occupational health and safety

What is occupational health and safety?

Occupational health and safety is a discipline with a broad scope
involving many specialized fields.
In its broadest sense, it should aim at:
the promotion and maintenance of the highest degree of physical,
mental and social well-being of workers in all occupations.
 the prevention among workers of adverse effects on health
caused by their working conditions.
the protection of workers in their employment from risks resulting
from factors adverse to health.
 the placing and maintenance of workers in an occupational
environment adapted to physical and mental needs.
the adaptation of work to humans.
 Cont..
 occupational health and safety encompasses the social, mental and physical
well-being of workers, that is the “whole person”.
 Successful occupational health and safety practice requires the collaboration
and participation of both employers and workers in health and safety
programmes, and involves the consideration of issues relating to occupational
medicine, industrial hygiene, toxicology, education, engineering safety,
ergonomics, psychology, etc.
 Occupational health issues are often given less attention than occupational
safety issues because the former are generally more difficult to confront.
 However, when health is addressed, so is safety, because a healthy workplace
is by definition also a safe workplace.
 The converse, though, may not be true - a so-called safe workplace is not
necessarily also a healthy workplace.
 The important point is that issues of both health and safety must be
addressed in every workplace.
 By and large, the definition of occupational health and safety given above
encompasses both health and safety in their broadest contexts.
 Mechatronics
“The word, mechatronics is composed of mecha from mechanics and tronics from electronics.
In other words, technologies and developed products will be incorporating electronics more and
more into mechanisms, intimately and organically, and making it impossible to tell where one ends
and the other begins.”

Mechanics mecha
Mechatronics

Eletronics tronics

Mechatronics Defined — II
“Synergistic use of precision engineering, control theory, computer science, and sensor
and actuator technology to design improved products and processes.”
“Synergistic integration of mechanical engineering with electronics and intelligent
computer control in the design and manufacturing of industrial products and processes.”
 Mechatronics Defined — III
 “Field of study involving the analysis, design, synthesis, and selection
of systems that combine electronics and mechanical components with
modern controls and microprocessors.”

Mechatronics: Working Definition for us

“Mechatronics is the synergistic integration of sensors,
actuators, signal conditioning, power electronics,
decision and control algorithms, and computer
hardware and software to manage complexity,
uncertainty, and communication in engineered systems”.
synergistic combined effort being greater than parts: the working
together of two or more people, organizations, or things, especially
when the result is greater than the sum of their individual effects or
capabilities.
 What is the Mechatronics?
 Mehatronics is applicable everywhere. such as in: Consumer
products, Defense system, Medicals, Aerospace, Automotive,
Manufacturing, Material process, etc…
 Hardware, Software, and Firmware

 Hardware is the name given to the physical devices and

circuitry of the computer.
 Software refers to the programs written for the computer.
 Firmware is the term given to programs stored in ROMs or
in Programmable devices which permanently keep their
stored information.
Embedded Systems:-A combination of hardware and
software which together form a component of a
Mechatronics systems.
 An embedded system is designed to run on its own
without human intervention, and may be required to
respond to events in real time.
Elements of Mechatronics
The followings are basic Elements of Mechatronics
Mechanical
Electromechanical
Electrical/Electronic
Control Interface/Computing Hardware
Computer/Information System
Mechanical elements refer to
mechanical structure, mechanism, thermo-fluid, and hydraulic
aspects of a mechatronics system.
Mechanical elements may include static/dynamic characteristics.
A mechanical element interacts with its environment purposefully.

