Lect re 3

Lecture
Todays
y Topic:
p
• Elements of Closed Loop
• Mechatronics Design Process
• Advanced Approaches in Mechatronics
• Intelligent Control System
• Model Based Monitoring System
• Control variables for maintaining Temperature
• Control variables for maintaining Water level
 Elements of Closed Loop
Reference
Value (+)
Control Correction
Process
Unit Unit
Error
Signal

Measuring
Device
Measured Value Feed Back Controlled
(-) Variable
 Comparison Element
¾Reference signal = +ve (That is adding or set value)
¾Measured value (Signal) = -ve (at out put)
¾Error signal
g = Reference Value – Measured Value
¾The summed value is fed to the segmented circle called
comparison element
¾All I/P are added
¾-ve Feedback: when it is subtracted from the I/P or
reference value
¾+ve Feedback: when it is added to the reference value
 Control Element
¾It decides when action has to be taken after receiving an
error signal
signal.

Correction Element
¾It produces a change in the process to correct or
change the controlled condition. In example of heating
the room, the switch is the key element which ‘ON’ a
h
heater & so increases
i the
h temp off theh process or a valve
l
which opens & allows more liquid to enter. Switch or
A t t is
Actuator i the
th element
l t usedd as a correction
ti unit.
it
 Process Element
¾The process is, what is being controlled. It may be a
room in a house with its temp being controlled or a tank
of water with its level being controlled, or a milling,
drilling or shaping process.

Measurement Element
¾It produces a signal related to the variable condition
of the process that is being controlled.
controlled For heating the
house ‘thermometer’ is the measurement element.
 Mechatronics Design Process
The Mechatronic design methodology is concerned not
only with producing high quality products but with
maintaining them as well,
well an area referred to as life cycle
design. The following are the important life-cycle
factors:
Delivery: Time, cost, and medium.
Reliability: Failure rate, materials, and tolerances.
Maintainability: Modular design (Design of components that can be assembled in a
variety of ways to meet individual consumer needs) .
Serviceability: On board diagnostics; prognostics,
prognostics and
modular design.
Upgradeability: Future compatibility with current designs.
Disposability: Recycling and disposal of hazardous materials
 Mechatronics Design Process
In the Mechatronic design approach, life cycle factors
are included during the product design stages, resulting
in products that are designed from conception to
retirement.
Mechatronics Design Process consists of three phases:
1.Modeling and Simulation
2 P t t i andd
2.Prototyping
3.Development
Modeling/Simulation

Recognition of Prototyping Development/Life Cycle

the
h Need d

Conceptual Design &

Functional Specification Hardware
d i the
in h Loop Development
l off
Simulation Embedded Software
First Principle Modular
Mathematical Modelingg Design Life Cycle
Optimization Optimization
Sensor & Actuator
Selection

