Professional Documents
Culture Documents
Prepared by:
Mohammed S. (Measurement & Instrumentation)
Tsegaye G. (Mechatronics)
Edited by:
Mechatronics, & Measurement & Instrumentation-Aregahegn A.
Contents
1 Competencies and Objectives of the Course 1
1.1 Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Competences (Learning Outcomes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Mechatronics, Introduction 1
2.1 Definition and Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.2 Measurement control Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Performance of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 The Wheatstone Bridge Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Review Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
List of Figures
1 (a) Concept of mechatronics: an interconnected energy and information flow (b) Definition: synergetic
integration of knowledge from main disciplines in mechatronics . . . . . . . . . . . . . . . . . . . . . . 2
2 (a) Wheatstone Bridge Circuit (b) Realtime step vs frequency Response . . . . . . . . . . . . . . . . . 4
3 (a) Comparison of Open and Closed Loop Controller (b) components of closed loop controller . . . . . 7
4 Schematic of Synergistic Mathematical Model of Actuation Control Systems (a)Mechanical (b) Hy-
draulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 (a) Types of Motor Actuators (b) Types of Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 (a) Watt-Governor (b) Electronic Furnace Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 (a) an 8051 µP Architecture & Components (b) bus (c)µcontrollers vs µprocessors . . . . . . . . . . . 12
8 Bivalent logic gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
I
9 Ladder Logic Program/Diagram of Pump Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . 20
10 (a) Sequential Function Chart (SFC) of the pump (b)Function Block Diagram (FBD) . . . . . . . . . 20
List of Tables
1 Measurement instruments construction A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Measurement instruments construction B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Differential Modelling of Physical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Comparison mathematical model of simple translational mechanical vs PID control systems . . . . . . 7
5 Basic Analogy of Computer Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6 8051 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7 Simple Programs in 8051 Assembly Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
I
1 Competencies and Objectives of the Course
1.1 Objectives
Mechatronics, as an engineering discipline, is the synergistic combination of mechanical engineering, electronics, control
engineering, and computers, all integrated through the design process. It involves the application of complex decision
making to the operation of physical systems. Mechatronic systems depend for their unique functionality on computer
software. This course studies mechatronics at a theoretical and practical level; balance between theory/analysis and
hardware implementation is emphasized; emphasis is placed on physical understanding rather than on mathematical
formalities.
A case-study, problem-solving approach, with video hardware demonstrations, is used throughout the course. The
course of studies should enable students to analyze complex physical-technical combinations and to describe, to
model, to simulate and to develop Mechatronics systems using the methods of mechanical engineering, electrical
engineering and computer science. Students’ central task is A case-study, problem-solving approach, with video
hardware demonstrations, is used throughout the course. The course of studies should enable students to analyze
complex physical-technical combinations and to describe, to model, to simulate and to develop Mechatronics systems
using the methods of mechanical engineering, electrical engineering and computer science. Students’ central task is
the optimal configuration of the complete system.
Understand the dynamic system investigation process and be able to apply it to a variety of dynamic physical
systems.
Understand the importance of physical and mathematical modeling (both from first principles and using system
identification experimental techniques) in mechatronic system design and be able to model and analyze mechan-
ical, electrical, electromechanical, fluid, thermal, chemical, and multidisciplinary systems.
Be able to develop a hierarchy of physical models for a dynamic system, from a truth model to a design model,
and understand the appropriate use of this hierarchy of models.
Become proficient in the use of MatLab/Simulink to model and analyze nonlinear and linear mechatronic systems.
Understand the key elements of a measurement system and the basic performance specifications and physi-
cal/mathematical models of a variety of analog and digital motion sensors.
Understand the characteristics and models of various electromechanical actuators (brushed dc motor, brushless
dc motor, and stepper motor) and hydraulic and pneumatic actuators.
Understand analog and digital circuits and components and semiconductor electronics as they apply to mecha-
tronic systems.
Understand and be able to apply various control system design techniques: open-loop feedforward control,
classical feedback control (root-locus and frequency response), and statespace control.
Have a general understanding of more advanced control design techniques: cascade control, inferential control,
model predictive control, adaptive control, fuzzy logic control, and multivariable control.
Understand the digital implementation of control and basic digital control design techniques.
Be able to use a microcontroller as a mechatronic system component, i.e., understand programming and inter-
facing issues. Be able to apply all these skills to the design of a mechatronic system
2 Mechatronics, Introduction
2.1 Definition and Concept
Mechatronics is a concept of Japanese origin (1980’s) and can be defined as the application of electronics and com-
puter technology to control the motions of mechanical systems. The word, mechatronics, is composed of “mecha”
from mechanism and the “tronics” from electronics. In other words, technologies and developed products will be
incorporating electronics more and more into mechanisms. [1] Mechanical systems are increasingly integrated with
actuators, sensors and digital electronics as in the figure 1 (a).[1]
1
(a) (b)
Figure 1: (a) Concept of mechatronics: an interconnected energy and information flow (b) Definition: synergetic integration of knowledge
from main disciplines in mechatronics
The design of mechatronic system involve interrelations during mechanical and electronic systems, the simultaneous
engineering with the goal of also creating synergetic effects as presented in the figure 1 (b).[2]. Mechatronics, therefore,
is the synergistic integration of mechanical engineering, with electronics and intelligent computer control in the design
and manufacturing of industrial products and processes.
An LVT consists of doppler works by A double-pulse laser An optical technique works in Bernoulli’s
a rod called the core the same principle illuminates a region involving a laser is laser principle where
(a permanent mag- as a car horn where of flow under study, Doppler velocimetry Pitot-static probe
net), and two elec- moving towards and a digital camera (LDV), also called laser either both pres-
trical coils around you (or away from (sometimes two sepa- velocimetry (LV) or laser sures are measured
the core slides in- you) has an ap- rate cameras) records Doppler anemometry (pierced two holes
side a hollow cylin- parently higher (or two images – timed (LDA). whereas PIV is from side), or the
drical tube called lower) pitch, only with the two flashes a Lagrangian technique, pressure difference
a bobbin and DC that doppler works (pulses) of laser light. following the motion of is measured (with
vltage generated in with radio wave The displacement of individual particles, LDV only one hole at
the coils. instead of sound illuminated particles is an Eulerian technique, the front edge).We
wave, or frequency, is then determined since the velocity is mea- consider here in-
by analyzing (interro- sured at a fixed point in compressible flow,
gating) the two im- the flow. and assume that
ages with image pro- the probe is aligned
cessing software into the flow,
in the physical phenomenon. Transducer is a device that converts one form of energy into another form of energy
2
Sensors are transducers when they sense one form of energy input and output in a different form of energy. For
example, a thermocouple responds to a temperature change (thermal energy) and outputs a proportional change in
electromotive force (electrical energy). Therefore, a thermocouple can be called a sensor and or transducer. The study
of mechatronic systems can be divided into the following areas of speciality:
1. physical system modelling: mechanical systems (mechanical elements, machines, precision mechanics); and elec-
tronic systems (microelectronics, power electronics, sensor and actuator technology);
2. information technology (systems theory: Signals and Systems,and Data Acquisition), and Logic Systems,
Software, Computers, artefacts and Intelligence: automation, software engineering, artificial intelligence).