Mechanical elements require physical power to produce motion,

force, heat, etc.
Elements of Mechatronics—Electromechanical
 Sensors
 A variety of physical variables can be measured using sensors, e.g., light
using photo-resistor, level and displacement using potentiometer,
direction/tilt using magnetic sensor, sound using microphone, stress and
pressure using strain gauge, touch using micro-switch, temperature
using thermistor, and humidity using conductivity sensor
 Actuators
 DC servomotor, stepper motor, relay, solenoid, speaker, light emitting
diode (LED), shape memory alloy, electromagnet, and pump apply
commanded action on the physical process
 IC-based sensors and actuators (digital-compass, -potentiometer, etc.).
 Elements of Mechatronics—Electrical/Electronic

 Electrical elements refer to:

 Electrical components (e.g., resistor (R), capacitor (C), inductor (L),
transformer, etc.), circuits, and analog signals
 Electronic elements refer to:
 analog/digital electronics, transistors, thyristors, opto-isolators,
operational amplifiers, power electronics, and signal conditioning
 The electrical/electronic elements are used to interface
electro-mechanical sensors and actuators to the control
interface/computing hardware elements
 Elements of Mechatronics— Control
Interface/Computing Hardware
 Control interface/computing hardware elements refer to:
 Analog-to-digital (A2D) converter, digital-to-analog (D2A) converter, digital
input/output (I/O), counters, timers, microprocessor, microcontroller, data
acquisition and control (DAC) board, and digital signal processing (DSP) board
 Control interface hardware allows analog/digital interfacing
 communication of sensor signal to the control computer and communication of
control signal from the control computer to the actuator
 Control computing hardware implements a control algorithm, which uses sensor
measurements, to compute control actions to be applied by the actuator.
 Elements of
Mechatronics—Computer/Information System
 Computer elements refer to hardware/software utilized to perform:
 computer-aided dynamic system analysis, optimization, design, and simulation
 virtual instrumentation
 rapid control prototyping
 hardware-in-the-loop simulation
 PC-based data acquisition and control
 Elements of Mechatronics
 Typical knowledgebase for optimal design and
operation of mechatronic systems comprises of:
 Dynamic system modeling and analysis
 Thermo-fluid, structural, hydraulic, electrical, chemical, biological,
etc.
 Decision and control theory.
 Sensors and signal conditioning.
 Actuators and power electronics.
 Data acquisition
 A2D, D2A, digital I/O, counters, timers, etc.
 Hardware interfacing.
 Rapid control prototyping.
 Embedded computing.
Key Elements of Mechatronics
 Mechatronics Applications
Smart consumer products: home security, camera, microwave
oven, toaster, dish washer, laundry washer-dryer, climate
control units, etc.

Medical: implant-devices, assisted surgery, hepatic, etc.

Defense: unmanned air, ground, and underwater vehicles,

smart munitions, jet engines, etc.

Manufacturing: robotics, machines, processes, etc.

Automotive: climate control, antilock brake, active suspension,

cruise control, air bags, engine management, safety, etc.

Network-centric, distributed systems: distributed robotics,

tele-robotics, intelligent highways, etc.
 Embedded Systems in Automotive Applications

■ Entertainment
■ Adaptive control
■ Generation II ABS ■Satellite services radio/GPS
■ Heads-up monitoring ■ Tele-operation
■ Night vision ■ Software control
■ Back-up collision sensor ■ Rain-sensing
■ Navigation ■ Auto parking
■ Simulators
■ Tire pressure sensing
■ Testing
■ Homonymic and non-holonomic motion
 Mechatronics Standards
 Many early standards were based on the human body: the length
of man’s hand, the width of his thumb, the distance between
outstretched fingertips, the length of one’s foot, a certain
number of paces, etc.
 In the beginning, while groups were small, such standards were
convenient and uniform enough to serve as the basis for
measurements
 One problem with standards is that there are several kinds.
 In addition to “measurement standards,” there are “standards of
practice or protocol standards” that are produced by the various
standards bodies such as the International Organization for
Standardization (ISO), the International Electro-technical
Commission (IEC), the American National Standards Institute
(ANSI), and the Standards Council of Canada (SCC).
Cont…
 The Need for Standards
 Standards define the units and scales in use,
and allow comparison of measurements made
in different times and places.
 components must be interchangeable
 symbols must be interpreted the same way by
any competent person
 there are many standards concerning things
such as health and safety.
 Pneumatic system
 Pneumatic systems are designed to control and direct the air stream through
an air circuit.
 Pneumatics are all about using compressed air to operate and power a system.
 Air is taken from the atmosphere and squeezed or compressed. This
compressed air is then used in a pneumatic system to do work.
Components of Pneumatic system
(a) Compressor
 A compressor can compress air to the required pressures.
 It can convert the mechanical energy from motors and engines into the
potential energy in compressed air.
 A single central compressor can supply various pneumatic components with
compressed air, which is transported through pipes from the cylinder to the
pneumatic components. Compressors can be reciprocatory or rotary.
 It takes in atmospheric air, compressing to the desired pressure, send it into
air receiver(air tank).
Air service unit and air compressor
 Air service unit
(i) Filter – can remove impurities from compressed air before it is fed to
the pneumatic components. i.e., it filters dirt and moisture from the
air line
(ii) Pressure regulator – to stabilise the pressure and regulate the
operation of pneumatic Components. i.e.:
– To reduce the air supply pressure.
– To keep the outlet pressure constant even if the inlet air supply pressure
fluctuates.
– Input (Inlet) pressure must be greater than the output pressure.
 