Detailed Modular
Mathematical Modeling

Control System Design

Design Optimization
 Mechatronics Design Process
Modeling: Block diagram or visual interface for
creating understandable models of physical or abstract
phenomenon. The ability to summarize complexity and
maintain several levels of sub-model complexity is
useful.
Simulation: Numerical methods for solving models
containing differential, discrete, hybrid, partial, and
nonlinear as well as linear equations.
equations Must have a real-
real
time operation and be capable of executing faster.
j
Project Management:
g Database for maintainingg project
p j
information and sub-models for eventual reuse.
Design: Numerical methods for constrained
optimization of performance functions based on model
parameters and signals.
 Mechatronics Design Process
Analysis: Numerical
N merical methods for frequency
freq enc domain,
domain time
domain, and complex domain design.
Real-Time Interface: A plug-in card is used to replace
part of the model with actual hardware by interfacing to it
with actuators and sensors. This is called a hardware-
in the loop simulation or rapid prototyping and must be
in-the-loop
executed in real time.
Code Generator: To produce efficient high
high-level
level source
code from the block diagram or visual modeling
interface. The control code will be compiled and used on
the embedded processor.
processor The C language is usually used.
used
Embedded Processor Interface: It resides in the final
pproduct,, and this ffeature provides
p communication
between it and the computer-aided prototyping
environment.
 Advanced Approaches in Mechatronics
Recent
ece t developments
deve op e ts in Mechatronics
ec at o cs are
a e also
a so creating
c eat g
opportunities in intelligent manufacturing. In order to produce
high-quality products at low life cycle costs, many
manufacturing g plants
p have been reducingg their workforce. As a
result, the reduced workforce has to cope with additional tasks
and responsibilities, and there is a broader area of control for
plant management.
p g This trend has significantly
g y influenced the
Mechatronics field, especially in the area of sensor-based
manufacturing. It has created opportunities for the use of
intelligent autonomous inspection systems as well as
intelligent decision-making systems that perform tasks
automatically, without human intervention.
In an intelligent inspection system,
system real-time control is
introduced during the process of manufacturing to provide an
increase in machining quality and productivity.
It ensures a quality standard for all products with minimal
sampling error. This method reduces the need for post-process
inspection.
 Intelligent Supervisory Control System in
Mechatronics
Manufacturing processes depend on many
layers of control sequences that are
p
separated byy different levels in their time Plant Control
scales.
Servo control Level (lowest level):
The motion of a cuttingg tool relative to a Shopp Floor Control
workpiece, such as position or velocity, is
controlled.
Supervisory Control
Process Control Level (Second
level): In this process variables such as
cutting forces or tool wear are controlled.
Control level strategies are aimed at Process Control
p
compensating g for factors not explicitly
p y
considered in the design of the servo and
process level controllers. For example, Servo Control
workpiece geometry, present in the
p
computer-aided design
g system,
y mayy be
used to determine the reference values of
process variables.
 Intelligent Supervisory Control System in
Mechatronics
Supervisory Level (Third level): It
monitors product characteristic
variables such as part dimension or
variables, Pl t Control
Plant C t l
surface roughness, and makes
adjustments by modifying commands
sent to the process and servo levels.
Shop Floor and Plant Control Level Sh Fl
Shop Floor C
Controll
(Last level):
Finally, all of this information can be
Finally Supervisory
p y Control
used to achieve on-line optimization of
the machining process at the shop floor
and plant control level. Process Control
Model-based monitoring using
intelligent sensors is an important Servo Control
technology holding much promise for
i
improving
i manufacturing
f t i productivity
d ti it
and quality.
 Model Based Monitoring System

Input Disturbances Decision Making

Manufacturing Process Models,

Process Algorithms
Sensing and
Measurement

Process Adjustments
Controller Monitoring
 Traditional Element for Controlling the
Room Temperature
¾Controlled Variable ¾The room Temp.
p
¾Reference value ¾The required room Temp.
¾Comparison Element ¾A person comparing the
measured value with the
required value of temp.
¾Error signal ¾The difference b/w the
measured & required Temp.
¾Controll Unit
¾C U i ¾The person
¾Correction unit ¾The switch
¾Process ¾H ti by
¾Heating b fire
fi
¾Measuring device ¾A thermometer
 Automatic Control of Water Level (By
Mechanical Elements)
Flap

Water In
Float
Ball

Pivot

Le er
Lever
Water
out
 Automatic Control of Water Level (By
Mechanical Elements)
¾Controlled Variable ¾Water level in tank
¾ i i l setting
¾Initial i off the
h float
fl &
¾Reference value lever position
¾Comparison Element ¾The lever
¾The difference b/w actual &
¾Error signal initial settings of lever positions
¾Control Unit ¾The pivoted lever
¾Correction unit ¾The flap opening or closing
the water supply
¾Process ¾Water level in Tank
¾Measuring device ¾Floating ball & lever
 How we can change the Mechanical
system for maintaining the water level
into a Mechatronics system, list the
Mechatronics elements
 List of Equipments

¾For electronic
¾F C t l Æ Level
l t i Control L l sensor Æ
supplying electrical signal Æ after suitable
conditioning
diti i or amplifying
lif i f d to
fed t Æ
t comparator
comparing with set value.
E
Error Si l
Signal Æ t
to th
the controller
t ll
Then correction element adjust the difference.
Aft
After suitable
it bl signal
i l conditioning,
diti i used
d tot
control the movement of an actuator in a flow
control
t l valve.
l Th it determine
Then d t i theth amountt off
water fed into the tank.