eae? NM CoiPh ition ELECTRONIC CONTROL SYSTEMS IN MECHANICAL AND ELECTRICAL ENGINEERINGPearson Eduea Edinburgh Gate Harlow Essex CM20 25E England and Associated Companies throughout the world Visit us on the World Wide Web at: sow, pearsoned.co.uk First published 1995 Second edition 1999 Third edition 2003 © Pearson Education Limited 1995, 2003 “The right of William Bolton to be identified as author of this work has been asserted by him in accordance with the Copyright, Designs and Patents Act 1988, All rights reserved. No part ofthis publication may be reproduced, stored in a retrieval pater, or transmitted in any form or by any means, electronic, mechanical Photocopying, recording or otherwise, without ether the prior written permission of the Publisher o licence permitting restricted copying in the united Kingdom issued by the Copyright Licensing Agency Ltd, 90 Tottenham Court Road, Londen WIT 4LP. ‘All trademarks used herein are the property of their respective owners. The use of any trademark inthis text does not vest inthe author or publisher any trademark ownership Fights in such trademarks, nor does the use of such trademarks imply any afilition with or endorsement of this book by such owners. ISBN 0 131 21633 3 British Library Cataloguing-in-Publication Data ‘A catalogue record for this book is available from the British Library Library of Congress Cataloging-in-Publication Data ‘A catalog record for this book is available from the Library of Congress 109876543 (08.07 06 05 04 Printed by Ashford Colour Press Ltd, Gosport4 Mechatronics 2. Sensors and transducers . 3 Signal conditioning Contents Preface ‘What is mechatronics? Systems ‘Measurement systems Control systeins ‘Microprocessor based conteollers 16 Response of systems 17 The mechatronics approach Probleins 2.1 Sensors and transducers 22 Performance terminology 2.3 Displacement, position and proximity 24 Velocity and motion 23 Force 2.6 Fluid pressure 2.7 Liquid fow 2.8 Liquid level 2.9 Temperature 2.10 Light sensors 211 Selection of sensors 212. Inputting data by switches Problems 3.1 Signal conditioning 3.2. The operational amplifier 3.3. Protection 34 Filtering 3.5 Wheatstone bridge 3.6 Digital signals 3.7 Multiplexers 3.8 Data acquisition 3.9. Digital signal processing 3.10 Pulse modulation Problemsvi Contents 4 Data presentation systems Pneumatic and hydraulic actuation systems Mechanical actuation systems Electrical actuation systems Basic system models System models 41 42 43 44 45 46 4a 5 52 53 34 53 36 37 6.1 62 63 64 63 66 68 69 8.1 83 84 85 Displays Data presentation elements Magnetic recording, Displays Data acquisition systems Measurement systems Testing and calibration Problems Actuation systems Pneumatic and hydraulic systems Directional control valves Pressure contol valves Cylinders Process control valves Rotary actuators Problems Mechanical systems ‘Types of motion Kinematic chains Cams Gear trains Ratchet and paw! Belt and chain drives Bearings Mechanical aspects of motor selection Problems Electrical systems Mechanical switches Solid-state switches Solenoids D.C. motors A.C. motors Stepper motors Problems Mathematical models Mechanical system building blocks Electrical system building blocks Fluid system building blocks Thermal system building blocks Problems Engineering systems Rotational-iranslational systems Electromechanical systems10 1 12 13 Dynamic responses of systems System transfer functions Frequency response Closedtoop controllers 14 Digital logic of wot 102 103 lo4 10s Ml 112 113 14 us le 7 ni 122 123 D4 3 6 Ba B2 B3 Ba BS BG 13.7 1s Bo 1.10 Bu Ba 1 142 143 44 4s 46 47 Contents vii Hydraulic~mechanical systems Problems ‘Modelling dynamic systems First-order systems Second-order systems Performance measures for second-order System identification Problems stems The transfer function First-order systems Second-order systems ‘Systems in series ‘Systems with feedback loops Effect of pole location on transient response MATLAB and SIMULINK Problems Sinusoidal input Phasors Frequency response Bode plots Performance specifications Stability Problems Continuous and discrete processes Controt modes Two-step mode Proportional mode Derivative control Integral control PID controller Digital controllers Control system performance Controller tuning Velocity controt Adaptive control Problems Digital logic Number systems Logic gates