Professional Documents
Culture Documents
Chapter 6
HARDWARE COMPONENTS FOR AUTOMATION AND PROCESS
CONTROL
REVIEW QUESTIONS
6.1 What is a sensor?
Answer: As defined in the text, a sensor is a device that converts a physical stimulus or
variable of interest (such as temperature, force, pressure, or displacement) into a more
convenient form (usually an electrical quantity such as voltage) for the purpose of
measuring the stimulus.
6.2 What is the difference between an analog sensor and a discrete sensor?
Answer: An analog measuring device produces a continuous analog signal such as
electrical voltage, whose value varies in an analogous manner with the variable being
measured. A discrete measuring device produces an output that can have only certain
values. Discrete sensor devices divide into two categories: (1) binary, in which the
measuring device produces an on/off signal, and (2) digital, in which the measuring device
produces either a set of parallel status bits or a series of pulses that can be counted.
6.3 What is the difference between an active sensor and a passive sensor?
Answer: An active sensor is one that responds to a stimulus without the need for any
external power. A passive sensor is one that requires an external source of power in order
to operate.
6.4 What is the transfer function of a sensor?
Answer: The transfer function of a sensor is the relationship between the value of the
physical stimulus and the value of the signal produced by the sensor in response to the
stimulus. It is the input/output relationship of the sensor.
6.5 What is an actuator?
Answer: An actuator is a hardware device that converts a controller command signal into a
change in a physical parameter. An actuator is a transducer, because it changes one type of
physical quantity, such as electric current, into another type of physical quantity, such as
rotational speed of an electric motor.
6.6 Nearly all actuators can be classified into one of three categories, according to type of
drive power. Name the three categories.
Answer: The three categories are (1) electrical, (2) hydraulic, and (3) pneumatic.
6.7 Name the two main components of an electric motor.
Answer: The two components are the stator, which is the stationary component, and the
rotor, which rotates inside the stator.
6.8 In a DC motor, what is a commutator?
Answer: A commutator is a rotary switching device that rotates with the rotor and picks up
current from a set of carbon brushes that are components of the stator assembly. Its
function is to continually change the relative polarity between the rotor and the stator, so
that the magnetic field produces a torque to continuously turn the rotor.
6-1
© 2015 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This publication is protected by Copyright and written permission should be obtained from
the publisher prior to any prohibited reproduction, storage in a retrieval system, or transmission in any form or by any means, electronic, mechanical, photocopying,
recording, or likewise. For information regarding permission(s), write to: Rights and Permissions Department, Pearson Education, Inc., Upper Saddle River, NJ 07458
Ch06 Automation Hardware-4e-A&S 03/26, 04-01/2013
6.9 What are the two important disadvantages of DC electric motors that make the AC motor
relatively attractive?
Answer: According to the text, the two important disadvantages of DC motors are (1) the
commutator and brushes used to conduct current between the stator assembly and the rotor
result in maintenance problems, and (2) the most common electrical power source in
industry is alternating current, not direct current. In order to use AC power to drive a DC
motor, a rectifier must be added to convert the alternating current to direct current.
6.10 How is the operation of a stepper motor different from the operation of conventional DC or
AC motors?
Answer: Conventional DC and AC motors rotate continuously based on a continuous DC
or AC power source. A stepper motor rotates in discrete angular displacements, called step
angles. Each angular step is actuated by a discrete electrical pulse. The total rotation of the
motor shaft is determined by the number of pulses received by the motor, and rotational
speed is determined by the frequency of the pulses.
6.11 What are three mechanical ways to convert a rotary motion into a linear motion?
Answer: The three conversion mechanisms described in the text are (1) lead screws and
ball screws, (2) pulley systems, and (3) rack and pinion.
6.12 What is a linear electric motor?
Answer: A linear electric motor provides a linear motion without the need for rotary-to-
linear conversion. Its operation is similar to that of rotary electric motors, except that the
ring-shaped stator and cylindrical-shaped rotor are straight rather than circular. The rotor is
called the forcer in a linear motor, and it moves along a straight track.
6.13 What is a solenoid?
Answer: A solenoid is an actuator that consists of a movable plunger inside a stationary
wire coil. When current is applied to the coil, it acts as a magnet, drawing the plunger into
the coil. When current is switched off, a spring returns the plunger to its previous position.
6.14 What is the difference between a hydraulic actuator and a pneumatic actuator?
Answer: Oil is used in hydraulic actuators, whereas compressed air is used in pneumatic
actuators.