In piezoelectric (acceler- C = ε0 εr A
d Bimetalic strip thermo- Gyroscopes in- The photoelectric
ation, strainguage, etc) couples: two dissimilar ertia navigation effect is a phe-
instruments, A seismic metals, joined together can be used to nomenon in which
mass is placed on an at one end, that produce construct gyro- photon energy (i.e.
elastic return blade a voltage (expressed in compasses, which from light) releases
equipped with two millivolts) with a change complement or electrons from their
or four piezoresistive in temperature. replace magnetic otherwise more
gauges in a Wheatstone compasses vehi- stable state on a
Bridge where the unit cles, to assist in surface where the
vibration of a mass stability disruption mea-
applied by a force sured called hall
proportional to acceler- effect with Loretz
ation & the piezoelectric force
element
Due to the fact that the controller is a digital computer, the following problems are introduced in a closed loop
control system: time delay associated with signal conversion and processing, sampling, quantization error due to finite
precision, and reconstruction of signals. While the switch is ON, the output voltage is
1 t
Z ¯
y(t) − y(t)
y(t) = i(τ )dτ where i(τ ) = (1)
C 1 R
3
Saturation: All real actuators/instruments have some maximum output capability, regardless of the input. Deadband:
The dead band is typically a region of input close to zero at which the output remains zero. Once the input travels
outside the dead band, then the output varies with input. Engineering measurement signals are continuous: voltage
that varies over time; a chemical reaction rate that depends on temperature, etc. Analog-to-Digital Conversion (ADC)
and Digital-to-Analog Conversion (DAC) allow digital computers to interact with these signals. The output from the
sensor is conditioned (amplified, filtered, etc.). The conditioned analog signal is digitized using an analog-to-digital
converter (ADC). The digital information is acquired, processed and recorded by the computer. The computer may
then modify the system by outputting control signals. The digital control signals are converted to analog signals using
a digital-to-analog converter (DAC). The analog signals are conditioned (e.g. amplified and filtered) appropriately for
an actuator The actuator interacts with the system to give desired response
(a) (b)
Figure 2: (a) Wheatstone Bridge Circuit (b) Realtime step vs frequency Response
The Wheatstone bridge can be used in various ways to measure electrical resistance in all measurement system
circuit/sensor/transducer design construction:
For the determination of the absolute value of a resistance by comparison with a known resistance
For the determination of relative changes in resistance
The latter method is used with regard to strain gauge techniques. The four arms or branches of the bridge circuit are
formed by the resistances R1 to R4. The corner points 2 and 3 of the bridge designate the connections for the bridge
excitation voltage Vs. The bridge output voltage V0 , that is the measurement signal, is available on the corner points
1 and 4. as shown in Fig 2
Note: There is no generally accepted rule for the designation of the bridge components and connections. In existing
literature, there are all kinds of designations and this is reflected in the bridge equations. Therefore, it is essential that
the designations and indices used in the equations are considered along with their positions in the bridge networks in
order to avoid misinterpretation.
R1 R4
= (2)
R2 R3
where the bridge output voltage V0 is zero. With a preset strain, the resistance of the strain gauge changes by the
amount ∆R. This gives us the following equation:
R1 + ∆R1 R4 + ∆R4
VO = Vs −
R1 + ∆R1 + R2 + ∆R2 R3 + ∆R3 + R4 + ∆R4
For strain measurements, the resistances R1 and R2 must be equal in the Wheatstone bridge. The same applies
to R3 and R4 . With a few assumptions and simplifications, the following equation can be determined. the H to
Measurements using Strain Gauges;
Vo 1 ∆R1 ∆R2 ∆R3 ∆R4
= − + − (3)
Vs 4 R1 R2 R3 R4
In the last step of calculation, the term ∆R/R must be replaced by the following:
∆R
=k·ε
R
Here k is the k-factor of the strain gauge, ε is the strain. This gives us the following:
Vo k
= (ε1 − ε2 + ε3 − ε4 ) (4)
Vs 4
4
The next section discuss about mathematical modelling, that involves Laplace and Fourier transformation of real-time
sampling to space variable and signal manipulation. It should be accompanied by physical device circuit design along
with implication design. A dedicated standard device setup or unit responsible for sampling and measurement manip-
ulation is called Data Acquisition System or in short DAQ. The modernized version of DAQ is Supervisory
Control and Aata Acquisition or in short SCADA is a control system architecture comprising computers,
networked data communications and graphical user interfaces for high-level supervision of machines and processes
5
Table 3: Differential Modelling of Physical Systems
Electrical System
d 1
Elec.Inductuctance v21 = L i Elec. power/Energy E = · L21
dt 2
1 1 2
Electrical Resistance i = · v21 power P = ·v
R R 21
Mechanical System
1 d 1 T2
Rotational Spring · T Energy E = ·
ω21 =
k dt 2 k
d 1
Rotational mass T = J · ω2 Energy E = · J · ω2 2
dt 2
2
rotational damper T = b · ω21 power P = b · ω21
1 d 1 F2
Translation Spring v21 = · F Energy E = ·
k dt 2 k
d 1
Translational Mass F = M · v2 E = · M · v22
dt 2
2
translational damper F = b · v21 power P = b · v21
Hydraulic Systems
d 1
fluid inertia P21 = I · QEnergy E = · I · Q2
dt 2
d 1 2
fluid capacitance Q = Cf P21 Energy E = · Cf P21
dt 2
1 1 2
fluid resistance Q = · P21 power P = · P21
Rf Rf
d 1
thermal capacitanceq = Ct T2 Energy E = · Ct T2
dt 2
1 1
thermal resistance q = · T21 power P = · T21
Rt Rt
the output of the controller u(t) and the actuating error signal e(t) is linear. In a controller with integral control
action,PI, the value of the controller output u(t) is integrated/summed-up and changed at a rate proportional to
the actuating error signal e(t). Proportional-Plus-Derivative Control Action,, PD, the control action of a
proportional, and derivative controller. Lastly, Proportional-Plus-Integral-Plus-Derivative Control Action,
PID, the combination of proportional control action, integral control action, and derivative control action is termed
proportional-plus-integral-plus-derivative control action. It has the advantages of each of the three individual control
actions. The typical model equation for general control system follows, emphtransfer function, formulation of a linear,
time-invariant, differential equation system is defined as the ratio of the Laplace transform of the output (response
function) to the Laplace transform of the input (driving function) under the assumption that all initial conditions are
zero.
Consider the linear time-invariant system defined by the following differential equation 5
(n−1)
a0 (n) y + a1 y + · · · + an−1 ẏ + an y
(5)
= b0 (m) x + b1 x + · · · + bm−1 ẋ + bm x (n ≥ m)
Where y is the output of the system and x is the input. The transfer function of this system is the ratio of the Laplace
transformed output to the Laplace transformed input when all initial conditions are zero, or with with common s
space domain that enables correlation as shown in eq. 6.
L[ output ]
Transfer function = G(s) =
L[ input ] zero initial conditions
(6)
Y (s) b0 sm + b1 sm−1 + · · · + bm−1 s + bm
= =
X(s) a0 sn + a1 sn−1 + · · · + an−1 s + an
6
Practical mechatronic/control systems are an integration of all system components. See Fig 6, 4 1. [4], [1], [5], [6],
[7]. There is no isolated electrical, mechanical or hydraulic actuating system model but the practical relevance of
synergistic or an integrated system demands individual and integrated system model of either open loop (system
response without feedback) or closed loop control systems (system response with feedback).
(a)
(b)
Figure 3: (a) Comparison of Open and Closed Loop Controller (b) components of closed loop controller
Table 4: Comparison mathematical model of simple translational mechanical vs PID control systems
ẋ1 0 1 x1 0 Kp Rt
= k b + 1 u u(t) = Kp e(t) + e(t)dt + Kp Td de(t)
ẋ2 −m −m x2 m
Ti 0 dt
↑→ Transfer Function
Individual components and physical phenomena inside them needs to be modelled following their corresponding
governing principles (governing mathematical laws) and integrated in space domain via transfer function in common
time invariant space s variable. kircholf’s law for exaple governs electrical circuit while newton’s second law governs
solid motion along with newton’s modified or navier-stokes equations or bernoulli governs fluid depending on param-
eter under consideration. It should be noted that as you can see in the figure 4, mechanical system can also have
varieties of components for which table 3
7
(a)
(b)
Figure 4: Schematic of Synergistic Mathematical Model of Actuation Control Systems (a)Mechanical (b) Hydraulic
8
(a)
(b)
torque-to-weight ratio than brushed motors. Apart from these general common construction, there are many other
types of motor precise electronic constructions such as: stepper motor a brushless DC servo motor that divides a
full rotation into a number of equal discrete steps, linear motor: servo type with its stator and rotor ”unrolled”
producing linear force, etc.
