MEC751 Project Milestone 2

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Toronto Metropolitan University *

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MEC 751

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Mechanical Engineering

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Dec 6, 2023

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Department of Mechanical and Industrial Engineering Program: Mechanical Engineering Course Number MEC751 Course Title Measurements Instruments and sensors Semester/Year Fall 2023 Instructor Dr. Ahmad Ghasempoor Section Number Group Number TA Project Milestone 2 Due Date November 17, 2023 Student Name Student ID (xxxx1234) Signature* (Note: Remove the first 4 digits from your student ID) *By signing above you attest that you have contributed to this submission and confirm that all work you have contributed to this submission is your own work. Any suspicion of copying or plagiarism in this work will result in an investigation of Academic Misconduct and may result in a “0” on the work, an “F” in the course, or possibly more severe penalties, as well as a Disciplinary Notice on your academic record under the Student Code of Academic Conduct, which can be found online at: http://www.ryerson.ca/senate/policies/pol60.pdf .

1 Table of Contents 1.0 Introduction ............................................................................................................................................ 2 2. LabVIEW and Physical Setup ................................................................................................................ 4 3.0 Results ..................................................................................................................................................... 8 3.1 Static calibration .............................................................................................................................. 10 3.2.0 Instrument Error Calculations: ............................................................................................... 11 3.2.1 Sensitivity ........................................................................................................................ 11 3.2.2 Zero Drift ......................................................................................................................... 11 3.2.3 Hysteresis ......................................................................................................................... 11 3.2.4 Non-linearity .................................................................................................................... 12 3.2.5 Repeatability Error .......................................................................................................... 13 3.2.6 Total Error ........................................................................................................................ 13 4.0 Appendix ............................................................................................................................................... 14 5.0 References ............................................................................................................................................. 14

2 1.0 Introduction This milestone is concerned with calibration and demonstration of gripper mechanism with load cell sensor data using LabVIEW. The below sections provide a summary of the results obtained during this milestone. Figure 1. Flowchart of the Labview program for PID control

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3 Figure 2. Wiring diagram documenting the feedback control

4 2. LabVIEW and Physical Setup In the below section, a few screenshots of the labVIEW model and the physical setup of the gripper system are shown. It is worth mentioning that the original setup was upgraded to this one for 2 main reasons, first, is the old design's complexity, and second is the size of it. The new design is simple, has less parts and overall smaller than its predecessor. The gripper mechanism is controlled via a Servo Motor and 2 claw arms. See Figures below. Figure 3. Top View of Physical Setup

5 Figure 4. Breakdown of Upgraded setup

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6 Figure 5. Block Diagram of LabVIEW-load cell Calibration setup Figure 6. Front Panel of LabVIEW-Load Cell Calibration

7 Figure 7. Block Diagram of LabVIEW-Servo Motor Controller though PWM and PID control Figure 8. Front Panel of LabVIEW-Servo Motor Controller showing load cell response when gripping ping pong ball

8 3.0 Results Figure 9. Force applied versus Voltage of load cell for Cycle 1 Figure 10. Force applied versus Voltage of load cell for Cycle 2

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9 Figure 11. Force applied versus Voltage of load cell for Cycle 3 Figure 12. Force applied versus Voltage of load cell for all Cycles combined

10 3.1 Static calibration The second part of the milestone was collecting static calibration data for 3 different cycles using 5 known weights and calculating the load’s cell error based on the results. This data collection method is the same as the one used in Lab 3 with the same loading cycles and weights used. This is shown in the table below. Table 1: Load Cell Calibration Data True Weight (gram) Force (Newton) Cycle 1 (mV) Cycle 2 (mV) Cycle 3 (mV) 0 0 0.030 0.034 0.032 80 0.785 0.184 0.181 0.179 100 0.981 0.214 0.225 0.216 150 1.471 0.301 0.301 0.318 200 1.961 0.406 0.407 0.403 300 2.942 0.581 0.590 0.589 200 1.961 0.403 0.399 0.411 150 1.471 0.305 0.311 0.306 100 0.981 0.212 0.217 0.221 80 0.785 0.172 0.180 0.182 0 0.000 0.028 0.031 0.035

