Unt No-6 -Tndustial mechatrans ystems

Principles of feed back and Ieigert contra) metnsdg

nslder a cocd dapS e of seeed cortolof DC motor es
Shwn in fige
Desivel sped field ootied
DC otay
0ivinyLoad
Torque
Sens
Tchometr|
In this erample, uhen the a t p t dffer fom the des lred

the feld cuYYent ot the

SPeed, te rY signcl auts
mstr n oYder to tue desved speed sueh claed lasp
restoe
If nc d sped
Stem tyeiy uses negatve Peedbaek
then the desired speed anegatve value Testts
become feuctey
as the eror siqnct.The negaive Veluer
Cewier tne DC msty

to reduce /n speed.
cedbaet msdo
Msty automcttc cstol stems are bas ed on
be co pas ed
feedsapk pncple suggetthot the atpct hes to
seachabilty
to the inpt prsduce tne err Signal· So the
Can be acheved
t e Ys em Can not be acheve!
A abve erample, reæchcbility of
beaouse of dynamlc nature ot the Sys km
feedback ylem tcsts tne tpt ie. if it iI n tthe
Ae
desred vaue then tue eror signa gets generated and
)s fe d to the System to achere the reachabluty level.
uhen feed back losp is added fo tae CÔNtrs system,the contsoller
latns the abiuty t rect.to -tne qety of the sespve
o the pant atpt. n Tis way the systen an kav beter
chance f pextormng as destel.
Autmtc ntol methds
Contoser
adoaptNe cshl me tnod,t
) tdetptive csyol- In
dynamis by acqwny
deans abrt tnesem
pcess itself and keeps n updtng the eristg
from
cntol mdel. tn oder to acheNe hi,
mathemattcd
Cntinsly
Pogsam caled parameter estinatoYr c h
the poresr and estmate tue process dynemi iS
moNtorS
rn. An algnnm is sed genertc Ctsoller prameks
f n theiY estrmteeTe Contlley tnen sends the yered
ommand slgnal t t e plert Dr psocess The mpoYtart
feature o ddeptve csnhser is tr stsuctuse of tne

t e prcmetex estmetY to estimate he

móde Sed 5y
Process dynamics

Asbt conto is appùed in the appiCetron Qreas Aere fue

pos Cess dynamiG are knwn dnd tne Vadotn Yanges fr
Un certivty is rediy obtned
OPredietre cstol- t is also Cued os model pred'ct
ntol Cmpc). In this methad, cgtsller ayoritnn based on
psedicrve noeel of tne sysem ts implemented.
he algornthm csonptee aseence of marpated
wOLraler tn Srder to opthmize the Aotfture pehavsut
of the plat Bas ed n tne istoscal knoledge, tane
mslelpTYdicts tne atpt as wel ay inpt
pml contol-metnod is baed n stute epuctrans

t wtmne (nttad tsol Coritons and arver ad t l

betve setpS)tsancfoimatn etn teqass othe
stte s acheved optru 2e Mqnrer
1

Tateigert cotsol
jnteegert ohol issoft
dely accepted do finetion of
Corpty. besed on atol imnplemensetron

unlre havd compt.} S tolerant igpreof

}mpsecisi ) tniCsfceinty and pantal tGuth In ctteot
-ne sle mel for sot Conettry }s the heman mrd
The
+ krae tbr inpscisn, concetchty and paticttutn
achere tDC Ctblty, obustness and low sól cetran cst
The Poinple ctitenS of stt coorpetmg ar
tz27y agic, neus cet netwoyk tnosy and probbisttc
eaçg.sfe conptihg is a Rastnesp betven the
|tee tb get ditihctve metdslog fos ahesy a poblem
in e, gven doncin
tuzzy ogie or Stt igustic Systern
gic basicay ametB voued lgic tcct lsws
fy ertsemes
intermedi ete vcuues to be defied between t s
c l s Say and 1 tr instknce, plety hot oY
Copletly Smu
caple tey cold, tomplety big
jmple met tzzy
Ja otnef wss) fuzzy ogic attempts to
hotcetions in order to oeize human ike way of thinking