An electronic circuit is composed of various types of components. Some of these components are termed as active
components because they take part in the transformation of the energy while other components, which only dissipate
or store energy, are called as passive elements. The vacuum tubes, rectifier, transistors are some of-the common ac-
tive while the resistances, which dissipate the power and energy storing elements such as capacitances and inductances
are known as passive elements. The transformers may be regarded as a matching device. The success of any electronic
circuit depends not only on proper selection of the active elements but on the passive and matching elements too. The
proper function, of an active device is decided by the proper values of these passive elements. Hence the selection of
these elements such as resistances, inductances, capacitance, and transformers not only require the proper attention,
but also decide the proper function of the active devices as well as the circuit as a whole.
9
to estimate the underlying state. In industry there is much more emphasis on measurement technology, for without
good sensing, good control is impossible. For process applications, analogue 4/20 mA transmitters were developed for
communicating measurements to a remote direct digital control (DDC) computer (see Figure 1b). Such a transmitter
has several advantages: the use of current loops allows for long cable runs without significant interference,transmitters
can be powered down the wires from the control room, and the standard enables the interworking of transmitters from
different vendors.
Classic example of automation is the watt governor where a closed loop cylinder position control system with mechan-
ical feedback used in the actuation of the main valve to widen or lessen the injection opening in accordance with the
requirements of driving conditions based on speed/centrifugal force measurements feedbacks of the flyballs: Flyballs
move outer with higher centrifugal force/speed demand rising lever by the push of lever arms increases fuel injection
and vice-versa Typical example is shown in the Figure a temperature control system that can be used to heat a room
(a) (b)
or oven. The heat is generated by the electric heater. Heat is lost to the outside through the walls. A thermometer is
used to measure the temperature. An analog controller has the desired temperature setting. Based on the difference
between the set and measured temperature, the op-amp turns ON or OFF the relay which turns the heater ON/OFF.
In order to make sure the relay does not turn ON and OFF due to small variations around the set temperature, the
op-amp would normally have a hysteresis functionality implemented on its circuit.
The question of actuator sizing is a question of determining the following requirements for an axis underworst operat-
ing conditions (i.e., largest expected inertia and resistive load), For example, for the mechanical system, the following
considerations taken:
1. maximum torque (also called peak torque) required, Tmax ,
5. gear mechanism parameters: gear ratio, its inertial and resistive load (force/torque), stiffness, backlash charac-
teristics.
Once the torque requirements are determined, then the amplifier current and power supply requirements are directly
determined from them.
10
In phase 1, the control software is developed by using graphical software tools, such as Simulink® and Stateflow,
simulated and analyzed on a non-real-time computer environment (Figure 1.29). The “plant model,” which is the
computer model of the machine to be controlled, is a non-real-time detailed dynamic model. Simulations and analysis
are done in this non-real-time environment. In phase 2, the “same control software” is tested on a target embedded
control module (ECM). That “same control software” is a C-code which is auto-generated from the graphical diagrams
of Simulink® and Stateflow using auto-code generation tools such as Simulink® Coder, Embedded Coder, and
MATLAB® Coder. The last phase involve physical experiment.
4. Write characteristics and importance of passive electronic components and compare them with an active electi-
cal/electronic components.
5. Define Servo Motors, synchronous motors and brushless motors.
6. What is the function of a microprocessor in a system?
11
(a)
(b) (c)
Figure 7: (a) an 8051 µP Architecture & Components (b) bus (c)µcontrollers vs µprocessors
Brain CPU
wall clock clock
deck of instruction cards read only memory (ROM)
chalk-eraser-black-board random access memory (RAM)
pocket cards accumulators (also called registers)
input-output tray I/O devices
eyes, hands and arms bus to access resources (read/write)
operates in binary numbers 0 and 1. A typical microprocessor consists of arithmetic and logic unit (ALU) in associa-
tion with control unit to process the instruction execution. Almost all the microprocessors are based on the principle
of store-program concept. In store-program concept, programs or instructions are sequentially stored in the memory
locations that are to be executed. To do any task using a microprocessor, it is to be programmed by the user. The
semiconductor manufacturing technologies used for chips are:
1. Transistor-Transistor Logic (TTL)
2. Emitter Coupled Logic (ECL)
3. Complementary Metal-Oxide Semiconductor (CMOS)
Microprocessors: classified based on their specification, application and architecture microprocessors are classified.
Based on size of data bus:
1. 4-bit microprocessor
2. 8-bit microprocessor
3. 16-bit microprocessor
4. 32-bit microprocessor
Based on application:
1. General-purpose microprocessor- used in general computer system and can be used by programmer for any
application. Examples, 8085 to Intel Pentium.
12
2. Microcontroller- microprocessor with built-in memory and ports and can be programmed for any generic control
application. Example, 8051.
3. Special-purpose processors- designed to handle special functions required for an application. Examples, digital
signal processors and application-specific integrated circuit (ASIC) chips.
3. Register (00h to 1Fh ASCII symbols/ R0 through R7 pins): Typical 8085 microprocessor includes six general
purpose registers to store an 8-bit data, one accumulator and one flag register. In addition, it has two 16-bit
registers: stack pointer and program counter. The programmer can use these registers to store or copy data into
the register by using data copy instructions.
4. Accumulator: Slower & cheaper version of RAM: The accumulator is an 8-bit register that is a part of ALU. This
register is used to store 8-bit data and to perform arithmetic and logical operations. The result of an operation
is stored in the accumulator.
5. Flag Register: The ALU includes five flip-flops, which are set or reset after an operation according to data
condition of the result in the accumulator and other registers. They are called Zero (Z), Carry (CY), Sign (S),
Parity (P) and Auxiliary Carry (AC) flags. The microprocessor uses these flags to test data conditions.
6. Counter: This 16-bit register deals with sequencing the execution of instructions. This register is a memory
pointer. The microprocessor uses this register to sequence the execution of the instructions. The function of the
program counter is to point to the memory address from which the next byte is to be fetched. When a byte is
being fetched, the program counter is automatically incremented by one to point to the next memory location
7. The stack pointer: is also a 16-bit register, used as a memory pointer. It points to a memory location in R/W
memory, called stack. The beginning of the stack is defined by loading 16- bit address in the stack pointer
8. Instruction Register/Decoder: It is an 8-bit register that temporarily stores the current instruction of a program.
Latest instruction sent here from memory prior to execution. Decoder then takes instruction and decodes or
interprets the instruction. Decoded instruction then passed to next stage.
9. Control Unit: Generates signals on data bus, address bus and control bus within microprocessor to carry out
the instruction, which has been decoded.
4. Write classifications of microprocessors based on their specifications and raw materials they are made from.
13
Bus (GPIB)
For the parallel interface to a printer the Centronics parallel interface is commonly used. However, with instrumen-
tation the most commonly used parallel interface in communications is the General Purpose Instrument Bus (GPIB),
the IEEE 488 standard, [8] originally developed by Hewlett Packard to link its computers and instruments and thus
often referred to as the Hewlett Packard Instrumentation Bus. Each of the devices connected to the bus is termed a
listener, talker or controller. Listeners are devices that accept data from the bus, talkers place data, on request, on
the bus and controllers manage the flow of data on the bus by sending commands to talkers and listeners and carry
out polls to see which devices are active..
An external bus is a set of signal lines that interconnects microprocessors, microcontrollers, computers and pro-
grammable logic controllers (PLCs) and also connects them with peripheral equipment (i.e. Sensors & Actuators).
