6/8/99 (C) 2001, Ernest L.

Hall, University of Cincinnati 1

Manufacturing
Controls
FALL 2001
Lecture 2
Manufacturing Controls
FALL 2001
Lecture 2
Syllabus
DATE TOPIC NOTES
1. Sep. 20 Mechatronics Design Process Ch. 1
2. Sep. 25 System Modeling and Simulation Ch. 2
3. Sep. 27 Laplace Transforms and Transfer Functions Ch. 2
4. Oct. 2 Electrical Examples Ch.2, Notes
5. Oct. 4 Mechanical Examples Ch.2, Notes
6. Oct. 9 Thermal and Fluid Examples, QUIZ 1 (Take Home)
7. Oct. 11 Sensors and Transducers Ch. 3
8. Oct. 16 Advanced MATLAB
9. Oct. 18 Analog and Digital Sensing Ch. 3,
Notes
10. Oct. 23 Actuating Devices Ch. 4

11. Oct. 25 DC Motor Model Ch. 4,
Notes
12. Oct. 30 Boolean Logic Ch. 5
13. Nov. 1 Programmable Logic Controllers Ch. 5, Notes
14. Nov. 6 Stability and Compensators, P, PI and PD Ch. 6
15. Nov. 8 PID Controllers Ch. 7
16. Nov. 13 QUIZ 2 (In Class - Open Book)
17. Nov. 15 Practical and Optimal Compensator Design Ch. 8
18. Nov. 20 Frequency Response Methods Ch. 9, Notes
19. Nov. 22 THANKSGIVING HOLIDAY Ch. 9, Notes
20. Nov. 27 Optimal Design of a Motion Control System Ch. 9, Notes
21. Nov. 29 QUIZ 3 (In Class - Closed Book)
22. Dec. FINAL EXAM (In Class - Closed Book) Comprehensive
Todays objective
To continue the introduction to systems
theory and the use of Matlab by studying a
simple example, the flexible link pendulum.
By the end of this class you will be able to
describe the pendulum, know the
parameters of its model, and simulate the
operation of this system.


Plant
System
Human not yet fully
understood
Machine Linear and
non-linear systems
theory
Man-Machine Best
of both
Has both input and
output - normally
Architecture of System
Uncontrollable
Example - sun
Plant

10/30/2013 (C) 2001, Ernest L. Hall, University
of Cincinnati
7
Architecture of System
Unobservable
Example black hole
Plant

Feedback Control
Feedback system measurements compared
to input and error used to drive plant


Plant
connection

Sensors
Digital Motion Control
Motion control is one of the
technological foundations of
industrial automation.
motion of a product
path of a cutting tool
motion of an industrial robot
arm conducting seam welding
motion of a parcel being moved
from a storage bin to a loading
dock by a shipping cart
The control of motion is a
fundamental concern.
Control theory
Control theory is a foundation
for many fields, including
industrial automation. The
concept of control theory is so
broad that it can be used in
studying
the economy
human behavior
spacecraft design
industrial robots
Automated guided vehicles
Motion control systems often
play a vital part of product
manufacturing, assembly, and
distribution.
Mechatronics
Motion Control is defined by the
American Institute of Motion Engineers
as:
"The broad application of various
technologies to apply a controlled force
to achieve useful motion in fluid or
solid electromechanical systems."
The field of motion control can also be
considered as mechatronics.
"Mechatronics is the synergistic
combination of mechanical and
electrical engineering, computer
science, and information technology,
which includes control systems as well
as numerical methods used to design
products with built-in intelligence."
Components
The components of a typical servo
controlled motion control system may
include
an operator interface
motion control computer
control compensator
electronic drive amplifiers
Actuator
Sensors
Transducers
and the necessary interconnections.
The actuators may be powered by
electro-mechanical, hydraulic or
pneumatic or a combination of these
power sources.
Motion Control Example
Consider the simple pendulum
shown that has been studied for
more than 2000 years.
Aristotle first observed that a
bob swinging on a string would
come to rest, seeking a lower
state of energy.
Later, Galileo Galilee made a
number of incredible, intuitive
inferences from observing the
pendulum.
Galileos conclusions are even
more impressive considering
that he made his discoveries
before the invention of calculus.
u
s
L
M
(a) Physical
diagram