AND b
faly logic In (or ParoteS a sinple scle b t 1£ Ci
TENc aPproach to soluq a Cotol poblem ther tnan
Ctremptry t madel a system mcthemtiy
pieeEH ttz4yie memers inte complesc
Contsl is emplsyed
ìc based
Meiny fuzzy avalcble
Rpplicety t uhere is
mptemetemctical mdel
U) No s nondner kiowled
Prscess s higly ngustc erpet
2) he brmulatranof stt
needs
The prsesr S
fezzy lg lc, no modeing
cotrolled sng
cuhen plert is
ehch S ne cessa
necessany fez2y dgic is cs
implenenty
Crt llexs The procedure of

obicetel of tne contol

1) Define the input and Stput
reletonshy between
1) Defhe down i t o d seies
7tsol poblem
SCgrmerty the ertse Shod defhe the
) les t n t
AND' THEN e
of Tf la nemser o
ven pet cadtts The
desred a t p t for g number of i p t
le ed depeds on
omplene ty of number of fuz?y
pocese and trc
Psametes thct cere
vamtles asiatd cudt eait paramet
fuzzy legic membership tunctns thct defae
e) cseetrsn ot
Ilo tem
the vues of the
SYSt m study
the control fn tan

mplemert Usng fuey lagic

Smuatian, testy, refirement

fuzey oic based contolled reist( n,

 Aduandges IplemeseeSrnt fuzry gic
) &mpler ard fester design netnodol I
|2) Reduce tae destqn de vekopment Phaes
B) snpi fles he cooypleriy nusved in de i9n paces
Sttsn to non linee Coto( Syslems
5) Cstol ertmance can be innpeved
6) ove cntol implementetom is eticient to conmetncd

APPlicaton of frz2y a)c

) Trteligent sbotics
Auton om as nangaton tatking and planring
3) Atonoa cotol system
chara ctntir
4) Csnplen idustnl pocese f t u y g hon has
5)machine isi a ,machine dignaustic Sen

eetsnv
Con Sumer eleetcs and hasehold entcytein nert
s)Thfomaton systens, SPee ch a image poesig.
fault detectton ad Tsolaton CFDT)
DAton and solati on of ats witn the sstem is
Trnpnt. he detcct on an so l e t n f fuet detined

as dicgnestis qnd prognostc CDMP). Prignast'e

help to estimate the tme semurhg betse macne
Lrcakdown CUs. h addtn nol oant f t u t deteh

aned i 6lton Systems qre n orporcuted btb the sYJttm tnen

fhe systcm Ssaid to be set Ciaynaytit Sys tem (F9T)

Ae effcot fD implermertetian nthe mechoLtoe Yem a

Syniticat 1) The Aocattan ,type, tme, gLe

s nd nature of fett

Cn be qeieky 6Crtifies
page-5
 ) ReicsiLiky Cn be inporcd Yeducin Maite nanc e

3) foductsnloss becones oy and oVer au Poduetr\y Becsme,

e) TAe t e of tne mcechhe and al'ary corpt incYeses

s) satety and repulat n icy Can be net
faults

pocess >ytdy
Ptde

Poestete ancs les

P process ParameterS
N’ stebance puumeter

Caern in the design an eeut deteetron S

Pestosmane ch jnplics fst rd acate iderjficaton
of fulunes The detton perfamdnce s mesr ed n terms
of so labity,Senslity ad sobtn es
Tuo classes of feults are seen nthe Sykm adtwe and
multipiccetve Additre feut are tuo types atdte
meuTmert and addtve Ascess fauts
Addtve eut measuscme nt seut cue o derotp un des
between te eired ard toue value f npwt-att
s?nad. dditve proC eS feets are zers duriny narnal prto
t enkred
Unerpeetedy and affect t e spertron
mtpicetve teeafs are tnose chlch descoetne detenraton
of tnc ents compnents cnd eupmertS
 fOIP pprodahe.
stettticel approeeh
moded based RProQ h
otrer aphes
DSttital approach os FOT-sttitical Parcenetos like
ean velue, standad devatan, vonince, densty function
develspmert
ets af te avculble otptsignct ere we pr
of POt dlgorm The snplest appoLh is to measUre thc
meanSuare f the pasameter wtn 3espet to time
Vaue
tnoctelle on gtat
/model based approQchohe metnod
npt
qucenttetve nctematie geltron between ne
Cnd outpt 2s ceed model b Oeel techne
Sensor f u l t
Actgtr
procegs Sen sor
Acuetr
model of
obs ever
model of
nomineel model f
fesu ttdeteetan

