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UNIT-1
Introduction to Mechatronics Course Outcome:
The student will be able to –
• 1. Select appropriate measurement system, actuators and control system for a mechatronic system, based on static and dynamic characteristics. • Introduction to Mechatronics and Its Approach • Measurement System • Control Systems • Microprocessor based controllers Sensors & Transducers • Performance terminology • Photoelectric transducers • Flow transducers • Optical sensors & transducers • Semiconductor lasers • Selection of sensors • Mechanical/electrical switches, inputting data by switches Actuators & Mechanisms • Actuation systems • Pneumatic & Hydraulic systems • Process control valves • Rotory actuators • Mechanical actuation systems • Electrical actuation systems Signal Conditioning • Filtering of digital signals • Multiplexers • Data acquisition • Digital signal processing • Pulse modulation • Data presentation systems Microprocessors & Microcontrollers • Control • Microcomputer structure • Microcontroller applications • Programmable logic controllers Modelinf & System Response • Mathematical Models • Mechanical, electrical, hydraulic, thermal systems • Dynamic response of systems • Transfer functions & Frequency response • Closed loop controllers • MATLAB as development tool Design & Mechatronics • Input/output system • Computer based modular design • System validation • Remote monitoring & control • Possible design solutions • Case studies Mechatronics? • Implementing electronics control in a mechanical system.
• Enhancing existing mechanical design with intelligent
control.
• Replacing mechanical component with a electronic
solution. Real life application-House hold Thermostat Mechatronic system • It consist of many types of interconnected subsystems and components.
• Energy conversions and transfer of one element into
other element is the Key concept in design of Mechatronic systems. These Three technologies have sub categories- • Thermodynamics • Fluid Mechanics • Hydraulics • Pneumatics • Electronics • Electrical Machinery • Microelectronics • Logic Functions • PLC • Software Programming • Instrumentation and Control Examples 1.CENTRE LATHE CNC MACHINE WASHING MACHINE CAMCORDER PAINT MIXING MACHINE AUTOMATED • AUTOMATED ASSEMBLY CELLS PACKAGING TRADITIONAL METHOD
Electric Load al Sub systems
DESIGN
Mechanical Source subsystems Problems in Traditional Model • 1. Original Characteristics and operating conditions of these systems will change due to -
• Actual Loading • Dynamic Interactions. Integrated Method of Mechatronic System Design • Mechanical and Electrical systems are designed with respect to Integrated approach that support concept of relation and Feedback system.
• Characteristics and operating conditions will be
maintained. Design of Mechatronic Systems • It consists of THREE concepts-
1. Modeling and Simulation
2. Prototyping 3. Deployment 1. Modeling and Simulation Physical systems are represented for describing the behaviour characteristics by - • suitable model and Numerical and computer simulation methods. Modeling and Design can be done by understanding the system and its intended function. This analysis by simulation will guide the design process. 2.Prototyping • Creating Partial Mathematical and Real Models • Actual Hardware’s of sensors and actuators are interfaced with input and output signals and are connected with the models. • These two parts are synchronised to understand and validate the design. 3.Deployment • This is associateith final product. • Development of software deployment • Manufacturers and testing Lifestyle. Modeling and Deployment Simulation Prototyping
• Recognition of • Hardware Design
• Development of Need and Simulation • Conceptual and software • Development of • Manufacturers and Control Design detailed Models • Mathematical testing lifecycle • Design Optimization Modeling System
Input Mechanical Electric
Output Electric Power Rotation Generator • System is a group of components combined to perform a specific function.