6.15 Briefly describe the three steps of the analog-to-digital conversion process?
Answer: The three steps of the A/D conversion process are (1) sampling, which consists of
converting the continuous signal into a series of discrete analog signals at periodic
intervals; (2) quantization, in which each discrete analog signal is assigned to one of a
finite number of previously defined amplitude levels, which are discrete values of voltage
ranging over the full scale of the ADC; and (3) encoding, in which the discrete amplitude
levels obtained during quantization are converted into digital code, representing the
amplitude level as a sequence of binary digits.
6.16 What is the resolution of an analog-to-digital converter?
Answer: The resolution of an ADC is the precision with which the analog signal is
evaluated. Since the signal is represented in binary form, precision is determined by the
number of quantization levels, which in turn is determined by the bit capacity of the ADC
6-2
© 2015 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This publication is protected by Copyright and written permission should be obtained from
the publisher prior to any prohibited reproduction, storage in a retrieval system, or transmission in any form or by any means, electronic, mechanical, photocopying,
recording, or likewise. For information regarding permission(s), write to: Rights and Permissions Department, Pearson Education, Inc., Upper Saddle River, NJ 07458
Ch06 Automation Hardware-4e-A&S 03/26, 04-01/2013
and the computer. In equation form, resolution RADC = L/(2n-1), where L = full scale range
of the ADC and n = number of bits.
6.17 Briefly describe the two steps in the digital-to-analog conversion process?
Answer: The two steps in the D/A conversion process are (1) decoding, in which the
digital output of the computer is converted into a series of analog values at discrete
moments in time, and (2) data holding, in which each successive value is changed into a
continuous signal (usually electrical voltage) used to drive the analog actuator during the
sampling interval.
6.18 What is the difference between a contact input interface and a contact output interface?
Answer: A contact input interface is a device by which binary data are read into the
computer from some external source (e.g., the process). It consists of a series of simple
contacts that can be either closed or open (on or off) to indicate the status of binary devices
connected to the process. A contact output interface is a device that communicates on/off
signals from the computer to the process.
6.19 What is a pulse counter?
Answer: A pulse counter is a device used to convert a series of pulses into a digital value.
6.20 What is a pulse generator?
Answer: A pulse generator is a device that produces a series of electrical pulses whose
total number and frequency are determined and sent by the control computer..
PROBLEMS
Answers to problems labeled (A) are listed in the Appendix at the back of the book.
Sensors
6.1 (A) During calibration, an Iron/Constantan thermocouple emits a voltage of 1.02 mV at
20°C and 27.39 mv at 500°C. The reference temperature is to be set to emit a zero voltage
at 0°C. Assume the transfer function is a linear relationship between 0°C and 500°C.
Determine (a) the transfer function of the thermocouple and (b) the temperature
corresponding to a voltage output of 24.0 mV.
Solution: (a) E = mT (27.39 – 1.02) mV = m(500 – 20)°C
m = 26.37/480 = 0.05494 mV/°C
Transfer function: E = 0.05494 T
(b) At E = 24.0 mV, T = V/m = 24.0/0.05494 = 437°C
6.2 A digital tachometer will be used to determine the surface speed of a rotating workpiece in
surface meters per sec. The tachometer is designed to read rotational speed in rev/sec, but
in this case the shaft of the tachometer is directly coupled to a wheel whose outside rim is
made of rubber. When the wheel rim is pressed against the surface of the rotating
workpiece, the tachometer should provide a direct reading of surface speed in m/sec. What
is the diameter of the wheel rim that will provide a direct reading of surface speed in
m/sec?
