CONTROL OF DC MOTOR SPEED IN PAINT MIXER BLADE TO GET EVENLY

PAINT COLOR BY USING PI METHOD

Sany Putra Ramadhan

Electrical Engineering, STT Atlas Nusantara
sanyramadhan31@gmail.com

ABSTRACT

Mixing is a process of combining 2 different materials so it can be merged into a

homogeneous subtance and it has perfect spread. The principle is based on the improvement
blending and distribution of two or more components which have different properties. Mixing
can be characterized from the time required, state of the product, or even the amount of
power needed for mixing

It atrract the author’s interest to do the design and implementation of control system
of DC motor rotation paint mixer tool to get evenly color with the PI method, on the
implementation of this final task. In making or designing a paint mixer rotation speed control
as a mixing medium requires components such as DC motors, rotary encoder sensor, Motor
drivers, step down, keypad, and LCD.

The method used in rotation speed control is the Proportional Integral (PI) adaptive
control by using Arduino Uno microcontroller. The motor as a stirrer drive is a DC motor by
providing a PWM signal. And a rotary encoder sensor as a DC motor rotation speed sensor
that provides feedback to the microcontroller and LCD. The working system is when the
rotation speed sensor receives a signal that the stirring rotation speed is approaching the
reference then the sensor will send a signal to the PWM so that the stirring rotation speed will
approach the reference to stabilize the rotation speed.

The purpose of this final project is to make a paint mixing device with a keypad
reference to provide DC motor rotation speed point settings on the paint mixer according to
the keypad input and get a mathematical model of the plant transfer function. Then, control
parameters are obtained by using Proportional Integral (PI) control, after that the results are
compared with the result of the speed of the stirrer motor, whether an error is founf to be
below 5% or is in accordance with the reference input using a rotary encoder sensor.

Keyword: Mixer Machine, Paint Mixer Blade, DC Motor, Arduino Microcontroller,

PI Controller.

1. Introduction

Mixing is a process that causes the mixing of a material into another material where
the ingredients are separated in different phases. In chemistry, a mixing is a substance that is
made by combining two or more different substances without chemical reactions occur, while
there are no physical changes in a mixing. The speed of mixing is depending on the
instrument used, using only wood, iron rods or use a mixer.

Mixing colors still exists among Carpenter, school building projects, housing and
others is still using the manual way with the help of wooden or iron stirrer. As for mixing
colors machine also was in the form of a blade that is mounted on the AC motors and the
lack of a container to a rallying paint. So the process of mixing the colors are still performed
by the operator and supervised so that no paint spilled from containers potluck.
Therefore, the author will make the tool dc motor speed controller tool with the speed
of the machine that is stable at paint and mixing which is done automatically. where there
will be 2 different paint colors in one stirring tank. Uneven stirring will only produce
gradations of color. Therefore, the development will be done on the mechanical design in the
form of a cylindrical vessel that has a vertical axis where the upper part of the vessel can be
open to air or closed.
Aside from the vessel, it is also necessary to add equipment that supports the stirring
process, such as a blade where there are various blades of varying shapes according to the
required stirring pattern. Hopefully, the use of this tool can improve the effectiveness and
efficiency of time and energy.

2. Literature Review

2.1 Closeloop

The close loop system is a sensor-equipped system to measure the output then
comparing it with the reference. If the output’s result is different with the desired output it is
called error. Error is used to direct the output value generated by reference value.

Figure 1 Closeloop System.

2.1.1 Proportional Control (P).

The use of P control has various limitations because of this non-dynamic control.
Changes in Proportional Gain values will affect the system for error and load changes.

c (t )=K P e (t)
Where:
Kp = Gain constants.

2.1.2 Integral Control (I).

This control unit is also called a reset control unit because of its ability to eliminate
offsets left by proportional controllers.
 1
c (t )=K P e ( t ) + K i∫ e ( t ) dt
0

1
Ki= ......................
Ti

Where:
Ki = Integral Constant.
Ti = Integral Time.

2.1.3 PI Type Controller

This controller states the relationship between the error signal and the control signal
so that it can be mathematically given the equation:
t
c (t )=K p e ( t ) + K i ∫ e ( t ) dt
0

The block can be pictured as a diagram.

Where:
c(t) = output from PI ontrol
Kp = Proportional Constant
Ki = Integral Constant
e(t) = error

2.2 Speed Sensor

A speed sensor is a device that can monitor the movement and position. A rotary
encoder generally uses optical sensors to produce a series of pulses which can be interpreted
into motion, position, and direction.