Stte estmehn paramebr

i)Dbçenver metnsd estimetton
iD Deteeton f'lter
ii) payity spce
Resiucl generator
Decisin makA
DDcciarn functon
euitt dec lgic

Fault tme sie Ccue locato

page-7
 felt dete cti) depen's Dy ntne availabisy
modet beset The pocedure ot
meel of tn plant
ot a mcetnemctitel generctC signcls to be Conpare!
usry msdel )tor mctn to
uentties 1s knnn as n alyti
ortn the siginet measced
that signals are qenected dn
sedundancy,uhch imples
twn the meesured quntiies. Te psimary
Csmpts ed genercte seSidua
bae techniue is to
objeetNe sf onael
Rercls an me ge t the feut
puls sihce Kog r
Mael based techiyes hve veny
tnis mplemertaton /s appliceble to au types ot Pchnt
Protess ncdng meeeneres
otrex ty per of fo.L appoe hes nlude

DLnt checkng
Kasdwore steucton of speela sens
3 Spcetu conpns
trtificial Lmmme Netusyk (AIN

DiStnbted atol Ystemn (Dc)

hug encbled
Emegence f micopocesos ard micrs cntollers
tne devetopment of Ds bped nstsumntthn, autncctr
and Contol sy tem A DcS Sastm Is sinply a anetsrk
df cotsolens The netusrk tuus foimed is fetfesed to as conto
netwsK. The ente feek hch was resiny ma certsal
csntolies is by tas deided amang ny Ctolies, vesettny
na Smoth exicutian f uhole conntll proes , he psibiy
of a conplete kiure t nikely up Ihto lerels of cnt)
fom bsic (evel Contol f nelwsK leved Prcerng.
 The besic lemends of Distbeed antl sysle9 ahcctse

OPsocessng t - usuawy caled as ocat PscesY

fed derice (sensors, actuatss, swrtehes, ete)
memsry for stonng tne cntsol code
() Psotbrols and devela pment tos (compiless and debyggar)
inc dng host compter.
I1 is appsopiate Suy tret tne Des anetok of
nodes thes than anetuok of Cntlles he nades

excltes t e s t o l ode jn tcrrms of Processhy npt deta

frorn Senos sr otptny kte o the actutn and apay
A Potlo) is c neccsan behcble tne nde t camnkclt
|wtn nsthes nde m the netwok in tne 3un tme
A host orptes s needed develop and dowed tre

srt )edg ntnm hto t e etok caole. Tre 6ntl

ode s usuely down locded nto the nsde y the tot
Cpter ng a denelopmt to/. The develspert
Al cmtcns appi cctton Dttuae e as code editor,
(MT)
cmpiler Netuom Managemert tol
Hos t
adve bupay
conpten