Solution: Circumference of wheel C = πD
Surface speed v = NπD
Let v = 1 m/sec. For the tachometer to read this value, N = 1 rev/sec
6-3
© 2015 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This publication is protected by Copyright and written permission should be obtained from
the publisher prior to any prohibited reproduction, storage in a retrieval system, or transmission in any form or by any means, electronic, mechanical, photocopying,
recording, or likewise. For information regarding permission(s), write to: Rights and Permissions Department, Pearson Education, Inc., Upper Saddle River, NJ 07458
Ch06 Automation Hardware-4e-A&S 03/26, 04-01/2013
© 2015 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This publication is protected by Copyright and written permission should be obtained from
the publisher prior to any prohibited reproduction, storage in a retrieval system, or transmission in any form or by any means, electronic, mechanical, photocopying,
recording, or likewise. For information regarding permission(s), write to: Rights and Permissions Department, Pearson Education, Inc., Upper Saddle River, NJ 07458
Ch06 Automation Hardware-4e-A&S 03/26, 04-01/2013
© 2015 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This publication is protected by Copyright and written permission should be obtained from
the publisher prior to any prohibited reproduction, storage in a retrieval system, or transmission in any form or by any means, electronic, mechanical, photocopying,
recording, or likewise. For information regarding permission(s), write to: Rights and Permissions Department, Pearson Education, Inc., Upper Saddle River, NJ 07458
Ch06 Automation Hardware-4e-A&S 03/26, 04-01/2013
© 2015 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This publication is protected by Copyright and written permission should be obtained from
the publisher prior to any prohibited reproduction, storage in a retrieval system, or transmission in any form or by any means, electronic, mechanical, photocopying,
recording, or likewise. For information regarding permission(s), write to: Rights and Permissions Department, Pearson Education, Inc., Upper Saddle River, NJ 07458
Ch06 Automation Hardware-4e-A&S 03/26, 04-01/2013
6.12 The step angle of a stepper motor = 1.8°. The motor shaft is to rotate through 15 complete
revolutions at an angular velocity of 7.5 rad/sec. Determine (a) the required number of
pulses and (b) the pulse frequency to achieve the specified rotation. (c) How much time is
required to complete the 15 revolutions?
Solution: α = 1.8° ns = 360/1.8 = 200 step angles
(a) To rotate 15 revolutions, Am = 15(360) = 5400°
np = 5400/1.8 = 3000 pulses
(b) To rotate at 7.5 rad/sec, fp = 7.5(200) / 2π = 238.7 Hz
(c) Time T = (3000 pulses) / (238.7 pulses/sec) = 12.57 sec
6.13 (A) A stepper motor has a step angle = 3.6°. (a) How many pulses are required for the
motor to rotate through five complete revolutions? (b) What pulse frequency is required for
the motor to rotate at a speed of 180 rev/min?
Solution: α = 3.6° ns = 360/3.6 = 100 step angles
(a) To rotate 5 revolutions, Am = 5(360) = 1800°
np = 1800/3.6 = 500 pulses
(b) To rotate at 180 rev/min, fp = Nns/60 = 180(100) / 60 = 300 Hz
6.14 The shaft of a stepper motor is directly connected to a lead screw that drives a worktable in
an x-y positioning system. The motor has a step angle = 5°. The pitch of the lead screw is 6
mm, which means that the worktable moves in the direction of the lead screw axis by a
distance of 6 mm for each complete revolution of the screw. It is desired to move the
worktable a distance of 275 mm at a top speed of 20 mm/sec. Determine (a) the number of
pulses and (b) the pulse frequency required to achieve this movement. (c) How much time
is required to move the table the desired distance at the desired speed, assuming there are
no delays due to inertia?
Solution: α = 5°/step ns = 360/5 = 72 step angles
Pitch p = 6 mm/rev
x = 275 mm at v = 20 mm/sec
Number of revolutions = 275/6 = 45.8333 revolutions of the motor shaft
N = (20 mm/sec)(60 sec/min)(1 rev/6 mm) = 200 rev/min = 3.3333 rev/sec
(a) Am = (45.8333 rev)(360°/rev) = 16,500°
np = 16,500°/5° = 3300 pulses
(b) fp = Nns/60 = 3.333(72) = 240 Hz
(c) Move time T = (3300 pulses) / (240 pulses/sec) = 13.75 sec
6.15 A single-acting hydraulic cylinder with spring return has an inside diameter of 95 mm. Its
application is to push pallets off of a conveyor into a storage area. The hydraulic power
source can generate up to 2.5 MPa of pressure at a flow rate of 100,000 mm3/sec to drive
the piston. Determine (a) the maximum possible velocity of the piston and (b) the
maximum force that can be applied by the apparatus. (c) Is this a good application for a
hydraulic cylinder, or would a pneumatic cylinder be better?
