Remote control of electromagnetic load emulator

for electric motors

Bozic Milos; Rosic Marko; Bjekic Miroslav
Faculty of Technical Sciences, University in Kragujevac, Serbia

Abstract This paper presents equipment and application
for remote control of electromagnetic load emulator.
Emulator is dedicated for testing of electrical motors in
laboratory environment. It can emulate different kinds of
loads which can be found in industrial environment like
pumps, funs, conveyors, elevators etc. The working
principle of electromagnetic emulator is based on
electromagnetic induction. Emulator control is realized with
CompactRIO controller that has a web server so it can be
accessed remotely. Programming is done via LabVIEW
software.
I ndex Terms CompactRIO, emulator, motor, labview,
remote.
I. INTRODUCTION
For making a real work regime of one electrical motor
in laboratory environment, it is necessary to load the shaft
with certain torque. For this purpose, the different types of
loads are in use (mechanical, hydraulic, electrical, etc.).
Electric loads are usually implemented as a complex
electromechanical group which is the optimal solution for
the precisely controlled torque. One of the most important
characteristics of electrical motors is efficiency
characteristic, which can be obtained by measuring of
speed and shaft torque precisely [1].
Standard laboratory tests that are performed in the
laboratories of the electrical machines are no load and
short circuit tests according to standard IEC 60034 - 2.
These tests represent extreme points of work regime of an
electric motor. The most interesting is working regime
between these two points, which can be obtained by
applying the load to the shaft, in this case with load
emulator. In this conception load torque is specified
indirectly with a current through the electromagnet
windings.
Laboratory classes are very important for future
engineers. Most of the laboratory classes are performed in
groups. This conception brings that some students are
actively involved in exercise while the rest of the group is
only present in the laboratory. Solution for this problem
may be if every student individually does laboratory
practice. Due to lack of time and equipment most often it
is not the practice. The introduction of a remote laboratory
exercises brings that students are actively involved in
carrying out experiments. Also, this concept would allow
institutions that do not have the necessary equipment to
remotely perform the exercises. It can be faculties or
secondary vocational schools [2] [3].
II. MAIN PARTS OF THE EMULATOR
The main parts of the system are presented in figure
(Fig.1).


Fig. 1. The main parts of the system

1. CompactRIO 9074 integrated system combines a real-
time processor and a reconfigurable field-programmable
gate array (FPGA) within the same chassis for embedded
machine control and monitoring applications. It integrates
a 400 MHz industrial real-time processor with a 2M gate
FPGA and has eight slots for NI C Series I/O modules. It
has two 10/100 Mb/s Ethernet ports that can be used to
conduct programmatic communication over the network
and built-in Web (HTTP) and file (FTP) servers as well as
to add expansion and distributed I/O to the system [4].
Modules used in this system are:
- NI 9402 is a 4-channel, 55 ns bidirectional digital
module. Digital lines can be configured as input and
output.
- NI 9227 is current input module designed to measure 5
A RMS, and has 50 kS/s per channel simultaneous
sampling. Function of this module in system is to measure
current through electromagnets.
- NI 9403 is a 32-channel, 7s bidirectional digital
input/output module. Purpose of this module in system is
to measure speed of shaft rotation.

2. Control interface contains DC power supply for
electromagnets, 0 - 350VDC, 3A; PWM amplifier and
Sensor for measuring speed of motor shaft.
DC Voltage
PWM amplifier
TTL output
NI 9402
Current module
NI 9227
Shaft
Digital Hall
Sensor
Digital input
NI 9403
Magnet
cRIO 9047
Electromagnets

Fig. 2. Block diagram of electrical connections



3. Electromagnetic emulator is calibrated retarder. The
electric retarder uses electromagnetic induction to provide
a load torque. There are no contact surfaces between the
rotor and stator, and air gap is 0.7 mm. When load torque
is required, the electrical windings in the stator receive
power, producing a magnetic field through which the rotor
moves. This induces eddy currents in the rotor, which
produces an opposing magnetic field to the stator. The
opposing magnetic fields slows the rotor, and hence the
shaft of attached electrical motor. The operation of the
system is extremely quiet in contrast to mechanical
braking. Electromagnet winding has 700 turns of 1 mm
2

copper wires. Electromagnets can be connected in series
or parallel, or combined depending on the desired
induction. Projected maximal torque is about 100 Nm.
Desired torque is achieved by measuring speed of shaft
rotation, and with PID controlled current through
windings. The required current for actual speed is
calculated from relatively complex math equations which
are obtained from calibration process. Desired torque is
achived with current feedback, and there is no need for
using an expensive torque sensor.


Fig. 3. 3D model parts of electromagnetic emulator
(1 cantilever, 2 electromagnets, 3 rotor disc)

4. IP camera is standard camera. It is connected to second
port of cRIO, and allows web casting during experiment.
III. EMULATOR APPLICATION
Emulator application is realised in LabVIEW. Time
crtical current loop is written on FPGA, measuring speed
and equations calculations are implemented on Real time
module. Fig. 4 shows applications front panel with its
parts during the experiment.


Fig. 4. Load characteristics tab with parts of application:
1,2,3,4 Load characteristic type and its parameters; 5,6,7 speed diagram; 8 speed - torque characteristic; 9 - current diagram; 10 torque diagram

IV. CONCLUSION AND FURTHER STEPS
In this paper remote control of electromagnetic
emulator for electric motors is presented. Students in this
experiment can adopt practical knowledge about PID
tuning and electric motor load characteristic. After
finished experiment most important parameters can be
saved in a form of laboratory document report.
Some further steps will be adding sensors for measuring
temperature in electromagnets and also in motor during
experiment. Adding microphone besides video feedback
users will have and audio feedback. With audio feedback
students can hear sound of motor with no load and loaded
motor. Besides measuring the current of the emulator,
current and voltage of the motor will be measured to.
ACKNOWLEDGMENT
This paper is a result of activities within the project
543667-TEMPUS-1-2013-1-RS-TEMPUS-JPHES
Building Network of Remote Labs for strengthening
university-secondary vocational schools collaboration
supported by The Education, Audiovisual and Culture
Executive Agency (EACEA).
REFERENCES
[1] M. Boi, M. Rosi, B. Koprivica, M. Bjeki, S. Anti.,
Efficiency classes of three-phase, cage-induction motors (IE-
code) software, INDEL2012, IX Symposium Industrial
Electronics, INDEL 2012, pp 87-91, November 1-3, Banja Luka,
Bosnia i Hercegovina, 2012
[2] L. D Feisel,. and G. D. Peterson, Learning Objectives
forEngineering Education Laboratories, 32nd ASEE IEEE
Frontiers in Education Conference, Boston MA. 2002.
[3] L. D. Feisel, and A. J. Rosa, The Role of the Laboratory in
Undergraduate Engineering Education, Journal of Engineering
Education, 94(1) pp. 121-130, 2005
[4] National Instruments. CompactRIO cRIO-9074 [PDF Manual]
Available at: http://www.ni.com/pdf/manuals/374639e.pdf.