Manufacturing Automation

M.Sc. Bui, Hoang Dung

Office: 208 - A2 Building
Division of ET Mechanical Engineering (DME)
Phone: +84 98 335 2439
Email: bhdung@tnut.edu.vn
 Agenda

1.Introductions
2.Mains Components in an Automation System
3.Numerical Control
4.PLC
5.Industrial Robotics
6.Group Technology and FMS
7.CAD, CAM and CIM
 Chapter 2: Hardware Components

* Objectives
- An overview of Sensors, Actuators, ADC, DAC,
Input/Output Device for Discrete Data
- Principle working of Optical Encoders, DC motor
Chapter 2: Hardware Components
 Contents
- Sensor
- Actuators
- Electric Motors
- Other Types of Actuators
-Analog – to – Digital Converters
- Digital – to – Analog Converters
- Input/Output Devices for Discrete Data
- Contact Input/Output Interface
-Pulse Counters and Generators
 Contents
- Sensor
- Actuators
- Electric Motors
- Other Types of Actuators
-Analog – to – Digital Converters
- Digital – to – Analog Converters
- Input/Output Devices for Discrete Data
- Contact Input/Output Interface
-Pulse Counters and Generators
 Sensors
- is one kind of transducer, converts a physical
stimulus or variable of interest into a more convenient
form for the purpose of measuring the stimulus
- Sensor Category (based on stimulus):
- Mechanical
- Electrical
- Thermal
- Radiation
- Magnetic
- Chemical
 Sensors
- Classified by output signal form: analog or discrete
-Analog Measuring Device:
produce a continuous analog
signal. It must be converted
to digital data by ADC in
order to process by digital
computer

- Discrete Measuring Devices: produce an output with

a certain value, are divided into two categories: binary
and digital
 Sensors
- Binary Measuring Devices:
produce an on/off signal (limit
switches, photoelectric sensor)
- Digital Measuring Devices:
produces a digital output signal (set
of parallel status bit or serial of
pulses that can be counted)
 Sensors
- Trend of sensor development
- Digital sensor is more common (stand-alone,
and compatible with digital computer)
- Development of very small sensor (micro range)
- Active Sensor: Respond to the
stimulus without the need for any
external power.
- Passive Sensor: Require an external
source of power in order to operate
 Sensors
- Transfer function: is the relationship between the
input and output, simply expressed as following:
S = f(s)
- Examples:
-Limit switches and other binary sensors have
transfer functons:
S = 1 if s > 0, and S = 0 if s ≤ 0
Ideal function for analog measuring device:
S = C + ms
- Common Measuring Devices: Lecture Note
 Sensors
- Desirable Features:

High accuracy Minimum drift

High precision High reliability
Wide operating range Low cost
High speed of response

- Before using the device, the transfer function (or

the inverse of the transfer function) should be
determined.
Incremental encoder

13
encoder

14
Incremental encoder

15
Incremental encoder

16
Incremental encoder

17
Incremental encoder

18
Absolute Optical Encoder

19
Absolute Optical Encoder

20
 Contents
- Sensor
- Actuators
- Electric Motors
- Other Types of Actuators
-Analog – to – Digital Converters
- Digital – to – Analog Converters
- Input/Output Devices for Discrete Data
- Contact Input/Output Interface
-Pulse Counters and Generators
 Actuators
- Functions: converts a controller command signal
into a change in a physical parameter (usually
mechanical).
- is also a transducer and require an amplifier
- Three common categories (based on type of
amplifiers):
- Hydraulic
- Pneumatic
- and Electrical
 Actuators -> Electric motors
- Functions: convert electrical power into
mechanical power, consist of two basic components:
Stator and rotor
 Actuators -> Electric motors
- Classification: Direct Current (DC) motors and
Alternating Current (AC) motors
- We focus on three common types in automation and
industrial control:
- DC motors
- AC motors
- Stepper motors
 … Electric motors-> DC motors
- powered by a constant current and voltage, the
continuously switching magnetic field by a
commutator
- Commutator continuously
change the relative polarity
between the rotor and the
stator -> the magnetic field
produces a torque to
continuously turn the rotor.
- Problems: arcing, brushes
wearing, and maintenance problem
 … Electric motors-> DC motors
- Dynamic Equations
 … Electric motors-> DC motors
- Dynamic Equations
dI m
Vm  I m Rm  Lm  Eemf  0
dt
Vm  Eemf
Im 
Rm
Eemf  K m m

Vm  K m m
 Im 
Rm
T  Kt I m
 … Electric motors-> DC motors
- To avoid these problems -> development of a
special type DC motor: Brushless DC motor