(b) Free body
diagram
s
T
De
W=Mg
u
Flexible Link Pendulum
The pendulum may be described as a bob
with mass, M, and weight given by W=Mg,
where g is the acceleration of gravity,
attached to the end of a flexible cord of
length, L as shown.
When the bob is displaced by an angle u, the
vertical weight component causes a restoring
force to act on it.
Assuming that viscous damping, from
resistance in the medium, with a damping
factor, D, causes a retarding force
proportional to its angular velocity, w, equal
to De.
Since this is a homogeneous, unforced
system, the starting motion is set by the initial
conditions. Let the angle at time u(t=0) be 45
.
For definiteness let the weight, W = 40 lbs.,
the length, L = 3 ft, D = 0.1 (lb.s) and g=32.2
(ft/s2).
u
s
L
M
(a) Physical
diagram



(b) Free body
diagram
s
T
De
W=Mg
u
Free Body Diagram
The analysis is begun by drawing a
free body diagram of the forces
acting on the mass. We will use
the tangent and normal components
to describe the forces acting on the
mass. The free body diagram
shown and Newton's second law
are then used to derive a
differential equation describing the
dynamic response of the system.
Forces may be balanced in any
direction, however, a particularly
simple form of the equation for
pendulum motion can be developed
by balancing the forces in the
tangential direction:
s
T
De
W=Mg
u
Newtons Second Law
Tangent direction
( ) 1

=
t
t t
Ma F
u
s
L
M
(a) Physical
diagram



(b) Free body
diagram
s
T
De
W=Mg
u
u
s
L
M
(a) Physical
diagram



(b) Free body
diagram
s
T
De
W=Mg
u
Balancing the forces in the tangential direction:

This gives the following equation:

= Mg D
d
dt
Ma
t
sinu
u
(2)
( ) 1

=
t
t t
Ma F
a
dv
dt
d s
dt
t
= =
2
2 (3)
s L = u (4)
a L
d
dt
t
=
2
2
u
(5)


The tangential acceleration is given in terms of the rate of change of velocity or arc length by the equation:



Since the arc length, s, is given by:



Substituting s into the differential in Equation 3 yields:

Combining Equation 2 and Equation 5 yields:

Note that the unit of each term is force. In English units, W is in lb
f
, g is in ft./sec
2
, D is in
lb.sec, L is in feet, u is in radians, du/dt is in rad/sec and d
2
u/dt
2
is in rad/sec
2
. In international
SI units, M is in kg, g is in m/sec
2
, D is in kg-m/sec, L is in meters, u is in radians, du/dt is in
rad/sec and d
2
u/dt
2
is in rad/sec
2
.
This may be rewritten as:

d
dt
D
ML
d
dt
g
L
2
2
0
u u
u + + = sin
(7)
= = Mg D
d
dt
Ma ML
d
dt
t
sinu
u u
2
2
(6)
System
This equation may be said to
describe a system.
While there are many types of
systems, systems with no output
are difficult to observe, and
systems with no input are difficult
to control.
To emphasize the importance of
position, we can describe a
kinematic system, such as y = T(x).
To emphasize time, we can
describe a dynamic system, such as
g = h(f(t)).
Equation 7 describes a dynamic
response. The differential equation
is non-linear because of the sin u
term.
u
s
L
M
For a linear system, y = T (x), two conditions must be satisfied:
1. If a constant, a, is multiplied by the input, x, such that ax is applied as the input, then
the output must be multiplied by the same constant, as in Equation 8:
2. If the sum of two inputs is applied, the output must be the sum of the individual
outputs and the principal of superposition must hold as demonstrated by the following
equations:

where
and

T x y ( )
2 2
=
(11)
T x x y y ( )
1 2 1 2
+ = +
(9)
T ax ay ( ) =
(8)
T x y ( )
1 1
=
(10)
This may be rewritten as:

d
dt
D
ML
d
dt
g
L
2
2
0
u u
u + + = sin
(7)
Equation 7 is non-linear because the sine of the sum of two angles is not equal to the sum of
the sines of the two angles. For example, sin(45) = 0.707 while sin(90) = 1.
Linear approach modeling
Returning to the pendulum example, the solution to this non-linear equation with D=0
involves the elliptic function. (The solutions of this non-linear system will be investigated
later using Simulink.) Using the approximation sin u = u in Equation 7 gives the linear
approximation:

d
dt
D
ML
d
dt
g
L
2
2
0
u u
u + + =
(27)
Simple Harmonic Motion
When D=0, Equation 27 simplifies to the linear differential equation for simple harmonic
motion:

d
dt
g
L
2
2
0
u
u + =
(28)

Linear System Theory
Since an arbitrary
input function, f(t)
may be expressed as a
weighted sum of
impulse functions
using the Dirac delta
function, o(t).


Linear System
Representation by Dirac delta
function
Sample with Delta
function at time t, then
integrate over all time.
}

= t t o t d t f t f ) ( ) ( ) (
Apply this input to the linear
system
(

=
}

t t o t d t f h t g ) ( ) ( ) (
Since the system is linear
}

= t t o t d t h f t g )] ( [ ) ( ) (
Impulse response

Therefore, the
response of the linear
system is
characterized by the
response to an impulse
function. This leads to
the definition of the
impulse response:

| | ) , ( ) , ( t o t t h t h =
Superposition integral
}
+

= t t t d t h f t g ) , ( ) ( ) (
Casuality condition
No output before input
0 0 ) , ( < = t t t for t h If
}

=
t
d t h f t g t t t ) , ( ) ( ) (
With the condition that f(t)=0 for
t<0,
}
=
t
d t h f t g
0
) , ( ) ( ) ( t t t
If the system is time invariant,
then
) ( ) , ( t t = t h t h
This leads to the familiar
convolution equation
}
=
t
d t h f t g
0
) ( ) ( ) ( t t t
Convolution
The relationship
between the input and
output of a linear, time
invariant system is a
convolution.
Direct computation of
a convolution involves
a shifting,
multiplication and
integration.
}
=
t
d t h f t g
0
) ( ) ( ) ( t t t
Laplace transform
Transformational techniques, such as the
Laplace transforms, can be used to convert
the convolution into an equivalent product
in the transform domain.
This simplifies the solution for any linear
system.
The Laplace transform F(s) of f(t)
is:
}

=
0
) ( ) ( dt e t f s F
st
The Laplace convolution theorem
states that
}
}
}

=
=
=
0
0
0
) ( ) (
) ( ) (
) ( ) (
dt e t h s H
and
dt e t g s G
dt e t f s F
If
st
st
st
Convolution reduced to product
) ( ) ( ) (
) ( ) ( ) (
0
s H s F s G
then
d t h f t g
t
=
=
}
t t t
Block diagrams
This transform relationship may be used to
develop block diagram representations and
algebra for linear systems, which is very
useful to simplify the study of complicated
systems.
Basic blocks
H(s)
Sum
Basic Block
Comparison
A
B
C=A+B
F(s) G(s)=F(s)*H(s)
Pick off point
A
A
Blocks in cascade
H1 H2
G(s)
F(s)
G1(s)
H1*H2
F(s)
G(s)
Blocks in parallel
H1
H2
text F(s)
G(s)
+
+
H1+H2
F(s)
G(s)
Feedback block
G(s)
H(s)
R(s)
C(s)
-
+
E(s)
F(s)
C(s) = G(s)E(s)
F(s) = H(s)C(s)
E(s) = R(s)-F(s)
C(s) = G(s)(R(s)-F(s)
C(s) = G(s)(R(s)-H(s)C(s))
C(s)=G(s)R(s)-G(s)H(s)C(s)
C(s)(1+G(s)H(s))=G(s)R(s)
C(s)/R(s) = G(s)/(1+G(s)H(s))
A Matlab
1
m-file may be used to determine the time response to the linear differential
equation. To use Laplace transforms in Matlab, we must use the linear form of the system and
provide initial conditions since no forcing function is applied.
Remembering that the Laplace transform of the derivative is:



and




(29) ) 0 ( ) (

O =
)
`

u
u
s s
dt
d
L
(30)
dt
d
s s s
dt
d
L
) 0 (
) 0 ( ) (
2
2
2

O =
)
`

u
u
u
Taking the Laplace transform of the linear differential Equation 27 gives:

This may be simplified to:

(31)
s s s
d
dt
D
ML
s s
g
L
s
2
0
0
0 0 O O O ( ) ( )
( )
( ) ( ) ( ) + + =

u
u
u
(32) O( )
( ) ( )
( )
s
s
D
ML
d
dt
s
D
ML
s
g
L
=
+
+ +


u u
u
0 0
0
2
Block diagrams clarify ideas
u(s)
1
?
su(s)
1/s ?
(Note that the initial conditions act as a forcing function for the system to start it moving.) It is
more common to apply a step function to start a system. The unit step function is defined as:


(Note that the unit step function is the integral of the delta function.) It may also be shown
that the Laplace transform of the delta function is 1, and that the Laplace transform of the unit
step function is 1/s.

<
>=
=
0
0
0
1
) (
t
t
for
for
t u
(33)
To use Matlab to solve the transfer function for u(t), we must tell Matlab that this is the output
of some system. Since G(s) = H(s)F(s), we can let H(s) = 1 and F(s) = O(s). Then the output
will be G(s) = O(s), and the impulse function can be used directly. If Matlab does not have an
impulse response but it does have a step response, then a slight manipulation is required.
(Note that the impulse response of system G(s) is the same as the step response of system s
(G(s)).)
The transform function with numerical values substituted is:

O( )
( . )
. .
s
s
s s
=

+ +
45 00268
00268 1073
2
(34)
Note that u (0) = 45, and du(0)/dt = 0. We can define T0 = u (0) for ease of
typing, and express the numerator and denominator polynomials by their
coefficients as shown by the num and den vectors below.

To develop a Matlab m-file script using the step function, define the parameters
from the problem statement:
T0 =45
D = 0.1
M = 40/32.2
L = 3
G=32.3
num = [T0, D*T0/(M*L), 0];
den = [1, D/(M*L), G/L ];
t= 0:0.1:10;
step(num,den,t);
grid on
title('Time response of the pendulum linear approximation')
This m-file or script may be run using Matlab and should produce an oscillatory output. The
angle starts at 45 degrees at time 0 and goes in the negative direction first, then oscillates to
some positive angle and dampens out. The period, T in seconds (or frequency, f = 1/T in
cycles/second or Hertz) of the response can be compared to the theoretical solution for an
undamped pendulum given in Equation 35 [4]. The is shown in Figure 3.


T
L
g
= 2t
(35)
Now try it!
Use Matlab to solve
the pendulum.
Just open a new
workspace in Matlab.
Copy the sample
program.
Run the m-file.

0 2 4 6 8 10
-50
0
50
Time (Seconds)
Time response of pendulum with linear approximation
D
e
g
r
e
e
s

Figure 3. Pendulum response with linear
approximation. u(0+)=45
Demonstration
How is the pendulum a system?
What are the parameters of its model?
Simulate the effect of changes in the
parameters.

How is the pendulum a system?
The
O( )
( . )
. .
s
s
s s
=

+ +
45 00268
00268 1073
2
(34)
su(s)
1/s ?
What are the parameters of its
model? L, g, D what about M?
The period, T in seconds (or frequency, f = 1/T in
cycles/second or Hertz) of the response can be compared to the theoretical solution for an
undamped pendulum given in Equation 35 [4]. The is shown in Figure 3.


T
L
g
= 2t
(35)
Simulate the solution for D= 1,
100
What happens?