• Can be considered as a box with relationship between
Input and Output. Measurement System • A system is used to measure a required parameter. • Input- A quantity being measure • Output-Value of quantity being obtained as output Ex.Rotation Speed Measurement : Digital Tachometer Input- Rotation of a shaft Output-Speed Number on LED display Mechatronic Measurement system Control System • A control system in mechatronics refers to a - • group of physical component connected or related in such a manner as to command direct or regulate it selfe or another system. • The physical components may be of electrical, mechanical, hydraulic, pneumatic, thermal or chemical in nature. • A control system manages, commands, directs, or regulates the behavior of other devices or systems using control loops. • It can range from a single home heating controller using a thermostat controlling a domestic boiler to large industrial control systems which are used for controlling processes or machine open-loop control system • The control action from the controller is independent of the process variable. • An example of this is a central heating boiler controlled only by a timer. • The control action is the switching on or off of the boiler. • The process variable is the building temperature. • This controller operates the heating system for a constant time regardless of the temperature of the building. Closed-loop control system • The control action from the controller is dependent on the desired and actual process variable.
• In the case of the boiler analogy, this would utilise a thermostat to
monitor the building temperature, and feed back a signal to ensure the controller output maintains the building temperature close to that set on the thermostat.
• A closed loop controller has a feedback loop which ensures the
controller exerts a control action to control a process variable at the same value as the setpoint. • For this reason, closed-loop controllers are also called feedback controllers Feedback Control • refers to the process of adjusting future actions on the basis of information about the past performance. Water level regulator for a toilet tank Single link Robot Air Pressure control in a vessel Pressure control system Effect of an input disturbance without and with feedback contro STATIC & DYNAMIC Measurement systems
with which the reading approaches the true value of • the quantity to be measured. The accuracy can be expressed in following ways: • Sensitivity: • The sensitivity denotes the smallest change in the measured variable to which the • instrument responds. It is defined as the ratio of the changes in the output of an • instrument to a change in the value of the quantity to be measured. Mathematically • it is expressed as, Linearity • Ability to reproduce input characteristics symmetrically and linearly. • Reproducibility: • Repeatability:
• It is the degree of closeness • It is defined as the variation of
with which a given value may scale reading & random in nature be repeatedly measured. Drift: • It is specified in terms of scale readings over a given period of time. • Resolution: • Threshold:
• If the input is slowly increased • If the instrument input is
from some arbitrary input increased very gradually from value, it will again be zero there will be some • found that output does not • minimum value below which change at all until a certain no output change can be increment is exceeded. This detected. This minimum • increment is called resolution • value defines the threshold of the instrument. • Stability: • Tolerance:
• It is the ability of an instrument • The maximum allowable error
to retain its performance in the measurement is throughout is specified specified in terms of some operating life. value which is called tolerance • Range or span:
• The minimum & maximum values of a quantity for
which an instrument is designed to measure is called its range or span. Dynamic characteristics:
i) Speed of response ii) Measuring lag iii) Fidelity iv) Dynamic error • Speed of response: • It is defined as the rapidity a) Retardation type: with which a measurement • In this case the response of the system responds to changes measurement system begins in the measured quantity. immediately after the • change in measured quantity has • Measuring lag: occurred. • It is the retardation or delay in b) Time delay lag: the response of a • In this case the response of the measurement system to measurement system begins after a changes in the measured dead time after the application of the quantity. The measuring lags input. are of two types: Fidelity: Dynamic error:
• It is defined as the degree • It is the difference between
to which a measurement the true value of the quantity system indicates changes changing with time & the in the measurand quantity value indicated by the without dynamic error. measurement system if no static error is assumed. • It is also called measurement error. Sensor • Sensors in manufacturing are basically employed to automatically carry out the production operations as well as process monitoring activities. Sensor technology has the following importan advantages in transforming a conventional manufacturing unit into a modern one. • Sensors alarm the system operators about the failure of any of the sub units of manufacturing system. • It helps operators to reduce the downtime of complete manufacturing system by carrying out the preventative measures. • Reduces requirement of skilled and experienced labors. • Ultra-precision in product quality can be achieved. • A device which provides a usable output in response to a specified measurand. • Here, the output is usually an ‘electrical quantity’ and measurand is a ‘physical quantity, property or condition which is to be measured’ Need for Sensors • Sensors are omnipresent.
• They embedded in our bodies, automobiles, airplanes,
cellular telephones, radios, chemical plants, industrial plants and countless other applications.