- Advantages: reduction the

inertia of the rotor assembly ->
allowing higher speed operation
 … Electric motors-> DC motors
- Two reasons for choosing DC motor:
- Convenient of using direct current as the power
source
- torque – speed relationships are attractive (vs.
AC motor)
 … Electric motors-> DC motors
- DC servomotor: is one kind of DC motor with a
feedback loop to achieve speed control
 … Electric motors-> AC motors
- DC motor: drawbacks of wearing of commutator
and brushes and need a rectifier to convert
alternating current to direct one -> AC can fix the
problems above.
- AC motor used widely in industry and compatible
with the predominant type of electrical power.
 … Electric motors-> AC motors
- Principal operations: it generate a rotating
magnetic field in the stator with the speed depends
on the frequency of input electrical power.
- The rotor turns at the same speed as the rotating
magnetic field.
 … Electric motors-> AC motors
- 2 types: Induction motors and synchronous motor.
- AC Induction motor (widely used): a magnetic field
is induced by the rotation of the rotor through the
magnetic field of the stator -> the rotor does not need
an external source of electrical power.
 … Electric motors-> AC motors
AC synchronous motor: operate by energizing the
rotor with alternating current -> generates a magnetic
field.
 … Electric motors-> AC motors
- Disadvantage of AC motors: They operate with
constant speed.

- Solution: An inverter (adjustable-frequency drives)

is used to control the speed by changing cycle rate o
the AC power to the motor.
 … Electric motors-> Stepper motors
- provides rotation in the form of discrete angular
displacement – called step angles by a discrete
electrical pulse.
- The total angular rotation is controlled by the
number of pulses, and rotational speed is controlled
by the frequency of the pulses.
 … Electric motors-> Stepper motors
- The typical torque-speed relationships:
 … Electric motors-> Stepper motors
- Two operating modes: locked-step and slewing.
- Locked-step mode: each pulse received by motor
cause a discrete angular step; the motor start and stop
with each pulse
- Slewing mode: using with higher speed; the
rotation is more or less continuous and not allow for
stopping or reversing with each subsequent step
- used in open loop control system in which torque
and power requirement are low
 Other types of Actuators
1. Electrical Actuators:
* Solenoid: = plunger + coil + spring
-> open and close valves in fluid flow system
 Other types of Actuators
1. Electrical Actuators:
* Electromechanical Relay: on/off switch = coil+arm
-> open and close electrical contact (operated with
relative low current)
 Other types of Actuators
2. Hydraulic Actuator
Used pressurized oil, provide linear/rotary motion,
with high force and accurate control
 Other types of Actuators
2. Pneumatic Actuator
Used pressurized air, provide linear/rotary motion,
with speed actuation
 Analog – to – Digital Converters
Uses: Convert analog signal from sensors to digital
data for computer processing
- Main components
 Analog – to – Digital Converters
Operation of the ADC: 3 phases = sampling +
quantization + encoding
- Sampling: convert the continuous signal into a
series of discrete analog signal at periodic interval
 Analog – to – Digital Converters
- Quantization: assign each discrete analog signal
into a finite number (in a predefined level list)
- Encoding: the finite number is converted into
digital code (binary digits)

- Calculation:
 Analog – to – Digital Converters
4 factors in process : (1) sample rate, (2) conversion
time, (3) resolution and (4) conversion method
- Sampling rate: the rate at which the continuous
analog signal are sampled.

- Conversion time: is the time interval between a

incoming signal and its digital form at output
- Depend on: type of conversion procedure,
number of bits n to define the converted digital
value
 Analog – to – Digital Converters
- Resolution: the precision with which the analog
signal is evaluated
- Conversion methods: depend on kind of method,
the error of quantization could be optimized

- Example: Suppose the inputs signal is 6.8 V. use

the successive approximation method to encode the
signal for a 6-bit register for an ADC with a full-scald
range of 10 V
Analog – to – Digital Converters
 Digital – to – Analog Converters
Uses: transform the digital output of the computer
into a continuous signal to drive an analog device
Implementation = decoding + data holding

- Decoding: convert a digital output to an analog

value
- Data holding: use the analog value to drive the
actuator device during a sampling interval
Digital – to – Analog Converters
 Digital – to – Analog Converters
Example: A DAC uses a ref. voltage of 100V and has
6-bit precision. In 3 successive sampling instants, 0.5
sec apart, the data contained in the binary register :
Instant Binary Data

1 101000
2 101010
3 101101

Determine (a) the decoder output values for the

three sampling instants, (b) the voltage signals
between instants 2 and 3 for a zero-order hold
 Input/Output Devices for Discrete Data

Uses: convert directly signal of system to digital

form
Categories of discrete data: (1) Binary data, (2)
discrete data other than binary, and (3) pulse data
Categories of these devices: (1) Contact Input/Output
interface, (2) Pulse Counters and Generators
 Contact Input/Output Interface
Uses: read binary data from process into computer
and vice versa
Consisting of a series of simple contact (e.g., limit
switches, photoelectric sensor array) -> provide 0/1
value or array of binary value
 Pulse Counters
Converting a series of pulse into digital value, in
counting and measurement.
 Generators
Producing a series of electrical pulses whose total
number and frequency are specified (stepper motor).
It operates by repeatedly closing and opening an
electrical contact
End of Chapter 2