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SEVENTH EDITION
SEVENTH EDITION
M E C H AT RO N I C S
Seventh Edition
William Bolton
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10 9 8 7 6 5 4 3 2 1
23 22 21 20 19
NOTE THAT ANY PAGE CROSS REFERENCES REFER TO THE PRINT EDITION
Chapter objectives 78
I. Introduction 1 3.1 Signal conditioning 78
3.2 The operational amplifier 79
1. Introducing mechatronics 3 3.3 Protection 90
3.4 Filtering 91
3.5 Wheatstone bridge 92
Chapter objectives 3 3.6 Pulse modulation 97
1.1 What is mechatronics? 3 3.7 Problems with signals 98
1.2 The design process 5 3.8 Power transfer 100
1.3 Systems 6 Summary 101
1.4 Measurement systems 8 Problems 101
1.5 Control systems 9
1.6 Programmable logic controller 21
1.7 Examples of mechatronic systems 22 4. Digital signals 103
Summary 26
Problems 27
Chapter objectives 103
4.1 Digital signals 103
4.2 Analogue and digital signals 103
II. Sensors and signal conditioning 29 4.3 Digital-to-analogue and analogue-to-digital
converters 107
2. Sensors and transducers 31 4.4 Multiplexers 113
4.5 Data acquisition 114
4.6 Digital signal processing 116
Chapter objectives 31 4.7 Digital signal communications 118
2.1 Sensors and transducers 31 Summary 119
2.2 Performance terminology 32 Problems 120
2.3 Displacement, position and proximity 37
2.4 Velocity and motion 54
2.5 Force 57
5. Digital logic 121
2.6 Fluid pressure 57
2.7 Liquid flow 61
2.8 Liquid level 62 Chapter objectives 121
2.9 Temperature 63 5.1 Digital logic 121
2.10 Light sensors 69 5.2 Logic gates 122
2.11 Selection of sensors 70 5.3 Applications of logic gates 130
2.12 Inputting data by switches 71 5.4 Sequential logic 135
Summary 74 Summary 143
Problems 75 Problems 143
12.3 Branches and loops 336 15.5 Open Systems Interconnection communication
12.4 Arrays 340 model 415
12.5 Pointers 342 15.6 Serial communication interfaces 418
12.6 Program development 343 15.7 Parallel communication interfaces 427
12.7 Examples of programs 345 15.8 Wireless communications 430
12.8 Arduino programs 348 Summary 431
Summary 352 Problems 432
Problems 352
Arduino and the addition of more topics in the Mechatronic systems chapter.
The seventh edition has continued the evolution of the book with updating of
mechatronic system components, clarification of some aspects so they read
more easily, the inclusion of information on the Atmega microcontrollers, a
discussion and examples of fuzzy logic and neural control systems, and yet
more applications and case studies. The number of Appendices has been
reduced as they had grown over previous editions and it was felt that some
were now little used. A revised and extended version of the Appendix
concerning electrical circuit analysis has ben moved to the Instructor’s Guide
as Supporting material: Electrical components and circuits, and so is available
to an instructor for issue to students if required.
The overall aim of the book is to give a comprehensive coverage of mecha-
tronics which can be used with courses for both technicians and undergradu-
ates in engineering and, hence, to help the reader:
• acquire a mix of skills in mechanical engineering, electronics and comput-
ing which is necessary if he/she is to be able to comprehend and design
mechatronic systems;
• become capable of operating and communicating across the range of engi-
neering disciplines necessary in mechatronics;
• be capable of designing mechatronic systems.
Each chapter of the book includes objectives and a summary, is copiously
illustrated and contains problems, answers to which are supplied at the end
of the book. Chapter 24 comprises research and design assignments together
with clues as to their possible answers.
The structure of the book is as follows:
• Chapter 1 is a general introduction to mechatronics.
• Chapters 2–6 form a coherent block on sensors and signal conditioning.
• Chapters 7–9 cover actuators.
• Chapters 10–16 discuss microprocessor/microcontroller systems.
• Chapters 17–23 are concerned with system models.
• Chapter 24 provides an overall conclusion in considering the design of
mechatronic systems.
An Instructor’s Guide, test material and PowerPoint slides are available for
lecturers to download at: www.pearsoned.co.uk/bolton.
A large debt is owed to the publications of the manufacturers of the
equipment referred to in the text. I would also like to thank those reviewers
who painstakingly read through through the sixth edition and my proposals
for this new edition and made suggestions for improvement.
W. Bolton
Objectives
The objectives of this chapter are that, after studying it, the reader should be able to:
• Explain what is meant by mechatronics and appreciate its relevance in engineering design.
• Explain what is meant by a system and define the elements of measurement systems.