ue
|Process
Cplant
Temt
Ses
Anotner
Plan

motor |
Enoder
Schematic doagrm
pump
Ds sys terr

page- g
 charceetenistic featunes of Dcs Sysem

)Real tme contol abllity

2) Response time
2)Netsk arcieeture
4) MesS eye sne Qnd nedum
5) Range of Commurieton hk
6) Irter percabiiity and Intrchang asil iy
|9 scalab)itity, enendebitiy and naduletity
8) Pogram mubility:
Ihe derign and ionplemetetn ot Ds syskm consjde toed
myor elemers sch as
)Terg et appliccton Aat faym T4piCt appticaton Platfosmy
are obsts, CNC machnes, CIanes, assembly 2ines,
proluctm ines Conveyor sysems, engine, vehcles
Atomgo maS Guded veheles (AU)
2) Electorve- Such es pocessors, tonse ivers,
Coonmuai eto medm,LJo ertece etc
) Deuelopment ls tost camptey lwrn QL and
Sottware applicat
 field bus techmogy
A fundarnertet enebling netuork technolgy n selo2jng
DCs is veffere a to as fe ldbs fechnoloy.
dgitced Cntol netsrking
The fieldbu technalgy is u
Dcs . iet b e
SSem, Su teble s realizcton ot
qod basis for dstnbles
)s a technol9y cehich Povide
contol syslems,
YCal tme catatysem D hbted
tnbet to the
7he technolgy enebles Procesg to be d
mfpoved
deice tevel in suct a way tuat grectty
seduced cst
Motong and conto| is asible ct
end sesut+ Ls fnct tne ffeld deicec becme mre
The
)nteigent and tney dse 6otn awtonsnous and
Copasab le and confiyusble,
the Teelatn
lcldbe incudes a cammncaton Pstocol for
netwt
mu lti chan nel dstbuted c t o l
of b-reetoncl
have been sucestuy toed and testcd n co de
feldbs
veybr
xange sf cntol cppilcctons nuding tod PrceTy
packapr Plant autontian
siartem autsmutron,
SCABACsuperisory ctaland
builng cutsmatn,
ausin) Syskeme, autmte owe duts t a
lota
appicatan, yobotta, c r cvatts Space technsgy
mori torAg and spermsoy Nade- ast capter

Node-2 Node-3 Node-4

A ctuctr Suiteh Seosos Iheliget
(he PLc

Ypical fie lbuy basr dsttbuk ontso7

 QSPts of feldbus tehnogy nldet
Techiccel
9 Process iny paor and tocction sf cootsol dec&ibas
) uhere cand how dcuee cun be stssd and accesN

B) tow Snuch Pocessig er canbe incorpsYcted to the

frcid dece

5) nouhpt respsnse trre

6) ot pee nde
) protocol t Pe and tpolagy
2) or response
 web bed mortonng and contsol
Ta iespDse t denands towds tsenspasancy a nd Pouchvnty
Yecety Demote monibring ant cantsol (Rmc) of industrjd
systerms )s getrting mamertum. Remote matoring
and coherent qpercutn of contl and man ag emet f n t s
wtnin one plattoYm. Contolem netwskny syster are
avculable ich is genericauy defn as fAd bus tcehyy
conmG avelcble dote netusmig sysems ase
A, WAN (utelecs Area netwn), MANCmetopalitun erea
netwoK)
7t tne eng ineey is wokiny tae Office fan at tne ment
ergasing the machne at wsx ntre fectny flr then fre
situctarn meay denand t supemvise and contol the meahne
from s os her office room hsugh doute netwsYk.
SUch type f mplementetran Can be reffered to as LAN
beyad or web based msitry ant conol ot tsget applicetim

dependng Dn hecetherthe deeta netwsK s LAN oY ternet

TPical onfiguretn of web b4s montorng chan

fiqure omputes2 carpttr3

ternd
SADA Com puer
Dotwbuted Dstobutd/
rnteliger
ontoller cntolles

fieldbus hrodge Remote

PLC
osbtcd fiedbw netuom

ctuatr
Sens
Actucet
Sensn Actuat paye-13
AAtomos uted veicles (A GHU)
mobi le obsts Gometmes (oed Autnoma Geule vencle
Cerrentty wsed tos toansptny ntenue
in Mdstny ,coareksues and undergrond oininy
A meyor actvity of curet deneloprment on ABv is nangatn
and crto), T pasitn AVS mthe GNen envsoment
tdo aPPOehes are fyaed
) Abssute pasny
) Reletve p s 9
Tn caSef AGvI the entire contolssten cun be claahed
7 t fy conpond Componetr

)servo ove oto] componerts

2) Tuttcad cool conponent
3) stat eg)c cntro coporet

The sevo
decorto] coponerts nke it parsb le to
adopt the coto) Sys tem to
actuets and chaage Pasmetx dVcrictons on tre
af the ve. Teeticcl
paro cSmpaot
optnum ses ot pesfsom the teek
sb
for porng
The motion n the en
statey ic contsl vronmet
rso
behaviuy basedCOMponerts plans te
on knaw ledge
bowt
espedent
Sensny Cmponets are TeSpnsible tor sranding
Pescepti5n, Pre-Procesg, and nfrmeton
ard stdtegic evel toansknng t tne ta stct
 Human input
P Human visual
E system Communication system Strategic level
Human intellect
R
Communication (operator)
A system
T
Human input A
R (joystic) A