(iii) Lubricator – To provide lubrication for pneumatic components
• To provide oil mist in the compressed air so as to lubricate the
pneumatic components.
• Reduce wear of component.
• Protect from corrosion.
 Valves 

• The valve will probably be the most critical (and

consequently the most expensive) part of a high
power pneumatics system.
• It has to restrain the pressure built up on one side
and be able 'pop' completely open and not restrict
the air as it rushes through on its way to the cylinder.
• When methods of operating valves considered; there
are many types of vales that can be used; Remotely
Operated, Manually Operated, and Solenoid Valves,
Mechanically operated.
• Theses valves can be classified as directional
controller and speed controller valves
 Directional control valves

• Directional control valves ensure the flow of air between air ports by
opening, closing and switching their internal connections.
• It controls start, stop, and directional of air flow so that the cylinder’s
movement can be controlled.
• It also used to tart or stop, forward or reduce stroke, clockwise or
anti-clockwise rotation of an air motor.
• Their classification is determined by the number of ports, the number
of switching positions, the normal position of the valve and its
method of operation.
• Common types of directional control valves include 2/2, 3/2, 4/2, 5/2,
etc.
• The first number represents the number of ports; the second number
represents the number of positions. For example, look at the
following representation.
 (i) 2/2 Directional control valve (shut-off valve)

 The structure of a 2/2 directional control valve is very simple.

 It uses the thrust from the spring to open and close the valve, stopping
compressed air from flowing towards working tube ‘A’ from air inlet ‘P’.
 When a force is applied to the control axis, the valve will be pushed
open, connecting ‘P’ with ‘A’.
 The force applied to the control axis has to overcome both air pressure
and the repulsive force of the spring.
 The control valve can be driven manually or mechanically, and restored
to its original position by the spring.
 (ii) 3/2 Directional control valve

 A 3/2 directional control valve can be used to control a single acting cylinder.
 In idle position the 3/2-way directional control valve with normally open
position opens from P to A and shuts off exhaust valve R.
 When the push rod is pressed the sealing disc shuts off flow of air from P to A.
 The second sealing disc is pushed off its seat by the shoulders of the push rod.
 A exhaust to R. It is used for control of single acting clamping cylinders(NO -
function).
 The normally closed directional control valve is shown at.
 The spring loaded ball shuts off the flow of compressed air from P to A.
 Working line A is connected with the atmosphere through port R in the pusher
rod.
 When the pusher rod is actuated, the ball first shuts off the exhaust port and
then it is lifted off its seat.
 In the reverse direction the ball first shuts off the pressure line P before the
exhaust port in the pusher rod is opened to allow ventilation from A to R, i.e.
ventilation of the valve does not overlap.
Cont…
 (iii) 5/2 Directional control valve
 When a pressure pulse is input into the pressure control port ‘P’,
the spool will move to the left, connecting inlet ‘P’ and work
passage ‘B’.
 Work passage ‘A’ will then make a release of air through ‘R1’ and
‘R2’. The directional valves will remain in this operational position
until signals of the contrary are received.
 Therefore, this type of directional control valves is said to have
the function of ‘memory’.
 (b) Control valve

 A control valve is a valve that controls the flow of air.