Thus a computer needs to have a bus connecting it with a printer if its output is to be directed to the printer and
printed. Multiprocessor systems are quite common. For example, in a car there are likely to be several microcon-
trollers with each controlling a different part of the system, e.g. engine management, braking and instrument panel,
and communication between them is necessary
Centralized computer control involves the use of one central computer to control an entire plant. This has the
problem that failure of the computer results in the loss of control of the entire plant. This can be avoided by the use
of dual computer systems. If one computer fails, the other one takes over. Such centralized systems were common in
the 1960s and 1970s. The development of the microprocessor and the ever reducing costs of computers have led to
multi-computer systems becoming more common and the development of hierarchical and distributed systems. [1].
With the hierarchical system, there is a hierarchy of computers according to the tasks they carry out. The comput-
ers handling the more routine tasks are supervised by computers which have a greater decision-making role. With the
distributed system, each computer system carries out essentially similar tasks to all the other computer systems.
In the event of a failure of one, or overloading of a particular computer, work can be transferred to other computers.
Serial data transmission occurs in one of three modes.
Simplex mode: Transmission is only possible in one direction, from device A to device B, where device B is not
capable of transmitting back to device A. This method is usually only used for transmission to devices such as printers
which never transmit information.
Half-duplex mode:Data is transmitted in one direction at a time but the direction can be changed. Terminals at each
end of the link can be switched from transmit to receive. Citizens Band (CB) radio is an example of half-duplex
mode; a person can receive or talk but not do both simultaneously.
Full-duplex mode: Data may be transmitted simultaneously in both directions between devices A and B. This is
like a two-lane highway in which traffic can occur in both directions simultaneously. The telephone system is an
example of full-duplex mode in that a person can talk and receive at the same time.
5.1 Networks
The term network is used for a system which allows two or more computers/ microprocessors to be linked for the
interchange of data. The logical form of the links is known as the network topology. The term node is used for a point
in a network where one or more communication lines terminate or a unit is connected to the communication lines.
The following are commonly used forms. Data Bus : This has a linear bus into which all the stations are plugged.
This system is often used for multipoint terminal clusters. It is generally the preferred method for distances between
nodes of more than 100m.
Star : This has dedicated channels between each station and a central switching hub through which all communications
must pass. This is the type of network used in the telephone systems (private branch exchanges (PBXs)) in
many companies, all the lines passing through a central exchange. This system is also often used to connect remote
and local terminals to a central mainframe computer. There is a major problem with this system in that if the central
hub fails then the entire system fails.
Hierarchy or tree : This consists of a series of branches converging indirectly to a point at the head of the tree.
With this system there is only one transmission path between any two stations. This arrangement may be formed from
a number of linked data bus systems. Like the bus method, it is often used for distances between nodes of more than
100m.
Ring: This is a very popular method for local area networks, involving each station being connected to a ring. The
distances between nodes are generally less than 100 m. Data put into the ring system continues to circulate round the
ring until some system removes it. The data is available to all the stations.
Mesh : This method has no formal pattern to the connections between stations and there will be multiple data
paths between them.
Local area network (LAN): used for a network over a local geographic area such as a building or a group of
buildings on one site. The topology is commonly bus, star or ring.
A wide area network (WAN): one that interconnects computers, terminals and local area networks over a
national or international level.
14
5.2 Sensor Communication
Sensor communication primarily concerned with local area networks. Network access control:Access control meth-
ods are necessary with a network to ensure that only one user of the network is able to transmit at any one time. The
following are methods used. With ring-based local area networks, two commonly used methods are:
Token passing : With this method a token, a special bit pattern, is circulated. When a station wishes to
transmit it waits until it receives the token, then transmits the data with the token attached to its end. Another
station wishing to transmit removes the token from the package of data and transmits its own data with the
token attached to its end.
Slot passing : This method involves empty slots being circulated. When a station wishes to transmit data it
deposits it in the first empty slot that comes along.
With bus or tree networks a method that is often used is:
Carrier sense multiple access with collision detection (CSMA/CD) : This method is generally identified
with the Ethernet LAN bus. With the CSMA/CD method, stations have to listen for other transmissions before
transmitting, with any station being able to gain control of the network and transmit, hence the term multiple
access. If no activity is detected then transmission can occur. If there is activity then the system has to wait
until it can detect no further activity.
Broadband and baseband: used for a network in which information is modulated onto a radio frequency carrier
which passes through the transmission medium such as a coaxial cable. Typically the topology of broadband local
area networks is a bus with branches. Broadband transmission allows a number of modulated radio frequency
carriers to be simultaneously transmitted and so offers a multichannel capability.
baseband transmission is used when digital information is passed directly through the transmission medium.
Baseband transmission networks can only support one information signal at a time.
5.2.1 Protocol
Protocol used by the interface/component between a computer and the network to control the transfer of the data
into the network or from the network into the computer. A protocol is a formal set of rules governing data format,
timing, sequencing, access control and error control. The three elements of a protocol are:
1. Syntax, which defines data format, coding and signal levels;
1. Physical layer : This layer describes the means for bit transmission to and from physical components of the
network. It deals with hardware issues, e.g. the types of cable and connectors to be used, synchronizing data
transfer and signal levels. Commonly used LAN systems defined at the physical layer are Ethernet and token
ring.
2. Data link layer : This layer defines the protocols for sending and receiving messages, error detection and correction
and the proper sequencing of transmitted data. It is concerned with packaging data into packets and placing
them on the cable and then taking them off the cable at the receiving end. Ethernet and token ring are also
defined at this level.
15
3. Network layer : This deals with communication paths and the addressing, routing and control of messages on
the network and thus making certain that the messages get to the right destinations. Commonly used network
layer protocols are Internet Protocol (IP) and Novell’s Internetwork Packet Exchange (IPX).
4. Transport layer : This provides for reliable end-to-end message transport. It is concerned with establishing and
maintaining the connection between transmitter and receiver. Commonly used transport layer protocols are
Internet Transmission Control Protocol (TCP) and Novell’s Sequenced Packet Exchange (SPX).
5. Session layer : This layer is concerned with the establishment of dialogues between application processes which
are connected together by the network. It is responsible for determining when to turn a communication between
two stations on or off.
6. Presentation layer : This layer is concerned with allowing the encoded data transmitted to be presented in a
suitable form for user manipulation.
7. Application layer : This layer provides the actual user information processing function and application-specific
services. It provides such functions as file transfer or electronic mail which a station can use to communicate
with other systems on the network.
10011011
= 1 × 27 + 0 × 26 + 0 × 25 + 1 × 24 + 1 × 23
+ 0 × 22 + 1 × 21 + 1 × 20
= 128 + 0 + 0 + 16 + 8 + 0 + 2 + 1
= 155
we can calculate the analog output voltage:
input × Vref 155 × 10 V
Vout = = = 6.05 V
256 256
6.05 V is the voltage we would expect on the analog output pin.
Similarly Binary number system has two symbols: 0 and 1, called bits. It is also a positional notation, for example,
10110B = 10000B + 0000B + 100B + 10B + 0B = 124 + 023 + 122 + 121 + 020
16
Hexadecimal number system uses 16 symbols: 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, A, B, C, D, E, and F, called hex digits. It is
a positional notation, for example,
Starting from the right-most bit (least-significant bit), replace each group of 4 bits by the equivalent hex digit (pad
the left-most bits with zero if necessary), for examples,
For examples,
A1C2H = 10163 + 1162 + 12161 + 2 = 41410 (base 10)
10110B = 124 + 122 + 121 = 22 (base 10)
Conversion from Decimal (Base 10) to Base r: Use repeated division/remainder. For example, To convert 261(base
10) to hexadecimal:
261/16 => quotient = 16 remainder = 5
16/16 => quotient = 1 remainder = 0
1/16 => quotient = 0 remainder = 1 (quotient = 0 stop)
Hence, 261D = 105H (Collect the hex digits from the remainder in reverse order) The above procedure is actually
applicable to conversion between any 2 base systems. For example, To convert 1023(base 4) to base 3:
17
Figure 8: Bivalent logic gates
18
column headers are tasks to be accomplished and the subsequent codes in each column are step by stem instructions
for an 8081 microcontroller. Higher level computer languages/instruction syntaxes/you name it with much enhanced
Address: exchange the Arithmetic: exchange the treat r6−r7 and r4−r5 as divide the content of r0
content of FFh and FF00h content of FFh and FF00h two 16 bit registers. Per- by r1. Store the result
form subtraction between in r2 (answer) and r3 (re-
them. Store the result in minder). Then restore the
20h (lower byte) and 21h original content of r0
(higher byte).