11 3.2.0 Instrument Error Calculations: 3.2.1 Sensitivity Is categorized the output of the sensor's signal over in mV over the force applied in Newtons. This can be found as the result of calculating the average of the slope of the curves shown in Figure 12. Sensitivity = output/input → = (0.189+0.191+0.189)/3 = 0.187 mV/N 3.2.2 Zero Drift It categorized the largest drift front the zero line between all 3 cycles and is obtained from Figure 12. This is found from cycle 3 which has the highest y intercept of magnitude 0.033mV Zero drift = 0.033 mV 3.2.3 Hysteresis The hysteresis error was found by averaging the weights reading for the 80, 100, 150, and 200g weights over 3 cycles with increasing and decreasing weights as it determines a path. The maximum difference between these average is taken as the hysteresis error which in this case is 0.009 mV. ± Table 2 - Determining Hysteresis Error Weight (g) Average_increasing (V) Avererage_decreasing (V) Difference 80 0.180 0.171 0.009 100 0.218 0.216 0.002 150 0.313 0.307 0.006 200 0.405 0.404 0.001 Hysteresis Error = 0.009 mV ±

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12 3.2.4 Non-linearity Non-linearity is taken as the maximum deviation the measured value at a certain point is, from the calculated value based on the line of best fit, see Table 3. The maximum deviation was found to be 0.02 mV and is considered the non-linearity error in this case. Table 3 - Determining Non-Linearity Error Force (Newton) Result of Line of Best fit (mV) Deviation of Cycle 1 (mV) Deviation of Cycle 2 (mV) Deviation of Cycle 3 (mV) 0 0.033 0.003 0.001 0.001 0.785 0.179795 0.004 0.002 0.001 0.981 0.216447 0.002 0.009 0.000 1.471 0.308077 0.007 0.013 0.010 1.971 0.401577 0.004 0.005 0.001 2.942 0.583154 0.002 0.007 0.006 1.961 0.399707 0.003 0.001 0.011 1.471 0.308077 0.003 0.003 0.002 0.981 0.216447 0.004 0.001 0.005 0.785 0.179795 0.008 0.020 0.002 0 0.033 0.005 0.002 0.002 Non-linearity Error = 0.02 mV ±

13 3.2.5 Repeatability Error The repeatability error is determined through calculating the sample's variance over each cycle for each loaded weight and then multiplying it with the z-score for the confidence interval of 95% (equal to 1.96). The maximum repeatability error from all the weights was found to be 0.0002 mV. ± Table 4 - Determining Repeatability Error Applied Force (N) Sample Variance (mV) Repeatability Error (mV) 0 6.67E-06 1.31E-05 ± 0.785 7.70E-05 1.51E-04 ± 0.981 2.27E-05 4.45E-05 ± 1.471 6.15E-05 1.20E-04 ± 1.971 1.70E-05 3.33E-05 ± 2.942 2.43E-05 4.77E-05 ± 3.2.6 Total Error To find the total error in this experiment, the Full Scale Output is determined as follows 𝐹𝑆? = (?𝑒??𝑖?𝑖?𝑖??) * (𝐼?𝑝?? ?𝑎? ) V 𝐹𝑆? = 0. 187 ?𝑉/? * 2. 942? = 0. 550 ? Then the %Full Scale output needs to be obtained for each single type of error calculated in part 2. This is then summed through the root mean square (RMS) to find out the total error. A summary of this calculation is outlined in Table 5 Table 5: Calculation of Total Error Uncertainty (mV) % FSO Zero Drift 0.033 ± 6.0% FSO Hysteresis 0.009 ± 1.6% FSO Non-linearity 0.002 ± 0.4% FSO Repeatability 0.0002 ± 0.04% FSO Total 0.034 ± 6.2% FSO

14 4.0 Appendix LabView FIles and video demonstration are all included with the submission file on D2L. 5.0 References [1] A. S. Morris and R. Langari, Measurement and Instrumentation: Theory and Application , Third Edition. Academic Press, Katey Birtcher, 2021. [2] Ghasempoor, A. MEC751_Labs_F23_Lab3 (Cantilever Beam)_ Handout for Cantilever Beam Calibration Lab, D2L_upload. Toronto; TMU, (2023, Sep 27).

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