Boolean algebra Karnaugh maps Applications of logic gates ‘Sequential logic Problems 27 20 222 224 230 236 240 240 aa 245 7 250 250 252 254 260 262 262 265 268. a 278 279 280 282 283, 284 288 290 293 298 297 299 301 301 305 307 308 314 320 325, 329 335 339)vill 415 7 18 49 20 Contents Microprocessors Assembly language C language Input/output systems Programmable logic controllers Communication systems 15.1 152 153 134 15.5 16.1 16.2 163 loa 16.5 m 112 173 4 ms 176 107 18.1 182 183 184 18.5 186 19.1 192 193 19.4 19.5 16 19.7 198 19.9 19.10 19.11 20.1 20.2 203 20.4 Control Microprocessor systems Microcontrollers Applications Programming Problems Languages Instruction sets Assembly language programs Subroutines Look-up tables Problems Why C? Program structure ‘Branches and loops Arrays Pointers Program development Examples of programs Problems Interfacing Inpavoutput addressing Interface requirements Peripheral interface adapters Serial communications interface Examples of interfacing, Problems Programmable logic controllers Basic structure Input/output processing Programming Mnemonics: ‘Timers, internal relays and counters Shift registers Master and jump controls Data handling Analogue inpu/output Selection of a PLC Problems Digital communications Centralised, hierarchical and distributed control Networks Protocols 342 343 356 33 375 377 378 379 386 392 396 400 401 401 409 412 413 415 416 419 421 421 424 432 437 440 443, 444 445 448. 449 454 438 460 461 462 465 466 466 468 468 471 473241 22 205 206 Fault finding ad 212 213 a4 215 216 27 Mechatronics systems 22.1 22 23 Appendix A: Al The Laplace transform 42 A ad Appendix B: Logic gates Appendix C: Instruction sets Appendix D: C library functions Open Systems Interconnection communication model 475 Communication interfaces Problems Fault-detection techniques Watchdog timer Parity and error coding checks Common hardware faults Microprocessor systems Emulation and simulation PLC systems Problems ‘Traditional and mechatronics designs Possible mechatronics design solutions Case studies of mechatronic systems Problems and assignments ‘The Laplace transform Unit steps and impulses Standard Laplace transforms The inverse transform AND gate OR gate NOT gate ‘AND gate NOR gate EXCLUSIVE-OR (XOR) gate Mo8HCLL Intel 8051 PICI6CHx Further information Answers, Index 478 486 487 488 489 491 492 497 498 500 502 508 518 530 33 532 S34 538 Sa SH SH 542 542 542 343 545 546 347 347 548. 548. 548. 349Overview Readership Preface ‘The integration of electronic engineering, electrical engineering, computer technology and control engineering with mechanical engineering is increasingly forming a crucial part in the design, manufacture and maintenance of a wide range of engineering products and processes. A consequence of this is the need for engineers and technicians to adopt an interdisciplinary and integrated approach to engineering The term mechatronics is used to desoribe this integrated approach. A consequence of this approach is that engineers and technicians need skills and knowledge that are not confined to a single subject area. They need to be capable of operating and communicating across a range of engineering disciplines and linking with those having more specialised skills, This book is an attempt to provide a basic background 10 mechatronics and provide links through to more specialised skills. The first edition was designed to cover the Business and ‘Technology Education Council (BTEC) Mechatronics A and B Units (1413G and 1414G) for higher technicians, these units being the core units of their Higher National Certificate/Diploma courses and designed to fit alongside more specialist units such as those for design, manufacture and maintenance determined by the application area of the course. The book was widely used for such ‘courses and has also found use in undergraduate courses in both Britain and in the United States. Following feedback from lecturers in both Britain and the United States, the second edition was considerably extended and with its extra depth it was not only still relevant for its original readership but also suitable for undergraduate courses. The third edition involves refinements of some explanations, more discussion of microcontrollers and programming, increased use of models for mechatronics systems, and the grouping together of key facts in the Appendices.