Mov dptr,# 0FF00h Mov a, r7→ get the con- Clr c →clear carry Mov a, r0 →get the con-
→take the address in tent in acc, tent of r0 and r1
dptr,
Movx a, dptr→get the Anl a, # 0F0h→mask Mov a, r4→ get first lower Mov b, r1→ in register A
content of 0050h in a lower bit byte and B
Mov r0, 0FFh → save the Mov r6, a→send it to r6 Subb a, r6 ; subtract it Div ab→ divide A by B
content of 50h in r0, with other
Mov 0FFh, a → move a to Swap a → xchange upper Mov 20h, a ; store the re- Mov r2, a → store result
50h and lower nibbles of acc sult in r2
Mov a, r0→ get content of Orl a, r6→ OR operation Mov a, r5→ get the first Mov r3, b→ and reminder
50h in a higher byte in r3
Movx @dptr, a ; move it Mov r6, a→finally load Subb a, r7→subtract from Mov b, r1→again get con-
to 0050h content in r6 other tent of r1 in B
Mov 21h, a→ store the Mul ab→ multiply it by
higher byte answer
Add a, r3→ add reminder
in new answer
Mov r0, a→ finally restore
the content of r0
performance such as PLC, simulink should be learnt along with these sets at this level so that those instructions can
easily be understood and designed.
Various comercial microcontroller board designs printings in recent mechatronic developments such as internet of
things include Aurduino Uno, Red Board, Arduino mini etc working under standard 5v input except pro with 3.3v,
16 MHz clock speed, 6 analogue inputs, 14 digital i/o, 6 pulse pulse width modulation, and 1 universal asynchronous
receiver/transmitter either Universal Serial Bus/USB or future technology device international/FTDI standard port
configurations or Programming Interface.
Arduino is an open-source hardware and software company, project, and user community that designs and manufactures
single-board microcontrollers and microcontroller kits. An IoT platform is a multi-layer technology that enables
straightforward provisioning, management, and automation of connected devices within the Internet of Things universe.
It basically connects your hardware, however diverse, to the cloud by using flexible connectivity options, enterprise-
grade security mechanisms, and broad data processing powers. For developers, an IoT platform provides a set of
ready-to-use features that greatly speed up development of applications for connected devices as well as take care of
scalability and cross-device compatibility.
6.1 Ladder Logic, Functional Block Diagram, Structured Text, Instruction List and
Sequential Functional Chart
There are four basic steps in the operation of all PLCs; Input Scan, Program Scan, Output Scan, and Housekeeping.
These steps continually take place in a repeating loop. Four Steps In The PLC Operations
1. Input Scan: Detects the state of all input devices that are connected to the PLC
2. Program Scan:Executes the user created program logic
3. Output Scan: Energizes or de-energize all output devices that are connected to the PLC.
4. Housekeeping: This step includes communications with programming terminals, internal diagnostics, etc...
Ladder Diagram (LD) Traditional ladder logic shown in the Figure 9 is graphical programming language. Initially
programmed with simple contacts that simulated the opening and closing of relays, Ladder Logic programming has
been expanded to include such functions as counters, timers, shift registers, and math operations. Structured Text
(ST) – A high level text language that encourages structured programming. It has a language structure (syntax)
that strongly resembles PASCAL and supports a wide range of standard functions and operators. For example; the
19
Figure 9: Ladder Logic Program/Diagram of Pump Motor Control
(a) (b)
Figure 10: (a) Sequential Function Chart (SFC) of the pump (b)Function Block Diagram (FBD)
structured level. A SFC program is an overview of the control system, in which the basic building blocks are entire
program files. Each program file is created using one of the other types of programming languages. The SFC approach
coordinates large, complicated programming tasks into smaller, more manageable tasks. The equivalent SFC for Figure
9 is shown in FIGURE 10 (a)
Function Block Diagram (FBD) - A graphical language for depicting signal and data flows through re-usable function
blocks. FBD is very useful for expressing the interconnection of control system algorithms and logic. The equivalent
FBD for Figure 9 is shown in FIGURE 10(b)
20
7. Determine truth table for S-R flip-flop based on NOR gate shown in the figure below
8. determine 32 bit single precision floating point signature number representation of 1.735.
9. Write an assembly language programming for the crystal frequency is given as 12 MHz. Make a subroutine that
will generate delay of exact 1 ms. Use this delay to generate square wave of 50 Hz on pin P2.0
3. For a 10 bit Data Acquisition System (Analogue to Digital Converter for this case) with a reference voltage
Vref = 1 volts, find the digital equivalent on the display that correspond to Vin = 0.6 volts.
Part II: Choose the best answer
1. In which of the following principle is the synergetic integration characterized by detects metal object, uses an
electro-magnetic field to detect a conductive target, sensing coil in the end of the sensor probe, when excited
creates an alternating magnetic field which induces small amounts of eddy current in the target object, eddy
currents create an opposing magnetic field which resists the field, being generated by the sensor probe coil, the
interaction of the magnetic fields is dependent on the distance, between the sensor probe and the target, and com-
paratively inexpensive but conducting targets sensing. a) Capacitive measurements b) Inductive Measurements
c) Optical Measurement d) all
2. Which of the following synergetic system employs stephan bolts man law by foccussing ray/radiation between
emissivity a) piezoelectric crystals b) Microphones condenser/ c) Camera temperature detector (Temperature
camera d) all
Part III: Say True or False
Part IV: Match by placing the letter correspond to the best explanation from column B to space
preceding associated numbers of mechatronic sensor elements under column A.
21
Column A Column B
1 Linear/Rotational variable differen- A Robust noncontact switching action, The digital
tial transducer (LVDT/RVDT) outputs are often directly fed to the digital controller
2 Photoresistors, photodiodes, photo B Alternate to strain gages with very high accuracy
transistors, photo conductors, etc. and bandwidth
3 Fiberscope C Good for measuring frequencies up to 40% of its
natural frequency
4 Inductance, eddy current, hall effect, D Good for small force measurements
photoelectric, capacitance, etc
5 Infrared thermography E Good for very high flow rates Can be used for both
upstream and downstream flow measurements
6 Interferometer F High resolution with wide range capability, Very
stable in static and quasi-static applications
7 Optical fiber As strain sensor G Laser systems provide extremely high resolution
in large ranges Very reliable and expensive
8 Seismic accelerometer H Measure light intensity with high sensitivity Inex-
pensive, reliable, and noncontact sensor
9 Strain gauge elements I Noncontact point sensor with resolution limited by
wavelength Measures whole-field temperature distri-
bution
10 Ultrasonic stress sensor J Small (0.2 mm diameter) field vision scope using
SMA coil actuators
K Very high accuracy in small ranges Provides high
resolution at low noise levels
References
[1] A. K. K.K., Introduction to MECHATRONICS, Oxford University Press, 2007.
[2] Institute of Mechatronic Systems: Research Focused on Mechatronics, https://www.zhaw.ch/en/engineering/
institutes-centres/ims/, Accessed: Feb 20, 2023.
[3] R. Isermann, Institut fu¨ r Automatisierungstechnik Technische Universita¨t Darmstadt Darmstadt Germany
2000, 22, 29–55.
[4] W. Bolton, MECHATRONICS: ELECTRONIC CONTROL SYSTEMS IN MECHANICAL AND ELECTRI-
CAL ENGINEERING Seventh Edition, Pearson Education Limited, 2019.