• Describe the various forms and elements of open-loop and closed-loop control systems.
• Recognise the need for models of systems in order to predict their behaviour.
1.1 What is
mechatronics? The term mechatronics was ‘invented’ by a Japanese engineer in 1969, as a
combination of ‘mecha’ from mechanisms and ‘tronics’ from electronics. The
word now has a wider meaning, being used to describe a philosophy in engineer-
ing technology in which there is a co-ordinated, and concurrently developed,
integration of mechanical engineering with electronics and intelligent computer
control in the design and manufacture of products and processes. As a result,
mechatronic products have many mechanical functions replaced with electronic
ones. This results in much greater flexibility, easy redesign and reprogramming,
and the ability to carry out automated data collection and reporting.
A mechatronic system is not just a marriage of electrical and mechanical
systems and is more than just a control system; it is a complete integration of
all of them in which there is a concurrent approach to the design. In the design
of cars, robots, machine tools, washing machines, cameras and very many
other machines, such an integrated and interdisciplinary approach to engi-
neering design is increasingly being adopted. The integration across the tra-
ditional boundaries of mechanical engineering, electrical engineering,
electronics and control engineering has to occur at the earliest stages of the
design process if cheaper, more reliable, more flexible systems are to be devel-
oped. Mechatronics has to involve a concurrent approach to these disciplines
rather than a sequential approach of developing, say, a mechanical system,
then designing the electrical part and the microprocessor part. Thus mecha-
tronics is a design philosophy, an integrating approach to engineering.
Mechatronics brings together areas of technology involving sensors and
measurement systems, drive and actuation systems, and microprocessor sys-
tems (Figure 1.1), together with the analysis of the behaviour of systems and
control systems. That essentially is a summary of this book. This chapter is
an introduction to the topic, developing some of the basic concepts in order
to give a framework for the rest of the book in which the details will be
developed.
Microprocessor
system for control
Consider the modern autofocus, auto-exposure camera. To use the camera all
you need to do is point it at the subject and press the button to take the picture.
The camera can automatically adjust the focus so that the subject is in focus and
automatically adjust the aperture and shutter speed so that the correct exposure
is given. You do not have to manually adjust focusing and the aperture or shutter
speed controls. Consider a truck’s smart suspension. Such a suspension adjusts
to uneven loading to maintain a level platform, adjusts to cornering, moving
across rough ground, etc., to maintain a smooth ride. Consider an automated
production line. Such a line may involve a number of production processes which
are all automatically carried out in the correct sequence and in the correct way
with a reporting of the outcomes at each stage in the process. The automatic
camera, the truck suspension and the automatic production line are examples of
a marriage between electronics, control systems and mechanical engineering.
1.3 Systems
In designing mechatronic systems, one of the steps involved is the creation of
a model of the system so that predictions can be made regarding its behaviour
when inputs occur. Such models involve drawing block diagrams to represent
Input: Output:
Thermometer
temp. number
on a scale
(c)
The response of any system to an input is not instantaneous. For example, for
the spring system described by Figure 1.2(a), though the relationship between
the input, force F, and output, extension x, was given as F = kx, this only
describes the relationship when steady-state conditions occur. When the force
is applied it is likely that oscillations will occur before the spring settles down
to its steady-state extension value (Figure 1.3). The responses of systems are
functions of time. Thus, in order to know how systems behave when there are
inputs to them, we need to devise models for systems which relate the output
to the input so that we can work out, for a given input, how the output will
vary with time and what it will settle down to.
As another example, if you switch on a kettle it takes some time for the
water in the kettle to reach boiling point (Figure 1.4). Likewise, when a
Input: Output:
Spring
force at extension Final reading
time 0 which changes
with time
0 Time
Temperature
Kettle
electricity temperature
of water
208C
0 2 min
Time
microprocessor controller gives a signal to, say, move the lens for focusing in
an automatic camera, then it takes time before the lens reaches its position for
correct focusing.
Often the relationship between the input and output for a system is
described by a differential equation. Such equations and systems are discussed
in Chapter 17.
In other than the simplest system, it is generally useful to consider the system
as a series of interconnected blocks, each such block having a specific function.
We then have the output from one block becoming the input to the next block
in the system. In drawing a system in this way, it is necessary to recognise that
lines drawn to connect boxes indicate a flow of information in the direction
indicated by an arrow and not necessarily physical connections. An example
of such a connected system is the driving system of an automobile. We can
think of there being two interconnected blocks: the accelerator pedal which
has an input of force applied by a foot to the accelerator pedal system and
controls an output of fuel, and the engine system which has an input of fuel
and controls an output of speed along a road (Figure 1.5). Another example
of such a set of connected blocks is given in the next section on measurement
systems.