 Examples include non-return valves, flow control valves, shuttle
valves, etc. 
(i) Non-return(check, poppet) valve
 A non-return valve allows air to flow in one direction only.
 When air flows in the oppositedirection, the valve will close.
 Another name for non-return valve is poppet valve and also called
check valve.
 (ii) Flow control (throttle relief) valve

 A flow control valve is formed by a non-return valve and a variable throttle.

 Designed to control the flow of air in the system.
 air flow is throttled in one direction only.
 check valve blocks the flow in one direction and the air can only pass through
the restricted passage.
 check valve allow the reversed air to by pass the restricted passage.
 used for speed regulation.
 Cont….
 Controlling the speed of actuators is achieved by controlling the
flow of air to or from the actuators.
 NOT BY ADJUSTING THE PRESSURE
 To reduce the speed of a cylinder
Single acting - use a one-way flow control valve to control the air
going in to the cylinder. (Supply air flow control).
Double acting - use a one-way flow control valve to control the air
being pushed out of the cylinder. (Exhaust air flow control).
 One flow control valve for each direction.
 To increase the speed of a cylinder
Double acting - use a quick exhaust valve to allow the exhaust air
out of the cylinder through as short a distance as possible.
Use larger valves and tubing.
 (iii) Shuttle valve

 Shuttle valves are also known as double control or single control non-return
valves. A shuttlevalve has two air inlets ‘P1’ and ‘P2’ and one air outlet ‘A’.
 When compressed air enters through‘P1’, the sphere will seal and block the
other inlet ‘P2’. Air can then flow from ‘P1’ to ‘A’.
 When the contrary happens, the sphere will block inlet ‘P1’, allowing air to flow
from ‘P2’ to ‘A’ only.
 The Actuator

 The actuator is the business end of a pneumatics system.

 All of the parts listed above are to make the actuator move, and move with
authority.
 Pneumatic execution components provide rectilinear or rotary movement.
 Examples of pneumatic execution components include cylinder pistons,
pneumatic motors, etc.
 Rectilinear motion is produced by cylinder pistons, while pneumatic motors
provide continuous rotations.

(i) Single acting cylinder

 A single acting cylinder has only one entrance that allows compressed air to
flow through.
 it can only produce thrust in one direction.
 The piston rod is propelled in the opposite direction by an internal spring, or
by the external force provided by mechanical movement or weight of a load.
Cont…
 Cont….
 The thrust from the piston rod is greatly lowered because it has to overcome
the force from the spring.
 Therefore, in order to provide the driving force for machines, the diameter
of the cylinder should be increased.
 In order to match the length of the spring, the length of the cylinder should
also be increased, thus limiting the length of the path.
 Single acting cylinders are used in stamping, printing, moving materials, etc.

(ii) Double acting cylinder

 In a double acting cylinder, air pressure is applied alternately to the relative
surface of the piston, producing a propelling force and a retracting force.
 As the effective area of the piston is small, the thrust produced during
retraction is relatively weak.
 The impeccable tubes of double acting cylinders are usually made of steel.
 The working surfaces are also polished and coated with chromium to reduce
friction.
Cont…..
 Advantages of Pneumatic System
Availability:-air is practically available everywhere in unlimited quantity.
Transportation:-can be easily transported in pipe lines.
-not necessary to return the compress air
Storage:-compressor need not be in continuous operation.
-can be stored in and remove from a reservoir or cylinder
Temperature:-insensitive to temperature fluctuation.
Ensure reliable operation.
Explosion proof:-no risk of explosion or fire.
-expensive protection against explosion is not required
Cleanliness:-leaking air does not cause contamination
-suitable for food, wood, textile and leather industries
Construction:-simple construction, inexpensive.
Speed:-very fast working medium, cylinders have working speed of 1 -2
m/s
 Disadvantages of Pneumatic System