2.3 Color Sensor

Color sensor that serves to detect the evenly color has an TCS3200 converter IC light
color to the value of the frequency. There are two main components forming the IC, the
photodioda and the current to the frequency converter.

2.4 Microcontroller.

Microcontroller is used in arduino uno device. Arduino uno has 14 Pin digital
input/output (where 6 pins can be used as PWM output), 6 analog inputs, 16 MHz crystal
oscillator, USB connection, power jack, ICSP header, and reset button.
2.5 DC Motor

DC motor is a motor that functions to convert electric current (DC power) into
mechanical power where the motion is a rotation of the motor.

2.6 Liquid Crystal Display (LCD).

LCD M1632 is a module with 2x16 display (2 rows x 16 columns) with low power
consumption.

2.7 Keypad
Keypad is used to enter set point speed input to microcontroller.

3 Research Method

The research method used in the research was literature study, system design,
mechanical design, and software design.

3.1 System Design.

The block diagram of the rotation speed of the DC motor consists of a keypad
reference input, the microcontroller arduino uno, LCD, DC motor drivers, DC motor
actuators, and optocoupler sensor, as shown in Figure 2.

Figure 2 Block Diagram Of Motor DC’s Speed Control

It consists of :

a. Arduino as the whole control center of the system

b. Keypad (reference) as the input to provide the desired speed reference
c. Speed sensor used as feedback for DC motor
d. DC motor driver used to activate the motor so the plant can be maintained
e. DC motor as the actuator to activate the blade
f. LCD display to display the reference and real rotations
3.2 Mechanical Design

Mechanical realization is used from iron. It is a square iron with table size of 95 cm ×
46 cm × 96 cm using a thickness of 3 cm. This machine part consists of a paint storage tank
and tiner storage tank measuring 34 cm in diameter 30 cm in height and 8mm iron thickness.
Then it is distributed to the paint mixer tank to be mixed. The paint stirrer uses a blade that is
rotated using a 12V DC motor and is designed according to the need to stir the liquid. For the
length of the lever on the stirrer is 20 cm with a thickness of 0.8cm. The stirring blade is 18
cm long, 8 cm high with 8 mm iron thickness.

3.3 Software Design

In designing software, arduino uno microcontroller serves to control the pressure

based on the reference input speed through keypad.

4. FINDINGS AND DISCUSSION

4.1 Hardware
Machine’s hardware consists of several parts, such as: 3 storages, framework, and box
panel.
4.2 Mechanics

Overall, the mechanical mixer paint looks like in Figure 3

.
Figure 3 Mechanical Mixer Paint
4.3 Electrics
Overall, the electrical mixer paint looks like in Figure 4.

Figure 4 Electrics Mixer Paint

4.4 The Test of Each System

DC motor driver testing (Figure 5) is to find out the driver voltage output comparison
and calibration of the speed sensors (Figure 6) to know the comparative value of the output of
the sensor.

Perbandingan Pengukuran dan Perhitungan Output Driver Motor

10
8
Tegangan (Volt)

6
4
2
0
0

50
60
70
80
90
10
20
30
40

100
110
120
130
140
150
160
170
180
190
200

PWM

Tega ngan Avometer Tega ngan Rata -rata

Figure 5 DC Motor Driver Testing Graph

 Perbandingan Pembacaan Sensor dan Tachometer
250
200
150

RPM
100
50
0

10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
0

PWM

Ta chometer Sens or Rota ry Encoder

Figure 6 The Sensor Calibration Testing Graph

4.5 System Identification

dentification of motor rotation speed response is needed to determine the function of

the result of identification and the model transfer function. The results of the identification
obtained are in the form of speed data starting from the stop until the top speed of 214.29
RPM that can be achieved by the actuator.

Figure 7 Plant Identification Graph

From the Figure 11 it can be found the value of T, the process is show below:
T =Ti , this parameter is a straight line withdrawal from the initial steady state
"y", then:
y=0.6328 × Steady State ¿ theGraphic of Identification
y=0.6328 × 214 .29
y=135.602
 If from the "y" point a straight line is drawn to the axis "x" on the graph then it
obtained the value of Ti, which is 0.3894. The result from the process of identifying the
output voltage to the pump pressure to produce the transfer function of the plant:
25.42
Gp ( s ) =
0.3894 s+ 1

4.6 Plant And Hope

From transfer function of plant response identification result, it is found that the
transient response of rotation speed of DC motor reaches its working value at 0.3894
second. Transient response will be accelerated as much as 0.1947 seconds, then the
desired design of response transients are:
25.42
Gh ( s )=
0.1947 s+ 1