1.4 Measurement
systems Of particular importance in any discussion of mechatronics are measurement
systems. Measurement systems can, in general, be considered to be made
up of three basic elements (as illustrated in Figure 1.6):
1 A sensor responds to the quantity being measured by giving as its output
a signal which is related to the quantity. For example, a thermocouple is a
temperature sensor. The input to the sensor is a temperature and the out-
put is an e.m.f., which is related to the temperature value.
2 A signal conditioner takes the signal from the sensor and manipulates it
into a condition which is suitable either for display or, in the case of a control
system, for use to exercise control. Thus, for example, the output from a
Figure 1.7 A digital thermometer Quantity Signal related Signal in suitable Value
system. being to quantity form for of the
measured: measured: display: quantity
Sensor Amplifier Display
temperature potential bigger
difference voltage
1.5.1 Feedback
(a) (b)
Feedback of data
about actual position
(c)
There are two basic forms of control system, one being called open loop
and the other closed loop. The difference between these can be illustrated
by a simple example. Consider an electric fire which has a selection switch
which allows a 1 kW or a 2 kW heating element to be selected. If a person
used the heating element to heat a room, they might just switch on the 1 kW
element if the room is not required to be at too high a temperature. The
room will heat up and reach a temperature which is only determined by the
fact that the 1 kW element was switched on and not the 2 kW element. If
there are changes in the conditions, perhaps someone opening a window,
there is no way the heat output is adjusted to compensate. This is an example
of open-loop control in that there is no information fed back to the element
to adjust it and maintain a constant temperature. The heating system with
the heating element could be made a closed-loop system if the person has a
thermometer and switches the 1 kW and 2 kW elements on or off, according
to the difference between the actual temperature and the required tempera-
ture, to maintain the temperature of the room constant. In this situation
there is feedback, the input to the system being adjusted according to
whether its output is the required temperature. This means that the input
to the switch depends on the deviation of the actual temperature from the
required temperature, the difference between them being determined by a
comparison element – the person in this case. Figure 1.9 illustrates these two
types of system.
An example of an everyday open-loop control system is the domestic
toaster. Control is exercised by setting a timer which determines the length
of time for which the bread is toasted. The brownness of the resulting toast is
determined solely by this preset time. There is no feedback to control the
degree of browning to a required brownness.
To illustrate further the differences between open- and closed-loop sys-
tems, consider a motor. With an open-loop system the speed of rotation of the
shaft might be determined solely by the initial setting of a knob which affects
the voltage applied to the motor. Any changes in the supply voltage, the char-
acteristics of the motor as a result of temperature changes, or the shaft load
Comparison
element
Input: Controller, Electric Output:
Switch
required Deviation i.e. person Hand Electric fire a constant
temperature signal activated power temperature
Measuring
Feedback of temperature-related signal device
(b)
Figure 1.9 Heating a room: (a) an open-loop system, (b) a closed-loop system.
will change the shaft speed but not be compensated for. There is no feedback
loop. With a closed-loop system, however, the initial setting of the control
knob will be for a particular shaft speed and this will be maintained by feed-
back, regardless of any changes in supply voltage, motor characteristics or
load. In an open-loop control system the output from the system has no effect
on the input signal. In a closed-loop control system the output does have an
effect on the input signal, modifying it to maintain an output signal at the
required value.
Open-loop systems have the advantage of being relatively simple and con-
sequently low cost with generally good reliability. However, they are often
inaccurate since there is no correction for error. Closed-loop systems have the
advantage of being relatively accurate in matching the actual to the required
values. They are, however, more complex and so more costly with a greater
chance of breakdown as a consequence of the greater number of components.
Figure 1.10 shows the general form of a basic closed-loop system. It consists
of five elements:
1 Comparison element
This compares the required or reference value of the variable condition
being controlled with the measured value of what is being achieved and
produces an error signal. It can be regarded as adding the reference signal,
which is positive, to the measured value signal, which is negative in this case:
error signal = reference value signal - measured value signal
The symbol used, in general, for an element at which signals are summed is
a segmented circle, inputs going into segments. The inputs are all added,
hence the feedback input is marked as negative and the reference signal posi-
tive so that the sum gives the difference between the signals. A feedback loop
is a means whereby a signal related to the actual condition being achieved is
fed back to modify the input signal to a process. The feedback is said to be
negative feedback when the signal which is fed back subtracts from the
input value. It is negative feedback that is required to control a system.
Positive feedback occurs when the signal fed back adds to the input
signal.