 Preparation:-require removing dirt and

humidity.
 Compressible:-Not possible to achieve uniform
and constant piston speeds.
 Force requirement:-low working loads
 Electro-pneumatic
 Electro-pneumaticsystem = electronics +pneumatics system.
 Combined in a way that results an integrated system.
Application area
 Widely used for large number of applications.
 Commonly used in many areas of industrial low cost automation.
 Found extensively in production, assembly, pharmaceutical, chemical and
packaging systems.
Components
 Electro-pneumatic system consists of electronic systemcontrolling and operating
pneumatic power systems.
 It involves basically the following components.
 Solenoid valves are used as interface between theelectrical and pneumatic systems.
 Electrical switches/pushbuttons are used for asan input component.
 Electrical limit switches and proximitysensors are used as feedback elements.
 Electrical relays or PLCs are used as a signal-processor.
 Voltage level

 In electro-pneumatic systems:-the signal medium or the control

signal is electrical and uses either of.
 DC source - Operating voltages commonly12V/24V.
 AC source – Commonly 110/220 V– Working medium is
compressed air.
Relay vs. PLC
 There is a significant change in controls systems.
 Relays have increasingly been replaced by PLCs in order to meet
the growing demand for more flexible automation.
 PLC offers a whole series of inherent advantages such as Greater
reliability and longer service life, Faster control development,
Simpler monitoring of stations, Less project planning work
 Pneumatic vs. electro-pneumatic

 The greatest advantage of electro-pneumatics over the pneumatic system are:

 The integration of various types of proximity sensors and PLC for very effective
control.
 As the signal speed with electrical signal, can be much higher, cycle time can
be reduced and signal can be conveyed over long distances.
8Basic components in electro-pneumatics.
 The basic electrical devices commonly used in the control of fluid power
systems are:
– Power supply
– Manually actuated switches
– Sensors
 Limit switches and proximity sensors.
 Pressure to electric (PE) converters or switches
– Solenoid operated valves
– Electrical relays, timers, counters
– PLCs
 Manually actuated switches

• There are two types based on the operating

mechanism:
– Pushbutton operated with spring return and
– Pushbutton operated with detent mechanism.
• They can be classified into
– Single pole single throw (SPST) switch and
– Single pole double throw (SPDT) switch (change
over switch).
• Depending on their operation/action they can be
classified into
– Break switch (normally closed) or
– Make switch (normally open).
 Position sensors

• For sensing the position of pneumatic piston

rod we can use.
• Mechanical position sensor commonly called
limit switch and Non-contact sensors
commonly called proximity switch such as
– magnetic,
– inductive,
– capacitive and
– optical sensors.
 Limit switches
• Any switch that is actuated due to the position of a
fluid power component (usually a piston rod or
hydraulic motor shaft or the position of load).
• A limit switch is actuated when a machine part or
workplace is in a certain position. Normally, actuation
is effected by a cam.
• The actuation of a limit switch provides an electrical
signal that causes an appropriate system response.
• Limit switches perform the same function as push
button switches. Push buttons are manually actuated
whereas limit switches are mechanically actuated.
 Solenoid operated valves

• Electrically actuated directional control valves form the interface

between the two parts of an electro-pneumatic control.
• Their task is switching supply air on or off thus extending and
retracting the cylinder drives.
• They are switched with the aid of solenoids, thus called solenoid
operated valves.
• They can be divided into two groups:
• Single acting valves - only remain in the actuated position as long as
current flows through the solenoid otherwise the spring returns it to
the initial or original position.
• Double acting valves - retain the last switched position even when no
current flows through the solenoid.
• They (two position) have no clear initial position, as they do not have
a return spring. 
 Relays

• The entire signal processing needs of an electro-pneumatic

control system can be implemented with relays.
• Even though, now a days PLCs are replacing them they are still
in use in industries especially in emergency stop switching
device and system.
• The principal advantages of relay control systems are the clarity
of their design and ease of understanding their mode of
operation.
Relays – structure and operations
• They are an electromagnetically actuated switch.
• When a voltage is applied to the solenoid coil, an
electromagnet field results.
• This causes the armature to be attracted to the coil core.
 cont..
• The armature actuates the relay contacts, either closing or
opening them, depending on the design.
• A return spring returns the armature to its initial position when
the current to the coil is interrupted.
• A relay coil can switch one or more contacts.
 Relays with delay (Timer)