[5] A. DP., Relay autotuning: a use of old ideas in a new setting. Transactions of the Institute of Measurement and
Control. 2000;22(1):103-122. doi:10.1177/014233120002200105, https://journals.sagepub.com/doi/abs/10.
1177/014233120002200105/, Accessed: Feb 20, 2023, 2000.
[6] R. H. Bishop, MECHATRONICS AN INTRODUCTION, CRC Press: Taylor & Francis Group, 2006.
[7] S. Cetinkunt, MECHATRONICS, John Wiley and Sons, 2007.
[8] IEE, Web-based networking protocol for expanding IEEE-488 ATE, https://standards.ieee.org/ieee/488/
6465/, Accessed: Feb 20, 2023, 2011.
[9] H. C. FacebookTwitterLinkedInRedditPinterestShare, Simple Programs in 8051 Assembly Language, engineers-
garage, https://www.engineersgarage.com/simple- programs- in- 8051- assembly- language/, Accessed:
Feb 20, 2023, 2011.
[10] I. R., Mechatronic systems: concepts and applications: Transactions of the Institute of Measurement and Control,
https://journals.sagepub.com/doi/10.1177/014233120002200103/, Accessed: Feb 20, 2023, 2000.
22
Instrumentation and Measurement
Course-4
Course Name: Instrumentation and Measurement /Course Code: MEng 3261
page1
Chapter One
1. Basic Concepts of Measurements and Instrumentation
1.1 Classification of instruments
• Analog instrument
The measured parameter value is display by the moveable pointer. The pointer will moved
continuously with the variable parameter/analog signal which is measured. The reading is inaccurate
because of parallax error (parallel) during the skill reading. E.g.: ampere meter, voltage meter, ohm
meter etc.
• Digital instrument
The measured parameter value is display in decimal (digital) form which the reading can be read thru
in numbers form. Therefore, the parallax error is not existed and terminated. The concept used for
digital signal in a digital instrument is logic binary ‘0’and ‘1’.
For example, the mass of an object is often measured by the process of weighing, where the measure
and is the mass but the physical measurement variable is the downward force the mass exerts in the
Earth’s gravitational field. There are many possible physical measurement variables.
The key functional element of the instrument model shown in Figure 1.1 is the sensor, which has the
function of converting the physical variable input into a signal variable output.
page2
Signal variables have the property that they can be manipulated in a transmission system, such as an
electrical or mechanical circuit. Because of this property, the signal variable can be transmitted to an
output or recording device that can be remote from the sensor. In electrical circuits, voltage is a
common signal variable. In mechanical systems, displacements or force are commonly used as signal
variables. Other examples of signal variable are shown in Table 1.1.
The signal output from the sensor can be displayed, recorded, or used as an input signal to some
secondary device or system. In a basic instrument, the signal is transmitted to a Display or recording
device where the measurement can be read by a human observer. The observed output is the
measurement M.
There are many types of display devices, ranging from simple scales and dial gages to sophisticated
computer display systems. The signal can also be used directly by some larger system of which the
instrument is a part.
Two basic characteristic of an instrument is essential for selecting the most suitable instrument for
specific measuring jobs:
1. Static characteristic
2. Dynamic characteristic
Static characteristic of an instrument are, in general, considered for instruments which are used to
measure an unvarying process condition.
1. Instrument – A device or mechanism used to determine the present value of a quantity under
observation.
page3
2. Measurement – The process of determining the amount, degree, capacity by comparison
(direct or indirect) with the accepted standards of the system units being used.
3. Accuracy – The degree of exactness (closeness) of a measurement compared to the expected
(desired) value.
4. Resolution – The smallest change in a measured variable to which instruments will response.
Also known as ‘Threshold.
output
S
input
Dynamic characteristic are concerned with the measurement of quantities that vary with time.
1.1 Process of measurement
Measurement is essentially the act, or the result, of a quantitative comparison between a given
quantity and a quantity of the same kind chosen as a unit. The result of measurement is
expressed by a number representing the ratio of the unknown quantity to the adopted unit of
measurement.
The step taken before measure:
page4
1. Procedure of measurement: Identified the parameter or variable to be measured, how to record
the result
2. Characteristic of parameter: Should know the parameter that to be measured; ac, dc, frequency
or etc.
3. Quality: Time and cost of equipment, the instrument ability, the measurement knowledge and
suitable result.
4. Instrument: Choose a suitable equipment; multi-meter, voltmeter, oscilloscope or etc.
During measurement:
1. Quality: Make sure the chosen, instrument is the best, the right position when taken result,
the frequent of measurement.
2. Safety first: Electric shock, overload effect, limitation of instrument.
3. Sampling: See the changing of parameter during measurement, which value should be
taken when the parameter keep changing. Take enough samples and it is accepted.
Chapter Two
2. Errors in measurement
Error is defined as the difference between the true value (expected value) of the measure and the
measured value indicated by the instrument.
Absolute errors are defined as the difference between the expected value of the variable and the
measured value of variable.
Xn = measured value
OR
page5
Yn X n
Percentage error = X100%
Yn
Yn X n
Relative Accuracy, A = 1
Yn
Example 1:
The expected value of the voltage across a resistor is 90 V. However, the measurement gives a
value of 89 V.
Calculate:
a) Absolute error
b) Percentage error
c) Relative accuracy
d) Percentage of accuracy
Solution
Expected value of voltage across a resistor, Yn = 90 V Measured value
of voltage across a resistor, Xn = 89 V
page6
incorrect spring tension, improper calibration, or faulty instruments.
Environmental errors – Environmental conditions in which instruments are used
may cause errors. Subjecting instruments to harsh environments such high
temperature, pressure, humidity, strong electrostatic or electromagnetic fields, may
have detrimental effects, thereby causing error.
Observational errors - Those errors that introduced by observer. Two most
common observational errors are probably the parallax error introduced in reading
a meter scale and error of estimation when obtaining a reading from a scale meter.
3. Random Errors – are generally the accumulation of a large number of small effects and
may be of real concern only in measurements requiring a high degree of accuracy. Such
errors can be analyzed statistically.
2.2.Statistical analysis of error in measurement
How to analyze an error? Use statistic method
When we measure any physical quantity, our measurements are effected by a multitude of
factors.
Arithmetic mean – the sum of a set of numbers divided by the total number of pieces of data
Where;
X + X + X + ... + Xn
Arithmetic Mean, X 1 2 3
n
1 n
= Xn
n n=1
page7
Where,
The standard deviation is the square root of the sum of all the individual deviations squared, divided
by the number of readings.
Standard deviation, S =
Example:
Most manufacturers of measuring instrument state that an instrument is accurate within a certain
percentage of a full-scale reading.
For example, the manufacturer of a certain voltmeter may specify the instrument to be accurate
within 2% with full-scale deflection.
When a quantity is calculated from measurements made on two or more instruments, it must be
assumed that errors due to instrument inaccuracy combine in worst possible way. The resulting
error is then larger than the error in any one instrument.
o Sum of quantities: E = (V1 + V2) (V1 + V2)
o Difference of quantities: E = (V1 - V2) (V1 + V2)
o Product of quantities
o Percentage error in P = (% error in I) + (% error in E)
o Quotient of quantities:
o Percentage error in E/I = (% error in E) + (% error in I)
o Quantity Raised to a power:
page8
o Percentage error in AB = B (% error in A)
Sum of Quantities
Where a quantity is determined as the sum of two measurements, the total error is the sum of the
absolute errors in each measurement. As illustrated in Figure 1.2:
Difference of Quantities
Figure 2.2 illustrated a situation in which a potential difference is determined as the difference
between two measured voltages. Here again, the errors are additive;
page9
Product of Quantities
When a calculated quantity is product of two or more quantities, the percentage error is the sum of the
percentage errors in each quantity.