2 Control element
This decides what action to take when it receives an error signal. It may
be, for example, a signal to operate a switch or open a valve. The control
Comparison
element
Control Correction
+ Process
Reference - Error signal unit unit Controlled
value variable
Measuring
Measured value device
plan being used by the element may be just to supply a signal which
switches on or off when there is an error, as in a room thermostat, or per-
haps a signal which proportionally opens or closes a valve according to the
size of the error. Control plans may be hard-wired systems in which the
control plan is permanently fixed by the way the elements are connected
together, or programmable systems where the control plan is stored
within a memory unit and may be altered by reprogramming it. Controllers
are discussed in Chapter 10.
3 Correction element
The correction element produces a change in the process to correct or
change the controlled condition. Thus it might be a switch which switches
on a heater and so increases the temperature of the process or a valve
which opens and allows more liquid to enter the process. The term actua-
tor is used for the element of a correction unit that provides the power to
carry out the control action. Correction units are discussed in Chapters 7,
8 and 9.
4 Process element
The process is what is being controlled. It could be a room in a house with
its temperature being controlled or a tank of water with its level being
controlled.
5 Measurement element
The measurement element produces a signal related to the variable condi-
tion of the process that is being controlled. It might be, for example, a
switch which is switched on when a particular position is reached or a
thermocouple which gives an e.m.f. related to the temperature.
With the closed-loop system illustrated in Figure 1.10 for a person controlling
the temperature of a room, the various elements are:
An automatic control system for the control of the room temperature could
involve a thermostatic element which is sensitive to temperature and switches
on when the temperature falls below the set value and off when it reaches it
(Figure 1.11). This temperature-sensitive switch is then used to switch on the
heater. The thermostatic element has the combined functions of comparing
the required temperature value with that occurring and then controlling the
operation of a switch. It is often the case that elements in control systems are
able to combine a number of functions.
Figure 1.12 shows an example of a simple control system used to maintain
a constant water level in a tank. The reference value is the initial setting of the
lever arm arrangement so that it just cuts off the water supply at the required
Thermostatic element
Comparison
element
Input: Output:
Controller Switch Heater
required Deviation Electric required
temperature signal power temperature
Measuring
Feedback of temperature-related signal device
Lever
Water input
Comparison
element: the lever Pivoted lever The flap Water level in tank
Control Correction
+ Process
Reference - Error signal unit unit Controlled
value: the variable:
initial setting water level
Measuring
Measured value device
level. When water is drawn from the tank the float moves downwards with
the water level. This causes the lever arrangement to rotate and so allows
water to enter the tank. This flow continues until the ball has risen to such a
height that it has moved the lever arrangement to cut off the water supply.
The system is a closed-loop control system with the elements being:
Tachogenerator
Speed measurement
Differential amplifier
Process, Output:
Amplifier Motor
Reference rotating shaft constant
value speed
shaft
Measurement
tachogenerator
Analogue systems are ones where all the signals are continuous functions of
time and it is the size of the signal which is a measure of the variable (Figure 1.14(a)).
The examples so far discussed in this chapter are such systems. Digital signals
can be considered to be a sequence of on/off signals, the value of the variable
being represented by the sequence of on/off pulses (Figure 1.14(b)).
Where a digital signal is used to represent a continuous analogue signal,
the analogue signal is sampled at particular instants of time and the sample
values each then converted into effectively a digital number, i.e. a particular
sequence of digital signals. For example, we might have for a three-digit signal
the digital sequence of:
no pulse, no pulse, no pulse representing an analogue signal of 0 V;
no pulse, no pulse, a pulse representing 1 V;
no pulse, pulse, no pulse representing 2 V;
no pulse, pulse, pulse representing 3 V;
pulse, no pulse, no pulse representing 4 V;
pulse, no pulse, pulse representing 5 V;
pulse, pulse, no pulse representing 6 V;
pulse, pulse, pulse representing 7 V.
Because most of the situations being controlled are analogue in nature and it
is these that are the inputs and outputs of control systems, e.g. an input of
temperature and an output from a heater, a necessary feature of a digital con-
trol system is that the real-world analogue inputs have to be converted to
digital forms and the digital outputs back to real-world analogue forms. This
involves the uses of analogue-to-digital converters (ADCs) for inputs and
digital-to-analogue converters (DACs) for the outputs.
Figure 1.15(a) shows the basic elements of a digital closed-loop control
system; compare it with the analogue closed-loop system in Figure 1.10.
The reference value, or set point, might be an input from a keyboard. ADC
and DAC elements are included in the loop in order that the digital control-
ler can be supplied with digital signals from analogue measurement systems
Signal
(a) 0
Time
(b) 0
Time
Figure 1.14 Signals: (a) analogue and (b) the digital version of the analogue signal showing the
stream of sampled signals.