A Low-Cost Dual-Rotor Platform for Control Systems Education and Digital Twin Integration

Resumo

Control of mechanical systems is a fundamental topic in undergraduate engineeringcurricula. To enhance students’ understanding of theoretical concepts, practicallaboratory experiments are often employed. These experiments typically rely on testbenches provided by commercial manufacturers; however, such equipment is oftenexpensive and not easily accessible.With the advancement of Internet of Things (IoT) technologies, low-cost boards andsensors have become widely available, enabling the development of simple, affordableprojects and prototypes. This study aims to develop and validate a digital twin for anaerodynamic system, specifically, a dual-rotor setup with two degrees of freedom. Thesystem will integrate sensing, actuation, and control techniques to improve the accuracyand operational performance of the physical prototype in a more accessible and cost-effective manner. The actuation mechanism will consist of brushless motors, similar tothose used in drones, allowing for precise dynamic control. Instrumentation will includean Inertial Measurement Unit (IMU), such as the MPU6050, with data acquisitionhandled via the Arduino platform and processed in MATLAB, using the MATLABSupport Package for Arduino Hardware for serial communication. Control algorithmswill be implemented and tested using both classical techniques (e.g., PID control) andmodern control methods (e.g., Full State Feedback and Kalman filtering) to evaluate thesystem’s dynamic response. Experimental data will also be used to feed and validate acomputational model of the prototype, thus establishing a robust integration betweenphysical experimentation and digital modelling within the framework of a digital twin.The application of digital twin technology to test bench systems with two degrees offreedom represents a significant advancement compared to conventional commercialsetups. This approach provides engineering students with affordable access to cutting-edge topics in control systems, particularly relevant in the modern engineeringlandscape, making it a valuable resource for undergraduate education.