• Without the use of sensors, there would be no automation
Classification of sensors
A. Displacement, position and proximity sensors
• Potentiometer • Strain-gauged element • Capacitive element • Differential transformers • Eddy current proximity sensors • Inductive proximity switch • Optical encoders C. Force • Pneumatic sensors • Strain gauge load cell • Proximity switches D. Fluid pressure (magnetic) • Diaphragm pressure gauge • Hall effect sensors • Capsules, bellows, B. Velocity and motion pressure tubes • Incremental encoder • Piezoelectric sensors • Tachogenerator • Tactile sensor • Pyroelectric sensors E. Liquid flow G. Temperature
• Orifice plate • Bimetallic strips
• Turbine meter • Resistance temperature detectors F. Liquid level • Thermistors • Floats • Thermo-diodes and transistors • Differential pressure • Thermocouples • Light sensors • Photo diodes • Photo resistors • Photo transistor Displacement and position sensors • Displacement sensors are basically used for the measurement of movement of an object. • Position sensors are employed to determine the position of an object in relation to some reference point. • Proximity sensors are a type of position sensor and are used to trace when an object has moved with in particular critical distance of a transducer. Potentiometer
https://www.youtube.com/watch?v=rZOuIbqNVsU LVDT Eddy current
https://www.youtube.com/watch?v=LdAPxQoixU4 Pneumatic Hall Effect
https://www.youtube.com/watch?v=ni-GfN8FKTE https://www.youtube.com/watch?v=Scpi91e1JKc Velocity, motion, force and pressure sensors
https://www.youtube.com/watch?v=YUzP18sIPSM Strain Gauge as force Sensor
https://www.youtube.com/watch?v=u9Riurh4y9U ACTUATOR • An actuator is a component of a machine that is responsible for moving and controlling a mechanism or system, for example by opening a valve.
• An actuator requires a control signal and a source of energy.
• The control signal is relatively low energy and may be electric voltage or current, pneumatic or hydraulic pressure, or even human power. Its main energy source may be an electric current, hydraulic fluid pressure, or pneumatic pressure. • When it receives a control signal, an actuator responds by converting the signal's energy into mechanical motion. Different Types of Actuators • Mechanical Actuator • Pneumatic Actuator • Hydraulic Actuator • Electrical Actuator • Hybrid Actuator Mechanical Actuator: • a rotary motion is converted into linear motion.
• Such actuator normally
involves gears, rails, pulley, chain, springs etc to operate. Pneumatic Actuator: • A device that converts energy typically in the form of compressed air into mechanical motion.
• Consisting of a piston, cylinder, and
valves or ports, a pneumatic actuator can convert energy into linear or rotary mechanical motions. Hydraulic Actuator: • Utilizes the hydraulic pressure as input in order to provide excitation to the motor.
• A hydraulic actuator consists of a
cylinder or fluid motor that uses hydraulic power to facilitate mechanical operation. The mechanical motion gives an output in terms of linear, rotary or oscillatory motion. Electrical Actuator: • It is one of the cleanest and readily available forms of actuating system as it does not involve oil; as there is no need to compress air, hence no extra machinery.
• Electrical energy is always available on ship.
• The electrical energy is used to actuate a mechanical system using
magnetic field i.e. EMF.
• Basic example are electrical motor operated valve and magnetic
valve actuator or solenoid valve. Hybrid Actuators: • These are mixture of some of the above systems which control the mechanical part of the system. • • Common example is a thermo hydraulic Electronic actuator used in operating valves in hot water system, wherein hot water liquid is used along with electronic system acting as control for the valve Examples of actuators • Comb drive • Screw jack • Digital micromirror device • Servomechanism • Electric motor • Solenoid • Electroactive polymer • Stepper motor • Hydraulic cylinder • Shape-memory alloy • Piezoelectric actuator • Hydraulic actuators • Pneumatic actuator Performance metrics • Force • ACTUATING DEVICES • Speed • Electromechanical locks • Operating conditions and latches • Durability • Electromagnetic locks • Turnstiles • Entrance security cabins • Elevators • Automatic gates
