPPER motors, reveal
several advantages, which make them more significant in the realm of applications. They
have brushless structure, which require less maintenance and deliver high peak torque and
have higher torque to inertia ratio[1-6]. They are simply implemented based on the open loop
configuration by receiving the rectangular train of pulses [1]. However In open loop
control[7-11], the speed response of the PMSM suffers from large overshoot, oscillatory
response and long settling time. Additionally[12-19], the motor must respond to each
excitation change. If the excitation changes are made too quickly, the stepper motor may lose
some steps and therefore it will be unable to move the rotor to the new demanded position.
Therefore, a permanent error can be introduced between the load position and that expected
by the controller [20-26]]. Due to these limitations, the stepper motor cannot be used without
feedback sensor and closed loop control system with high performance applications where the
exact position or rotor speed is required. The digital closed loop principle was introduced by
Fredriksen [3], Kuo [27-31] and Takashi [5] in 1969, 1970 and 1984 respectively. They used
the closed loop algorithm in order to increase the stepper motor positioning accuracy and
making it less sensitive to load disturbances. Zribi and Chaisson, [6] transformed the
nonlinear system dynamics of a stepper motor into a linear one, and then linear feedback
controller is designed to acquire the desired performance. But there exists an error between
the exact nonlinear system and an approximate linear model. The stability and control
performance will be deteriorated by the effect of the approximation error. The use of self-
tuning regulator (STR) to control the stepper motor speed was introduced by Betin et al. [32-
36]. It has been found that this controller requires a large amount of floating-point
computation, which may lead to increase in the sampling period. Nevertheless, it is still
difficult to design and implement a real-time math-model-based optimization control for
highly nonlinear, considerably uncertain, and critically coupled stepper motor drive systems.
Another method to control the stepper motor speed by using fuzzy logic is applied and
developed by Franck Betin et al. [8]. In their paper, the output from the fuzzy controller is not
the control variable itself but its increment. Therefore, the controller can be considered as an
incremental fuzzy controller. When the system is subjected to a load disturbance, the fuzzy
control system gives a reasonable result with the stepper motor compared to that of open loop
control. However, the system suffers from some oscillatory response because they used a
pulse train to drive the stepper motor instead of sine and cosine signals. Also, their
experimental results show that the system performance depends mainly on the encoder
resolution. For a high resolution, the system performance increases and vice versa. Moreover,
this control algorithm requires a large external memory size for storing the fuzzy control
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table[37-40]. In the present paper, the digital PID control system is used to enhance the
properties of the open loop control system of the PMSM. Also, instead of using pulse train to
drive the stepper motor, a microstepping technique, which consists of sine and cosine signals,
is used. The performance of the proposed control system is compared with the open loop
control system[41-45].

~ Sensor

Power
SM
Electronic
~ Converter
~

Three
phase
supply Gate Driver

MATLAB /

Simulink
Microcontroller Controller
Setting

Figure 1 General block diagram of project

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OBJECTIVES OF PROJECT

Basically, this project is listing four main objectives.

1. To develop the three phase controlled rectifier.
2. To develop the three phase gate driver.
3. To design the PID current control using MATLAB R2013a Simulink Toolbox
function block.

THREE PHASE CONTROLLED RECTIFIER

In general, control strategy for switching patterns and their duty cycles on the rectifier uses
voltage or current. Figure 2.5 represents the topology of the three phase active rectifier
proposed. The dynamic model of rectifier consists of a three-phase network connected to
three-phase supply voltage ea , eb , ec by assuming a balanced three-phase system, the
three-phase input line currents ia, ib, ic and va, vb, vc which represent the three-phase
voltages generated by the PWM active rectifier. R and L are the resistance and inductance
of the line, a smoothing capacitor, and the load represented by a current source [4].

Figure 2 Three-phase active rectifier system [4]

A three-phase synchronous controlled rectifier is very efficient rectifier which uses power
MOSFETs in place of passive pn-diodes. The advantage of power MOSFETs is that the
conduction path for the current does not go across a pn junction. The problem with pn
junctions is that they have an inherent, current independent voltage drop of around 0.7V for
silicon. Power MOSFETs have a continuous n-doped conduction channel in the on state,
which has no current independent voltage drop and behaves like a resistive element. By
reducing the resistance of the channel 1 by cry cooling and paralleling of MOSFETs,

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arbitrarily low on-state voltages and corresponding low losses can be achieved. The design
discussed here uses the reverse (body) diodes of the n-channel power MOSFETs for
passive rectification which can be switched to active (synchronous) rectification by
applying appropriate gate drive pulses to the power MOSFETs [17].