• In many applications it is necessary for the piston of a pneumatic

cylinder to remain at a certain position for a set length of time.
• There are control systems which are purely affected or combination
of path scanning and time.
• This isthe case for the drive of a pressing machine, for example,
which presses two work-pieces together until the adhesive has set.
• Thus control systems which are assigned a particular timing
sequence must be equipped with electrical time delay relays.
26Relays with delay (Timer)- types
• Time-delay relays, which are usually electronic time relays nowadays,
have two basic types of timed response. They are referred to as
– On-delay timer- time-delay relays with energizing or switch-on
delay and.
– Off-delay timer- de-energizing or switch-off delay.
 BASICS OF HYDRAULICS

• Hydraulics is the transmission and control of forces and motions

through the medium of fluids. Short and simple. Hydraulic
systems and equipment have wide-spread application
throughout industry.
For example: -
• machine tool manufacturing ,press manufacturing, plant
construction, vehicle manufacturing, aircraft manufacturing,
shipbuilding, injection molding machines
Hydraulic to Electrical Analogy
• Hydraulics and electrics are analogous, because they both deal
with flow, pressure and load.
• The components in each type of circuit perform similar functions
and therefore can be related, a few examples are listed below:
Cont…
 Cont….
• Various forms of energy are converted to accomplish mechanical movement
in the injection molding machine.
• Electrical energy is converted to mechanical energy, which in turn is converted
to hydraulic energy to operate and control the moving components of the
machine.
• The hydraulic energy is converted to mechanical energy to achieve the final
desired result, which may be "mold clamping pressure" or "material
injection".
• The figure above summarizes the energy conversions for an injection molding
machine. Click on the thumbnail for a larger view

Pressure Control
• In order to safeguard the system, pressure relief valves are installed.
• The valves serve to limit the amount of pressure that can develop in the
hydraulic system since the various hydraulic components are expensive and
they are subject to pressure limitations before failure occurs.
 Cont….
• One characteristic of fluid flow that is important to note here is
that flow occurs always in the path of least resistance.
• Pressure would continue to rise in the circuit consistent with the
load being moved.
• The pressure relief valve is always set to allow flow to travel
through the relief valve well before pressure rises above safe levels
and causes damage to the system and its components.
• In other words, the path of least resistance is employed here to
safeguard the system after the other movements have taken place.
 Pressure Override

• An extremely important concept to understand about

pressure relief valves is their pressure override
characteristics.
• Pressure override is the difference between the
pressure at which the relief valve just starts to crack
open and the pressure at the full open position.
 Cont….
• Hydraulic pump or air compressor- which converts
mechanical power to fluid power.
• Cylinder or motor- which converts fluid power to linear or
rotary mechanical power.
• Valves- which control the direction, pressure and rate of flow.
• Filters, regulators and lubricators-which condition the fluid.
• Manifolds, hose, tube, fittings, couplings- etc., which conduct
the fluid between components.
• Sealing devices- which help contain the fluid.
• Accumulators and reservoirs- which store the fluid.
• Instruments such as pressure switches, gauges, flow meters,
sensors and transducers-which are used to help monitor the
performance of a fluid power system.
Cont….
Cont…
 TRANSDUCERS AND CONVERTERS Activities

 A transducer is a device that translates a mechanical signal

into an electrical signal.
 For example, inside a capacitance pressure device, a
transducer converts changes in pressure into a proportional
change in capacitance.
 A converter is a device that converts one type of signal into
another type of signal.
 For example, a converter may convert current into voltage
or an analog signal into a digital signal.
 In process control, a converter used to convert a 4–20 mA
current signal into a 3–15 psig pneumatic signal (commonly
used by valve actuators) is called a current-to-pressure
converter.
 TRANSMITTERS