TV Perception Navigation t
rough path
KB
Laser Scaner Perception Behaviour
base n
KB

O E Ultrasonic sensor Perception C

KB Pre-defined
Battery monitoring Perception routing planing
KB
R
Another sensor Perception Obstacle
t
KB
avoiding
z- Perception
u
KB Position
holder C
z+ Perception
KB
Perception Movement
Commands
Guidance KB
wire Tactical Level
antenna Safety sensor Pulse encoder Wheel control Servo drive Leve

Fig. 15.8 AGVarchitectural view in the control context

AGy Ach letuval vel in te (ntsl Context

page-1s
 Doling mechine- (Mechatonic systens)
A tsee anis pcu fom br cilLohy the PeB bscad was
Chosen bs gng an exanple f mehatonic systen.
Ie Plctfom how tre axes 2, 9, and z, Zdris holds tne
|needle to doil hsles on the PB boad. The Pce baesds Qse
pass ed the workbench thYough coNveyor Ssten cmen
an Ac mots ehen Pce bavds reaches tre yn psi
Ceued as sttton, tne q ppes qidly hstds tne bsuDd so that
the 2-ris of te Plat rn uwiu be cble to do
Popesly Thecmtol Sys tem for tuee ons Potforsn heset
genenc se o esserttal egremerts in trms of
Co-sncetln,synchozatan, ackhsw ledy emert tin ing et
The c o l gontnm s shawn in below tiyure
CSTAATJ
keset tne system

Run motor

TS PCB
No at the

) Bingy x -aic and y-ris rollers

to fne mddle of wsYKbnh
tne PcB as pes specificutn

Yeyob

lo) PcB as pers speuhatan

 dI
ihe DcS netcoó m Qtn fve ndes hæs been es)gned ss and
mechnC Tree PocesY
n a c h cSTtcenng a neursn chp
tsnsreejves; Inpt.utpt
ieesfexcd ciYuts @nd deices Gech ar
|inertacS Sensors, encodess,cwere develo prl in orde fo Cs
tAc pastn of shaft alny ne tnree aes.
Node number s respSnsible conts] the Ac motos ard
fitth n de s sad t> cootol tre grPpe aws witn tne
hep ot Prorimity Sersr hoct dete f c lof the
PCB boayd t tne worhbench

kos t
Coptr

conto) Netwsh

N1 N2
X-cOntole y-Cotsles Z-cotlles mot- Ohdy Cripper cotruer

TNertcg|zy Lntesfacig/ Iefecey Terfecy

}cirwits ìrcu

Encoder Encode ncoder for mtr

Prooùmty
Sen Sos

Dm'ng mcechne

pape-1
 OveyDY based meteiad handling sysems
Ihe poductn lines and assebly ines are (MKS)
Moteal Aandig systme ( MHS),A mtsad hendng s +i
haverment, Protectim, storcage of mteskle and pouets
fhroughoct tne Pocess ot tner mneteetue, ssemb ly
and dos tibn, MKS 25 the mehet lc
systecms thot
does tne metenad and)ing opesctms TpCcet mHe ues
oitndare ')ndsty re (renes cnveysu, AGe ve
Mutencd handing System cen be a conveysY system incday
ConNeyor belt, plck and plae nobtic wsmsttim, csnto|
Cooponent such as snle phe Ae motos) tempseese
SensoY, tuo msoScrtches and slous SenSr
The coveysr belt toled eih CqySpced wsk
ich locate and hsld the Produet
ding tounsportct
Apik and place rsotic
CwonrStettsn is used booca and
Unocd the pset fom Cnveyor
Sysen
tneStsre ge
Contcnexs ThePsoduts re Coded and toed acosYh
to colsur
codg Scheme i The Coto]
fiven as per fowchart sequen ce 3
START
power suppy t motr, olsur
yobats and sensor
Interteny ns
HRun the mstr
No Tenp senr