The developing trend in switching power supply system has been aiming high-efficiency
and low-cost power converters. A conventional power supply commonly has a simple
diode rectifier, which consists of several diodes, an output inductor and a capacitor.
However, AC/STEPPER diode converter with low output voltage, total loss is consumed
over 85% by the diodes, and the output inductor; for this reason, AC/STEPPER power
MOSFET rectifier is developed to operate with low power loss, unity power factor, low
harmonic and low output ripple.

THREE PHASE GATE DRIVER

There are numerous IC gate drives that are commercially available for gating power
converters. These include pulse-width modulation (PWM) control, power factor correction
(PFC) control, combined PWM and PFC control, current mode control, bridge driver, servo
driver, hall-bridge drivers, stepper motor driver and thyristor gate driver .
Recently, the interest with solid state pulsed power modulator has been growing because of
many advantages such as long life span, rectangular pulse waveforms and easiness of
controlling the pulse width and repetition rate.

Efficiency is one of the most important issues among high power converters where IGBTs
are widely used, and the gate drive circuit serving as the interface.
Between the IGBT power switches and the logic-level signals can be optimized to achieve
low losses. Conventional Gate Driver (CGD) circuits have employed fixed gate voltage and
resistor networks, which are selected to minimize switching losses, suppress cross-talk and
EMI noise, and also limit the power device stresses at switching transients. However, these
conflicting requirements are difficult to be realized in a conventional gate driver.
Basically, the purpose of using a gate driver is the application of to charge pump circuit to
the gate of the MOSFET in the rectifier circuit. The gate requirements for a MOSFET or an
IGBT switch are satisfy as follows; i) Gate voltage must be 10V to 15V higher than the
source or emitter voltage. Because the power drive is connected to the main igh voltage rail
+Vs, the gate voltage must be higher than the rail voltage. ii) The gate voltage that is
normally referenced to ground must be controllable from the logic circuit. Thus, the
control signals have to be level shifted to the source terminal of the power device, which in
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most applications swings between the two rails V+. iii) A low-side power device generally
drives the high-side power device that is connected to the high voltage. Thus, there is one
high-side and one low-side power device. The power absorbed by the gate drive circuitry
should be low and it should not significantly affect the overall efficiency of the power
converter.

PROPORTIONAL-INTEGRAL-DERIVATIVE (PID) CONTROLLER

Proportional-Integral-Derivative (PID) controller has the optimum control dynamics

including zero steady state error, fast response (short rise time), no oscillations and higher
stability. The necessity of using a derivative gain component in addition to the PI controller
is to eliminate the overshoot and the oscillations occurring in the output response of the
system. One of the main advantages of the PID controller is that it can be used with higher
order processes including more than single energy storage.

PID controllers are widely used in industrial practice over 60 years ago. The invention of
PID control is in 1910 (largely owing to Elmer Sperry’s ship autopilot) and the
straightforward Ziegler-Nichols (Z-N) tuning rule in 1942. Today, PID is used in more than
90% of practical control systems, ranging from consumer electronics such as cameras to
industrial processes such as chemical processes. The PID controller helps get our output
(velocity, temperature, position) where we want it, in a short time, with minimal overshoot,
and with little error. It also the most adopted controllers in the industry due to the good cost
and given benefits to the industry. Many nonlinear processes can be controlled using the
well-known and industrially proven PID controller.

The control structure used was the PID (Proportional + Integral + Derivative) as a base for
software development. This type of controller was initially chosen, because it is generally
applied to most of the control systems of continuous processes, proving its usefulness by
providing a generally satisfactory control. The connection among the proportional, integral
and derivative actions result in the PID controller, which can be found in various formats.
Among the existing formats, the one chosen to be implemented in the experiment was
parallel PID, since it is the most common among industrial controllers. Figure 6 shows the
block diagram of a closed loop control system using PID controller.

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SIMULINK

FIGURE 2: Simulink diagram of armature controlled Stepper motor without load.

FIGURE 3: Simulink model of armature controlled STEPPER motor with load.

FIGURE 4: Block diagram of armature controlled STEPPER motor with PID controller under the effect of load.

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RESULTS AND DISCUSSION

This section presents the results of the proposed speed control system model’s simulations,
which have been performed on the Simulink platform of Matlab software. The complete
step by step simulation results of STEPPER motor speed control under the effect of load
with speed – Torque characteristic curve have been illustrated in this section.

