Propeller Control of Wind Tunnel Models

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1 Propeller Control of Wind Tunnel Models Martin Hasler RUAG Aviation CH-6032 Emmen

2 Contents RUAG Aerodynamics Propeller Testing Propeller Control of Wind Tunnel Models

3 RUAG Aerodynamics Low Speed Wind Tunnel Tests Model Design & Manufacturing Strain-Gauge Balances, Instrumentation Controlled Systems, Test Benches Wind Tunnel Accessories Aerodynamic Engineering Wind Tunnel Consulting

4 RUAG Aerodynamics Large Wind Tunnel Emmen (LWTE) Test Section 7 x 5 x 12 [m] Max. Speed 245 [km/h] Automotive Wind Tunnel Emmen (AWTE) Test Section 2.45 x 1.55 x 3.80 [m] Max. Speed 215 [km/h]

5 RUAG Aerodynamics

6 Propeller Testing Simulation of power effects for propeller driven airplanes Realistic thrust for full scale propellers

7 Propeller Testing Long time experience with hydraulic driven wind tunnel models Wide range of hydraulic motors up to rpm, 790 kw Counter Rotating Open Rotor (CROR) pusher & puller RUAG F31-10 RUAG F11-19 RUAG CROR PROPULSOR RUAG XL-Drive Nominal power [kw] Maximum engine speed [rpm] 12'000 7'000 10'000 1'800 Maximum torque [Nm] '000 Hydraulic mass flow [l/min] (in single configuration) Encoder Pulses per rev Approx. diameter [mm] Approx. length [mm] (in single configuration) 650 (in tandem configuration) 710

8 PropCon «Propeller Control» Requirements System Overview crio RT Program RIO Scan Engine FPGA Data Exchange GUI RT GUI Blinking, logging, alarms Initialization, programmatic events Conclusion

9 PropCon Requirements Operating the pumps in manual or automatic mode Safety of persons and equipment (motors, pumps, pipes, propeller) Independent speed control of 4 motors under variable load conditions (+/-10 rpm) User interface with input and output Configurable parameters (alarming levels, encoder, PID, tank heater, cooler ) Real-time rpm coupling to wind tunnel speed 2 or 4 pumps in parallel mode for big hydraulic motors

starter 4 x 360 l/min, 420 bar NI crio / EtherCAT RIO with 14 I/O modules hydraulic controller cards,

10 PropCon System Overview hydraulic pipes symbolic airplane model key switch, door switch emergency stop rpm (pulses) temperatures acceleration ethernet Pumps 4 x 250 kw electric motors with soft starter 4 x 360 l/min, 420 bar NI crio / EtherCAT RIO with 14 I/O modules hydraulic controller cards, bypass- proportional valve pressure and temperature sensors oil filter with monitoring oil cooler, tank heater

PropCon System Overview [ ] [ ] Main flow (rpm) control with swash plate on the hydraulic pump Fine rpm control with a proportional valve between forerun and return pipe Additional bypass valve for

11 PropCon System Overview [ ] [ ] Main flow (rpm) control with swash plate on the hydraulic pump Fine rpm control with a proportional valve between forerun and return pipe Additional bypass valve for safety reasons (works like a freewheeling diode) rpm control - technical hitches: Very long pipes (70m) and a wide range of motors (10ccm 750ccm) Pressure range from 15 to 420 bar => Volumetric efficiency (pump / motor) Negative or positive power based on the propeller settings and wind speed Encoder feedback from only 8 to 100 pulses per revolution

12 PropCon crio NI crio - EtherCAT RIO 14 I/O modules 216 analog / digital inputs and outputs 64 AI 48 AO 12 RTD 8 CTR 64 DI 20 DO crio-9022: NI 9205, 3x NI 9217, NI 9264, NI 9423, NI 9425, NI 9485 crio-9144: NI 9205, 2x NI 9264, NI 9425, NI9481, NI 9485

13 PropCon RT Program 8 parallel tasks at individual rates to optimize CPU load at 70% Tasks (timed loops) synchronized with Scan Engine 3-modes "manual control, rpm control crio/ external manual control rpm control crio external rpm control safety monitoring doors, buttons pumps on/off 6 PID oil cooler counter rpm measurement windspeed measurement time synchronization FPGA interface DMA averaging AI from scan engine DO oil heater

14 PropCon RIO Scan Engine FPGA RIO Scan Engine Polling of all I/O s with one fix rate (e.g. 40 Hz) Simple access to I/O s or Block Data Access with API Use of I/O s is simple "drag and drop from project explorer Advanced configuration options for counter inputs No filtering of analog inputs => single shot => so be careful! FPGA FPGA much faster than scan engine => AI at max. sampling rates DMA to transfer AI data of accelerometer to RT Code runs directly on FPGA => No direct processor load Compiler needs more than 2 seconds...

15 PropCon Data Exchange GUI RT Data Exchange GUI to RT with "Shared Variables" GUI approx. 300 variables => aliases variables of RT library or RT I/O s RT about 120 variables I/O variables Scan Engine & FPGA Creating I/O aliases or «bound variable» on the host in the project explorer: 1. Create a variable on the RT target 2. Create a host library 3. «right click» on the host Library and select «create Bound variable» => select one or multiple RT or RT I/O variables 4. Optional: renaming, scaling, advanced configuration, etc. Works with customized data types e.g. «Clusters»

16 PropCon GUI 7 parallel tasks 1 event structure Individual rates DSC module alarm monitoring and logging initialization GUI main window event structure 59 different events, "value change" power/torque graph engine temperature graph acceleration graph pump temperature graph rpm graph

17 PropCon GUI FP data binding Blinking indicators (warning/alarm) Tabs for configuration etc.

18 PropCon GUI [ ] [ ] Manual control FP data binding [ ] [ ] [ ] [ ] [ ] [ ]

19 PropCon Blinking, logging, alarms? Individual alarming levels? Enable/disable blinking? Turn on/off alarms? Log the alarm events including time, values etc.?

20 PropCon Blinking, logging, alarms => DSC Module Activate the alarm function of the SV Set the alarm level, priority etc. Enable the logging function

21 PropCon Blinking, logging, alarms => DSC Module Drag and drop the SV to the FP Checkbox Blinking (only with DSC Module )

22 PropCon Blinking, logging, alarms => DSC Module SV-property node Change alarming levels etc. at runtime Turn on/off alarms

23 PropCon Blinking, logging, alarms => DSC Module Read the alarm status depending on the priority Action depending on the alarm state and the priority

24 PropCon Initialization Read INI File (OpenG Variant Configuration File VI s) Write the values with property node «value» to the FP elements Generate «value change Event» => property node «value SGL»

25 PropCon Programmatic events Event cases: value change Multiple variables per event Configuring of DSC alarms overwrite the GUI INI file

26 PropCon Conclusion Scan Engine for easy I/O access of your crio or EtherCAT RIO Shared variables bound variables for easy data exchange over ethernet Front panel data binding for controls and indicators DSC module for the Integration of alarming and logging functions FPGA and DMA for advanced or high speed I/O With LabVIEW it s so easy if you use the right tools and products if you have a certain knowledge =>

27 Thank you for your attention! Thank you for your attention!

Designing Real-Time Control Applications Using LabVIEW and CompactRIO. Developer Days 2009

Designing Real-Time Control Applications Using LabVIEW and CompactRIO Developer Days 2009 Agenda CompactRIO Overview Technology Applications Real-Time Control Software Architecture Basic Process Control