 A transmitter is a device that converts a reading from

a sensor or transducer into a standard signal and
transmits that signal to a monitor or controller.
 Transmitter types include:
 Pressure transmitters
 Flow transmitters
 Temperature transmitters
 Level transmitters
 Analytic (O2 [oxygen], CO [carbon monoxide], and pH)
transmitters
 Single loop control
 The act of controlling one specific variable with in a process
through the use of either analog or digital control methods.
 Single loop control the controller set point is set by an operator
and its out put drives control element.
 Single loop controllers are used to control a thermal or process
machine in systems which need a single control loop or discrete
devices.
 Single loop controllers are cost effective an easy to use devices
used in temperature and other processes to control one specific
variable.
 Single loop controllers are widely used in industry today to
power plants chemical plants steel plants oil renineries
petrochemical etc.
 Multi loop control
 Multi loop control are used to control a thermal or process
machine in systems which need more than one control loop
with in a single system.
 If you have more than one control loop with in a single
system then multi loop controller can be used.
 Multi loop control are capable of small machine control with
advanced features and options.
 Flexible input output options to control and measure a
multitude of processes including temperature, carbon
potential, humidity, flow ,pressure, level, viscosity and
additive dosing.
 Parallel form have a common input and an output formed by
the algebraic sum of the outputs from all of the subsystems.
Cascade Form: Each signal is derived from the product of the input
times the transfer function.
 Closed and open control loops

 A closed control loop exists where a process variable is

measured, compared to a set point, and action is taken
to correct any deviation from set point.
 An open control loop exists where the process variable is
not compared, and action is taken not in response to
feedback on the condition of the process variable, but is
instead taken without regard to process variable
conditions.
 For example, a water valve may be opened to add
cooling water to a process to prevent the process fluid
from getting too hot, based on a pre-set time interval,
regardless of the actual temperature of the process fluid.
 Distributed control system (DCS)
 DCS, the data acquisition and control functions are
performed by a number of distributed microprocessor-
based units, situated near to the devices being
controlled or, the instrument from which data is being
gathered.
 DCS systems have evolved into providing very
sophisticated analogue (e.g. loop) control capability.
 A closely integrated set of operator interfaces (or man
machine interfaces) is provided to allow for easy system
configurations and operator control.
 The data high way is normally capable of high speeds -
typically 1 Mbps up to 10 Mbps.
Distributed control system (DCS)
 Cont…..
 A DCS controller is a high-performance device capable of handling
hundreds of discrete or regulatory control loops per second.
 The control performance capability of a DCS controller varies from
manufacturer to manufacturer.
 But a user can customize his control configuration to meet the application
requirements.
 For configuring a DCS controller, it is important to understand the types of
controller slots and control functions and algorithms the DCS controller
offers.
 Control modes: A basic DCS controller has the following operating modes:
 Manual mode
 Automatic mode.
 Cascade mode.
 Backup cascade mode.
 Control functions

 The DCS controller provides a variety of control tools that can be customized to
address a wide range of process automation needs.
 from I/O scanning through regulatory and logic control to more advanced control
strategies can be easily implemented through the DCS advanced controller.
Control strategies include; a sophisticated regulatory control package, fully
integrated interlock logic functions, and an advanced high level, process
engineer-oriented control programming language.
 DCS controller can be thought of as partitioned into slots of various types. These
slots provide an allocated resource of processing power and money that can be
user-configured, including the assignment of a tag name.
 A tagged slot is referred to as a data point, or point in some DCS systems.
Predefined groups, detail displays as well as custom graphics support this data
point structure.
 Following are some of the different types of data points that can be configured
into a DCS controller slot:
- Regulatory PV - Numeric - Regulatory control - Digital composite - Device
control - Flag -Timer Logic - String, etc
 SCADA (supervisory control and data acquisition)