V1 V1
Figure 1.4: Percentage error in product or quotient of quantities equals sum of percentage errors
Quotient of Quantities
Here again it can be that the percentage error is the sum of the percentage errors in each quantity.
Example 1:
A 600V voltmeter is specified to be accurate within 2% at full scale. Calculate the limiting
error when the instrument is used to measure a voltage of 250V.
Solution
page10
Example 2:
A voltmeter reading 70V on its 100V range and an ammeter reading 80mA on its 150mA range are used to
determine the power dissipated in a resistor. Both these instruments are guaranteed to be accurate within
1.5% at full-scale deflection. Determine the limiting error of the power. (Ans: 4.956%)
Chapter Three
In other word it is a device that is capable of converting the physical quantity into a proportional electrical
quantity such as voltage or current. The physical quantity may be mechanical, chemical, optical or thermal.
Application.
Method of energy conversion.
Nature of output signal.
Electrical transducers: voltage, current, frequency, R-C- I component and its effects.
Non-electrical transducers: Detector (sensor) and Physical quantity is obtained which is converted to
electrical quantity.
Displacement transducers: Capacitive, oscillation, potentiometric, photoelectric, piezoelectric (Force
Summing Devices).
Opto-electronic transducers: Converts light energy into electrical energy, Photoconductive cell,
photovoltaic cell, solar cell, photo tube, photo multiplier, etc.
A) Active Transducers
These transducers do not need any external source of power for their operation. Therefore they are also called
as self-generating type transducers.
The active transducers are self-generating devices which operate under the energy conversion principle.
page11
As the output of active transducers we get an equivalent electrical output signal e.g. temperature or
strain to electric potential, without any external source of energy being used.
B) Passive Transducers
These transducers need external source of power for their operation. So they are not self-generating type
transducers.
page12
Active and Passive transducers (Comparative view)
Active Transducers
Self-generating type.
Energy for generating output is obtained from physical phenomenon.
Thermocouple
Piezoelectric transducer
Photovoltaic cell
Photoelectric (photoemission) cell
Passive Transducers
Externally powered.
Resistance type
Strain gauge
Potentiometric device
Thermistor
Inductive type
LVDT
Capacitive type
Hall effect transducer
3.2. Basic requirements of a transducer
Linearity –characteristics between input and output.
Ruggedness –ability to withstand overload and protection measures.
Repeatability –ability to produce same output for same input at different times and environment.
High stability & reliability –output should not be affected by temperature, vibration, other
environmental conditions, with minimal error.
Good dynamic response –ability to change output quickly for dynamic variation in input with respect
to time.
Convenient instrumentation –high analog output, high SNR, direct measurement or after
amplification.
Good mechanical characteristics –ability to withstand deformation and deterioration in performance
caused by various mechanical strains.
A) Resistive Transducer
Resistive transducers are those transducers in which the resistance changes due to the change in some physical
phenomenon. The resistance of a metal conductor is expressed by a simple equation.
R = ρL/A
Where R = resistance of conductor in Ω
L = length of conductor in m
page13
ρ= resistivity of conductor material in Ω-m.
Fig.
B) Capacitive Transducer
In capacitive transduction transducers the measurand is converted to a change in the capacitance. The
relationship between the capacitance and the size of capacitor plate, amount of plate separation, and the
dielectric is given by
C = εoεrA / d
d = is the separation distance of plates (m)
A movable diaphragm forms one plate of the capacitor. The distance between diaphragm and static plate
changes when a force applied to the diaphragm. The change in capacitance is measured with an ac- bridge
circuit or oscillator circuit as change in frequency.
page14
Fig.
C) Inductive Transducer
When a force is applied to the ferromagnetic armature the air gap changes and varying the reluctance of the
magnetic circuit.
Fig.
page15
Chapter Four
4. Signal Conditioning
The output from a transducer is generally a continuously varying or analogue signal. In contrast digital
processors store and process signals sampled at particular times and represented as binary numbers. Any
modern instrumentation must therefore include a component (described in the P2 course), known as an
Analogue-to-Digital converter (ADC), which converts the analogue input signal into a digital signal that can
be read by the digital processor.
Figure 4.1: A block diagram of a typical instrumentation system with several different output devices
The simplest and cheapest possible instrumentation system is one in which the output from the transducer is
connected directly to the input of an ADC. However, both the transducer and the ADC are standard
components that have not been designed for any particular application. More importantly, transducers rely
upon physical processes that rarely, if ever, generate output signals that are compatible with the ADC input
range. In particular the maximum change in the output signal from a sensor is often smaller than the minimum
change in signal that can be detected by the ADC. This means that in this simplest system even the maximum
change in the transducer output may be undetectable.
Instrumentation systems must therefore include a circuit before the ADC that amplifies the output from the
transducer to make it detectable by the ADC. Such a circuit is referred to as signal conditioning.
In instrumentation, signal conditioning generally means manipulating an analogue signal (from a sensor) in
such a way that it meets the requirements of the next stage of a system for further processing. In general the
most common “next stage” will involve analogue-to-digital converters.
Signal inputs accepted by signal conditioning circuits include DC voltage and current, AC voltage and current
(and possibly but rarely electric charge). The processes that are performed by these circuits will almost
certainly include amplification and filtering. In addition to these functions the signal conditioning may also
include a step to isolate the input circuits from the rest of the system (one area where this is important is in
medical electronics where isolation protects the patient who is hosting the sensors) and/or a non-linear step
(such as a log or an anti-log amplifier) to compensate for any non-linearity of the sensor.
Although isolation and non-linear stages are key to a few systems this course will focus on the amplification
and filtering that must be included in almost all systems. Commonly used amplifiers for signal Conditioning.
page16
Simple Amplifier Circuits for Signal Conditioning
The output from many transducers is a voltage and there are two simple circuits (described in the P2 course),
the non-inverting and the inverting amplifier, which can be used to amplify a voltage signal.
Don’t forget the analysis of any op-amp circuit to understand its function is based on the simple ideal op-amp
rules (taken from P2):
An ideal op-amp has an infinite input resistance, an infinite differential gain and an output resistance of zero.
The infinite gain means that provided there is negative feedback: (be sure you understand WHY?)
This equation and the characteristics of an ideal op-amp can be used to show that for the non-inverting
amplifier
page17
Inverting amplifier (P2 Revision):
Using the same rules as above and noting that for the inverting amplifier V+ is connected to ground (V) we
can show that:
Equation???????????????
Instrumentation systems are widely used to control and monitor many different “host” systems. Any physical
variable that is being measured has to be converted to an electrical signal, usually an analogue signal, by an
input transducer or sensor. Useful information then has to be extracted from this signal, most often by a
program in a digital processor. Conversion from an analogue sensor output to a digital input for the processor
is a two-stage process involving analogue signal processing (conditioning) and an analogue-to-digital
converter.
Each instrumentation system therefore usually consists of four constituent parts, the sensor, and analogue
signal processing circuits, an analogue-to-digital converter and a digital processor.
Sensors rely upon physical processes that allow an electrical signal to be generated in response to a change in a
physical variable. These physical processes usually result in small output signals. A key part of any analogue
signal processing circuit is therefore a circuit that amplifies the changes in the output signal from a sensor.
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Chapter Six
5. Data Transmission, Processing, Display And Recording
6.1. Concept and Classification of Recorders
Concept
• A recorder records electrical and non-electrical quantities as a function of time.
• Currents and voltages can be recorded directly while the non-electrical quantities are recorded indirectly by
first converting them to equivalent currents or voltages with the help of sensors or transducers.
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Analog Recording
An analog recording is one where a property or characteristic of a physical recording medium is
made to vary in a manner analogous to the variations in air pressure of the original sound.
Generally, the air pressure variations are first converted (by a transducer such as a microphone)
into an electrical analog signal in which either the instantaneous voltage or current is analogous
to the instantaneous air pressure.