Swtch4
Stop mAor
Detcet csls of Sbirt
 B

picn oycet and plee it ad tne

apeP piate plce as pes calbur code

swth2

Yes
Suitel s ctteehed b he comveyor bett nd
switch2 s fXed wi the rdot

hen tne produt Stihes Switch-1's levev, t sent fne

siqnato tne mot to eep Stp the belt and actees tre
obots plck and place lgoytnm Serence
5witeh-2 fied atte robott Pro vide siÍnal to the motoy
dre te belt egch once tne Pick and place
completd
Rotny pticad encades are places on motos
posit feedtaek ntomton G sevo chatts to podd
corto7.
The Yole ot en coder fo meese.fne sped of
oony spicad ecsdes ees sed nceyor syJem

Peye-ag
*Ttsoduot n to PLC
c9Ntlle CiL c) is a digtel eletan
detce tAot uies panase nenory to ste nstactn any
to mplement fenct ms sch as Ag ic,seen ug,
tmng
Ontiìng and cithmatic n ordes t csnto mceehsnes ah
Prese and has been Seesew
Prag rammng easy
sperficely desipn ed to make
A plc JS
contissly running thujh its psg Ten and
updetg H as a vrst ot the inpt
signas EachcVCh
Aoop is termed as cyde: The
tnfon form ot Pgramny
Commny ws ed rtn Plc S lodd er
Progrmnàrg mis inól ve
eueh posram teek beng spceifid
asthsgh a ng ofa
ladder. There is an altencctve way st
eteslhy apgRm
nstrecton lit w h conSSt of seris
Df instct7ns sepasated atn (inC
Axes s b s
lntol bu
user Cbut Stem Thpct
program CPU Data
RAM Ram atp

Detabu

eutfer TLatch

opto Dvers
hput caipl er
Tterfcc
Fnput
charnels
Dtpt
AChitectue of fLC channelr
PLC are Sinlar to aptes bt hone cetein featses
chch re spefic to tnesi Cas cotsollex. hese ar

n TAey ae ggd hd designtd to cuthstend vistrar, tempretre

hendity ard nsise
) The inesfeucing for inpts and oLp is mide the
contol|ey

fique shws Aschitcetuse of PLc hwch hag

lateh c i c u t t is a cirut tnot, ftex beoy eneosa

îs eceved
mastons tne stte until censte s inpt
ud fors
The tem nternad telay , tuni|jary Teloy s
hat an be CanSdese as Stermal rely ntne tLC

consered to behae lire Yelay cutncS|

77nors Con be
opeNcty
ch cihen energised resut hthe clsure or
dlock
of contects ates come preSet tine or adely
nt e ng ctich delays iynals n the reachny the
number
atpt; corters are used to c o t a Speltied
o
2fcnteet petines A Shitt reyjster 3 c numsr
întencl relay cewch have been grspd bgtner to for
aseies seen ce of in dvdee Aite
asegz tCX toY
A mes er tely ehcbles chsle blck otg p t p t
be shtane usy tned or on.The cndtnal,tns
fencton enatles asehn the Psrn tb beVonpa
condton eists.
P cetun
Perenns t t moy be comed at cwity dete asst o
inchedre mavmg deta, conpaMsn magntte of dlet
ithnctc perens and ConveSiaS Betweeh bhan
oded de smal CBCD)
page- 24)
 Example of PLC System
npt gaS foom
On- off temPs etne Cts) in chch tne
Low to hgh ehen tnpeture Snsr
tempretue,e p t x tnen go tom n to of. The
yempsetue sencoyshwn in the figse is Thermstos conntcd
n abdye nangemert Qinstpt tb an opestonat
amplifier coNnetrd as a CmeYtY . The Pgam
Shwa (n tige shs npt ces c nog on ly Cl se pY
Cotucts, s Jny tne n ignat ard hence cen atp
Chen tae coteets ae pen ed toge the s sPncl, h
then tne o t p t D swtched off

Theyanistoy PLC
t24,v
Relay
X409
Heaty
elenet

X400

-[END

Progrem
The psgTan stows the tnpt as
noimy chsed par of otets
So Sivig the on Sij and hene an autpt. hen the
cnteets are
Aoned t gve th otf signat hen autput is Seteh
ff