4.7 Determination of Control Parameters

After getting the model of the speed response and set the desired design response
model, then the transfer function of PI is obtained, namely:
0.03064 s+ 0.07868
Gc ( s ) =
0.3894 s

4.8 Control Parameter

The desired design model pattern will affect the control parameters that will be used
on the controller. Then the parameters of Kp and Ti are known as follows:
Ti = 0.3894
Kp = 0.0787

4.9 The Mixer Paint Test After The Close Loop Control

The mixer paint test aims to identify the motor speed charts in actuality with load.
Figure 8 Rpm response with 100 rpm references with a load that have been Controlled

Figure 9 Rpm response with 120 rpm references with a load that have been Controlled
 Figure 10 Rpm response with 140 rpm references with a load that have been Controlled

4.10 Error Steady State

Steady state error is the actual speed difference with the reference speed with load.
Table 1 shows steady state errors with the reference of 100, 120, 140 RPM.

Table 1. The speed of error steady state using the pattern design model with the total weight
4kg
Speed Reference (RPM) Error (%)
100 5.71
120 7.141
140 4.07
Rata-rata Error Steady State 6.187

4.11 Mixing Colors

Mixing paint colors in this study uses 2 different paint colours, namely yellow and
blue to produces green color.

5. Conclusion and Suggestion

5.1 Conclusion

From the control motor rotation speed explanation, it can be concluded as follows:
a. The implementation of PI control algorithm on dc motor speed rotation control system
in paint mixer obtained where the parameters of Kp that is 0.0787 and Ti that is
0.3894.
 b. Steady state error is the difference in average of actual speed with reference and it is a
measured without load or with a load in percent (%). Measurements were made with 3
kinds of references and it found an error rate of the closeloop circuit control system
was 6.187%. So it needs to be developed again for the next research to achieve a
steady state error below 5%.
c. From this study the steady state value speed after applying PI control with 100 rpm
reference reaches a maximum value of 102.86 rpm and a minimum value of 94.29
rpm.
d. The time to reach the steady state / nominal value that has been given a certain
reference input is at the 10th seconds, it is not too critical if only to control the DC
motor speed on the paint mixer blade because it does not include a sequence system
such as DC motor speed control on conveyor belts .

5.2 Suggestion

a. an experiment using other methods can be tried to compare with the methods that
have been used at this time. e.g. fuzzy logic method or the other.
b. it is expected that in the next research the selection of an actuator (motor) should be
equipped with the gearbox so as not to consume large currents when given the load.
c. It is necessary to add ask bearing on the upper and lower blades so that the blade does
not experience a shock which can interfere with the reading of the speed sensor
because it can reduce the percentage of steady state error.

6. Bibilograpy

[1] ATMEL. 2004. AVR241: Direct driving of LCD display using general IO. California:
ATMEL
[2] Karim, Syaiful. 2013. Sensor dan Aktuator. Malang: VEDC Malang.
[3] Ksatria. 2013. RGB scanning menggunkan TCS3200 dan Arduino Uno
https://ksatriaunisi.wordpress.com/2013/08/04/rgb-scanning-menggunakan-tcs-3200-
dan-arduino-uno/. Diakses pada tanggal 12 januari 2018
[4] Label elektro, 2016. http://www.labelektronika.com/2016/09/high-current-motor-
driver-Ibt-2-arduino.html . Diakses pada tanggal 12 juli2018.
[5] Maulana. 2014. https://aozon.blogspot.com/2014/03/mengenal-arduino-uno-lebih-
rinci.html. Diakses pada tanggal 2 maret 2018.
[6] Nanda, Arimbi. 2017 .http://chemistisfunhaha.blogspot.com/2017/ Diakses pada
taggal 21 januari 2018.
[7] Priyo, yogi. 2013. Rotary Encoder dan Sensor Speed. http://yogin37. blogspot.co.id/
2013/01/rotary-encoder.html. Diakses pada tanggal 2 januari 2018.
[8] Rawung, Arie Eric. 2014. Kontrol PID Kecepatan Putaran Motor DC.
http://www.vedcmalang.com/pppptkboemlg/index.php/menuutama/listrik-
electro/1035-aer. Diakses pada tanggal 6 november 2017.
[9] Santoso, Hari. 2015. Arduino- Apa itu PWM?. http://www.elangsakti.com/
2015/06/arduino-konsep-dan-cara-kerja-pwm.html. diakses pada tanggal 1 Desember
2017