Solution: Area of cylinder A = 0.25π(95)2 = 7088 mm2
(a) V = Q/A = (100,000 mm3/sec) / 7088 mm2 = 14.11 mm/sec
6-7
© 2015 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This publication is protected by Copyright and written permission should be obtained from
the publisher prior to any prohibited reproduction, storage in a retrieval system, or transmission in any form or by any means, electronic, mechanical, photocopying,
recording, or likewise. For information regarding permission(s), write to: Rights and Permissions Department, Pearson Education, Inc., Upper Saddle River, NJ 07458
Ch06 Automation Hardware-4e-A&S 03/26, 04-01/2013
6-8
© 2015 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This publication is protected by Copyright and written permission should be obtained from
the publisher prior to any prohibited reproduction, storage in a retrieval system, or transmission in any form or by any means, electronic, mechanical, photocopying,
recording, or likewise. For information regarding permission(s), write to: Rights and Permissions Department, Pearson Education, Inc., Upper Saddle River, NJ 07458
Ch06 Automation Hardware-4e-A&S 03/26, 04-01/2013
1 ⎛ L ⎞
Solution: (a) ± 5 V max = ± 0.5 RADC = ⎜ ⎟
2 ⎝ 2n − 1 ⎠
0.5(115)
5.0 = n
, (2n-1) = 0.5(115)/5 = 11.5, 2n = 12.5
2 −1
n 1n(2) = 1n(12.5) n = 2.526/0.693 = 3.64 → Use n = 4
1 ⎛ L ⎞
(b) ± 1 volt max = ± 0.5 RADC = ⎜ ⎟
2 ⎝ 2n − 1 ⎠
0.5(115)
1.0 = n
, (2n-1) = 0.5(115)/1 = 57.5 2n = 58.5
2 −1
n 1n(2) = 1n(58.5) n = 4.069/0.693 = 5.87 → Use n = 6
1 ⎛ L ⎞
(c) ± 0.1 volt max = ± 0.5 RADC = ⎜ n ⎟
2 ⎝ 2 − 1 ⎠
0.5(115)
0.1 = n
, (2n-1) = 0.5(115)/0.1 = 575.0 2n = 576.0
2 −1
n 1n(2) = 1n(576) n = 6.356/0.693 = 9.17 → Use n = 10
6.20 A digital-to-analog converter uses a reference voltage of 120 V dc and has eight binary
digit precision. In one of the sampling instants, the data contained in the binary register =
01010101. If a zero-order hold is used to generate the output signal, determine the voltage
level of that signal.
Solution: Vo = 120{0.5(0) + 0.25(1) + 0.125(0) + 0.0625 (1) + 0.03125(0)
+ 0.015625(1) + 0.007812(0) +0.003906(1)}
Vo = 39.84 V
6.21 A DAC uses a reference voltage of 80 V and has 6-bit precision. In four successive
sampling periods, each 1 second long, the binary data contained in the output register were
100000, 011111, 011101, and 011010. Determine the equation for the voltage as a function
of time between sampling instants 3 and 4 using (a) a zero-order hold, and (b) a first-order
hold.
Solution: First sampling instant: 100000, Vo = 80(0.5) = 40.0 V
Second sampling instant: 011111, Vo = 80(0.25 + 0.125 + 0.0625 + 0.03125 + 0.015625) =
38.75 V
Third sampling instant: 011101, Vo = 80(0.25 + 0.125 + 0.0625 + 0.015625) = 36.25 V
Fourth sampling instant: 011001, Vo = 80(0.25 + 0.125 + 0.015625) = 31.25 V
(a) Zero order hold: V(t) = 36.25 between instants 3 and 4
(b) First order hold: V(t) = 36.25 + α t between instants 3 and 4
α = (36.25 - 38.75)/1 = -2.5
V(t) = 36.25 - 2.5t
6.22 In the previous problem, suppose that a second order hold were to be used to generate the
output signal. The equation for the second-order hold is the following: E(t) = E0 + αt + βt2
, where E0 = starting voltage at the beginning of the time interval. (a) For the binary data
given in the previous problem, determine the values of α and β that would be used in the
equation for the time interval between sampling instants 3 and 4. (b) Compare the first-
order and second-order holds in anticipating the voltage at the 4th instant.
Solution: t = 0: V(t) = 36.25 = 36.25 + α (0) + β (0)
6-9
© 2015 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This publication is protected by Copyright and written permission should be obtained from
the publisher prior to any prohibited reproduction, storage in a retrieval system, or transmission in any form or by any means, electronic, mechanical, photocopying,
recording, or likewise. For information regarding permission(s), write to: Rights and Permissions Department, Pearson Education, Inc., Upper Saddle River, NJ 07458
Ch06 Automation Hardware-4e-A&S 03/26, 04-01/2013
6-10
© 2015 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This publication is protected by Copyright and written permission should be obtained from
the publisher prior to any prohibited reproduction, storage in a retrieval system, or transmission in any form or by any means, electronic, mechanical, photocopying,
recording, or likewise. For information regarding permission(s), write to: Rights and Permissions Department, Pearson Education, Inc., Upper Saddle River, NJ 07458