The block diagram of system model without and with PID controller is developed on the
Simulink platform. First of all, the step response of the system model without PID
controller is taken and illustrated in figure. The output voltage reached up to the 0.1v (10%
of the final value) when the 1V unit step volt is applied at the input. The rise time is 1.2
seconds, while the settling time is 1.5 seconds. The steady state error is about 90% of the
final value.

In the next step of this experiment, the PID controller has been employed in the existing
block diagram of system model in order to attain the desired speed. The step response of
PID controlled system model is shown in figure. The output voltage reaches up to the
desired value of 1V. The rise time has been greatly reduced and is only 0.2 second, while
the settling time for PID controlled system is 0.25 second.

After that, the system model has been tested without PID controller with full load
condition. The speed – torque step response is also shown in figure. It is obvious that the
speed is not attained to the desired reference value. It has also been observed from the
graph that the speed slows down for about 15000 rpm below the running speed as the load
torque changes from 0 to 1500.

Next, once again the PID controller is employed in the existing block diagram of system
with load disturbance. PID controller is used to overcome the current problem of speed
control under the effect of load. The simulation graph of the system model is demonstrated
in the figure. By using the same parameter values of PID controller, the response of the
system become good with respect to the desired speed sustainability with zero load torque.
However, this speed sustainability become drastically demolishes as the load torque
changes from zero to 1500Nm. This figure illustrates that the motor speed is tremendously
hunted with open loop speed control in full-load condition
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FIGURE 5: Uncontrolled STEPPER Motor Speed Response.

FIGURE 6: PID Controlled Response of STEPPER Motor.

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REFERENCES:
1. P.C. Sen, “Principles of Electrical Machines & Power Electronics”, USA: John
Wiley & Sons, 1996.

2. K. J. Astrom and T. Hagglund,”PID controllers Theory, Design and Tuning”, 2nd

edition,
3. Instrument Society of America, 1994

4. “PID Design Method for the STEPPER Motor Speed Control”, Internet:
www.dii.unisi.it/~control/ctm/examples/motor/PID2.html, 2012 [Feb 20, 2015].

5. “WATLOW PID practical guide for process control”, Internet:

https://www.watlow.com/downloads/en/whitepapers/pid%20practical%20guide.pdf
, Aug 2005, [Feb 17, 2015].

6. M. Shahrokhi and A. Zomorrodi , “Comparison of PID Controller Tuning

Methods”, Internet: www.personal.psu.edu/users/a/u/auz107/Publications-
files/Zomorrodi-Shahrokhi-PID- Tunning-Co mparison.pdf, 2013 [Jan 25, 2015].

7. W. Djatmiko and B. Sutopo, “Speed Control STEPPER Motor under Varying Load
Using Phase- Locked Loop System”, International Conference on Electrical,
Electronics, Communication and Information CECI, Jakarta 2001

8. Elsrogy, Fkirin, Hassan, “Speed control of STEPPER motor using PID controller
based on artificial intelligence techniques” International Conference on Control,
Decision and Information Technologies (CoDIT), 2013, pp. 196-201

9. Rajeshkanna, “Modern speed control of separately excited STEPPER Motor by

Boost converter fed field control method”, International Conference on Computer
Communication and Informatics (ICCCI), 2013, pp. 1-7

10. K. Rajanwal, R. Shakya, S. Patel, R. K. Maurya, “Comparative Analysis of PI, PID

and Fuzzy Logic Controllers for Speed Control of STEPPER Motor”, International

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 Journal of Engineering Research and Technology, Vol. 3 - Issue 1, pp. 1319-1324,
Jan 20, 2014.

11. H. L. Chan and K. T. Woo, “Closed Loop Speed Control of Miniature Brushless
STEPPER Motors”, Journal of Automation and Control Engineering, Vol. 3, No. 4,
pp. 329-335, Aug 2015.

12. C. Perez and M. Strefezza, "Speed control of a STEPPER motor by using fuzzy
variable structure controller," in Control Conference, 2008. CCC 2008. 27th
Chinese, 2008, pp. 311-315

13. R. K. Munje, M. R. Roda, B. E. Kushare, "Speed Control of STEPPER Motor

Using PI and SMC", Proc. of IEEE Int. Conf. on Power and Energy, Singapore, Oct
2010, pp. 945-950

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