The variations of the electrical signal in turn are converted to variations in the recording
medium by a recording machine such as a tape recorder or cutting lathe.
Example – PMMC instrument (Permanent Magnet Moving Coil)
Graphic Recorders
Graphic recorders generally are devices which display and store a pen and ink record of the
history of some physical event.
Basic elements of a recorder include a chart for displaying and storing the recorded information,
a stylus moving in a proper relationship to the paper and suitable means of interconnection to
couple the stylus to the source of information.
Strip chart recorders: A strip chart recorder records one or more variables with respect to time. It is an
X-t recorder.
X-Y recorders: An X-Y recorder records one or more dependent variables with respect to an
independent variable.
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(i) Paper drive systems: It should move the paper at a uniform speed. A spring wound
mechanism may be used but in most of the recorders and a synchronous motor is used for
driving the paper.
(ii) Marking mechanism: The most commonly used marking mechanisms are as following:
a. Marking with ink filled stylus
b. Marking with heated stylus
c. Chopper bar
d. Electric stylus marking
e. Electrostatic stylus
f. Optical marking method
(iii) Tracing systems: There are two types of tracing systems used for producing graphic
representations.
Curvilinear system
Rectilinear system
1. Galvanometer type
2. Null type
This type of strip chart recorder operates on the deflection principle. The deflection is produced by a
galvanometer which produces a torque on account of a current passing through its coil. This current is
proportional to the quantity being measured.
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Figure 6. 3 Galvanometer type strip chart recorder
Many recorders operate on the principle whereby a change in its input, produced
by the signal from the sensor or transducer, upsets the balance of the measuring
circuit of the recorder.
As a result of this unbalance, an error signal is produced that operates some
device which restores balance or brings the system to Null conditions.
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The amount of movement of this balance restoring device then, is an indication
of the magnitude of the error signal, and the direction of the movement is an
indication of the direction of the quantity being measured has deviated from
normal.
The signal from the transducer may take any of the several forms. It may be a
voltage, a current or it may be a value of resistance, inductance or capacitance.
The recorder, therefore, must be of a type able to accept the form of the input
signal.
Potentiometric recorders
Bridge recorders and
LVDT recorders
A strip chart recorder records the variations of a quantity w.r.t. time while a X-Y
recorder is an instrument which gives a graphic record of the relationship between two
variables.
In X-Y recorders, an emf is plotted as a function of another emf. This is done by having
one self-balancing potentiometer control the position of the rolls while another self-
balancing potentiometer controls the position of the recording pen (stylus).
In some X-Y recorders, one stylus moves in the X direction and second stylus moves in
the Y direction at right angles to the X direction, while the paper remains stationary.
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With the help of X-Y recorders and appropriate transducers, a physical quantity may be
plotted against another physical quantity.
Hence, an X-Y recorder consists of a pair of servo-system, driving a recording pen and
moving arm arrangement, with reference to a stationary paper chart. Attenuators are
used to bring the input signals to the levels acceptable by the recorder.
A signal enters each block of the two channels. The signals are attenuated to the
inherent full scale range of the recorder; the signal then passes to a balance circuit where
it is compared with an internal reference voltage. The error signal and the reference
voltage is fed to a chopper which converts d.c. signal to an a.c. signal. The signal is then
amplified in order to actuate a servomotor which is used to balance the system and hold
it in balance as the value of the quantity being recorded changes.
The action described above takes place in both axes simultaneously. Thus we get a
record of one variable w.r.t. another.
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The use of X-Y recorders in laboratories greatly simplifies and expedites many
measurements and tests. A few examples are being given below:
Speed torque characteristics of motors
Lift drag wind tunnel tests
Plotting of characteristics of vacuum tubes, Zener diodes rectifier and transistors etc.
Regulation curves of power supplies
Plotting stress-strain curves, hysteresis curves and vibrations amplitude against swept frequency
Electrical characteristics of materials such as resistance vs. temperature plotting the output from
electronic calculators and computers.
Principle
When a magnetic tape is passed through a recording head, any signal recorded on the
tape appears as magnetic pattern dispersed in space along the tape, similar to the original
coil current variation with time.
The same tape when passed through a reproduce or playback head reproduces variations
in the reluctance of the winding thereby inducing a voltage in the winding dependent
upon the direction of magnetization and its magnitude on the magnetic tape. The
induced voltage is proportional to the rate of change of flux linkages. Therefore the emf
induced in the winding of reproducing head is proportional to the rate of change of level
of magnetization on the tape.
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Figure 6. 6 Elementary Magnetic Tape Recorder
There are three methods of magnetic tape recording which are used for instrumentation purposes. They
are:
Direct recording
Frequency Modulation (FM) recording
Pulse Modulation (PM) recording
FM recorders are generally used for instrumentation purposes.
The PDM recording is used in instrumentation systems for special applications where a large number
of slowly changing variables have to be recorded simultaneously.
Advantages
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This works because the metallic substrate of the disc is reflective, and the unburned dye
prevents reflection while the holes in the dye permit it, allowing digital data to be
represented.
The digital data recorders are basic two type, namely, Incremental and synchronous.
Construction
DSOs use digital storage techniques while analog storage CROs use special CRTs called
storage tubes.
In this technique, the waveform to be stored is digitized, stored in a digital memory, and
retrieved for display on the storage oscilloscope. The stored waveform is continually
displayed by repeatedly scanning the stored waveform and therefore, a conventional
CRT can be employed for the display and thus some of the cost of the additional
circuitry for digitizing and storing the input waveform is offset.
The stored display can be displayed indefinitely as long as the power is applied to the
memory, which can be supplied with a small battery. The digitized waveform can be
further analyzed by either the oscilloscope or by loading the contents of the memory
into a computer.
A generalized block diagram of digital storage oscilloscope is shown in fig. 6.7.
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Some of the DSOs use 12 bit converters, giving 0.025% resolution and 0.1% accuracy
on voltage and time readings, which are better than the 2-5% of analog storage
oscilloscopes.
Split screen capabilities enable easy comparison of the two signals.
The only drawback of DSO is limited bandwidth by the speed of their analog-to-digital
converters. However, 20 MHz digitizing rates available on some oscilloscopes yield a
bandwidth of 5 MHz, which is adequate for most of the applications.
Limitations
1. Oscilloscope loading and Probe Use: To counteract the loading effect on an oscilloscope, voltage probes are
used. Voltage probes are devices which increase the input impedance of an oscilloscope by inserting high
impedance in series with the oscilloscope inputs.
2. Hum and Noise Pickup: The oscilloscope is designed to be capable of amplifying and displaying small input
signals. This capability also makes it susceptible to amplification of small unwanted signals and noise,
especially when set to its most volts/division capability.
The magnitude of hum picked up by an oscilloscope depends upon the impedance of the circuit under testing,
the length of the oscilloscope leads, and the type of shielding used by these leads. Hum signals are largest
when long, unshielded leads are connected to high-impedance circuits. The best way to reduce the level of
such interference signals is to use short cables which have a shield that can be connected to ground.
Differential inputs are also designed to help reduce noise pickup in low-level signals.
Oscilloscope Errors:
Reading error
Parallax error
Calibration error
Frequency-response error
Loading error
1. Checking individual electrical components such as vacuum tubes, diodes, transistors, ICs, magnetic
components, relays, and choppers.
2. Checking amplifiers and amplifier circuits.
3. Displaying transducer outputs.
4. Television, radio and communication equipment checking and repair.
5. Electrical diagnosis of automobile engines.
6. Special curve-tracer oscilloscopes are available for plotting the current-voltage characteristics of
transistors, diodes, and other elements.
7. In Radar, CRO is used for providing the visual indication of target such as airplane, ship etc.
8. In Medical Sciences, the low speed time base CROs are used in electrocardiogram (ECG),
electromyogram (EMG) and Electroencephalogram (EEG), which are employed for diagnosis of the
condition of heart, brain and muscles, respectively of the patient body.
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