 SCADA is a type of industrial control system (ICS). Industrial control

systems are computer controlled systems that monitor and control
industrial processes that exist in the physical world.
 SCADA systems historically distinguish themselves from other ICS
systems by being large scale processes that can include multiple sites,
and large distances.
 These processes include industrial, infrastructure, and facility-based
processes, as described below:
• Industrial processes include those of manufacturing production,
fabrication, and refining, and may run in continuous, batch, repetitive,
or discrete modes.
• Infrastructure processes may be public or private, and include water
treatment and distribution, wastewater collection and treatment, oil
and gas pipelines, electrical power transmission and distribution, wind
farms, civil defense siren systems, and large communication systems.
Cont…
 Common system components

 A SCADA system usually consists of the following subsystems:

• A human–machine interface or HMI is the apparatus or device which
presents process data to a human operator, and through this, the
human operator monitors and controls the process.
• SCADA is used as a safety tool as in lock-out tag-out
• A supervisory (computer) system, gathering (acquiring) data on the
process and sending commands (control) to the process.
• Remote terminal units (RTUs) connecting to sensors in the process,
converting sensor signals to digital data and sending digital data to the
supervisory system.
• Programmable logic controller (PLCs) used as field devices because
they are more economical, versatile, flexible, and configurable than
special-purpose RTUs.
• Communication infrastructure connecting the supervisory system to
the remote terminal units.
 Systems concepts

 The term SCADA usually refers to centralized systems which

monitor and control entire sites, or complexes of systems spread
out over large areas (anything from an industrial plant to a nation).
 Most control actions are performed automatically by RTUs or by
PLCs.
 Host control functions are usually restricted to basic overriding or
supervisory level intervention.
 For example, a PLC may control the flow of cooling water through
part of an industrial process, but the SCADA system may allow
operators to change the set points for the flow, and enable alarm
conditions, such as loss of flow and high temperature, to be
displayed and recorded.
 The feedback control loop passes through the RTU or PLC, while
the SCADA system monitors the overall performance of the loop.
 STRUCTURE OF SCADA
• Control center – main computer, router, data
historian, HMI and engineering workstation
- Collect data, analyze trends and events,
generates action
• Communication link – any long distance
communication system: fiber, cable and RF
- Serial communication protocol
• Filed sites – RTU or PLC
- Local control of actuators
Cont…
 Information Transfer

Master to Remote Data Transfer

Remote to Master Data Transfer
The advantages of the SCADA system
The computer can record and store a very large amount of
data.
The data can be displayed in any way the user requires.
Thousands of sensors over a wide area can be connected to
the system.
The operator can integrate real data simulations into the
system.
Many types of data can be collected from the RTUs.
The data can be viewed from anywhere, not just on site.
 The disadvantages

 The system is more complicated than the sensor

to panel type.
 Different operating skills are required, such as
system analysts and programmer.
 With thousands of sensors there is still a lot of
wire to deal with.
 The operator can see only as far as the PLC.
LO2: Install Mechatronics devices
2.1 drawing interpretation
• a00
 Cont…
 Design a control circuit for power circuit which drives
the cylinders’ piston rod forward and retract
continuously until the operator stop it manually.
 Design a control circuit for power circuit which full fill
the following conditions and sequences.
 The Preconditions for safe operations should be:
 Initially, both piston rods of the cylinders should be at
retraction position.
 The operation stars when the operator presses a switch.
 The system operates continuously and sequentially
according to the following sequence.
 Sequence of operation

Step 1: The piston rod of cylinder 2A advances.

Step 2: The piston rod of cylinder 1A advances.
Step 3: The piston rod of cylinder 2A retracts.
Step 4: The piston rod of cylinder 1A retracts. 
 The system will stop by the operator.  
 circuit diagram of the feeding device
Sensor evaluation
 In a relay circuit the signals are combined with each other by the contacts of
control switches, pushbuttons and relays.
 The electronic proximity switches used here do not have contacts; instead they
generate an output signal by means of an electronic circuit.
 Each sensor output signal therefore acts on the coil of a relay, which in turn
switches the necessary contact or contacts .
 If proximity switch 1B1 is tripped, for example, current flows through the coil of
relay K1.
 The related contacts switch to the actuated position.
Electrical circuit diagram with sensor evaluation
1ststep:The following preconditions must be satisfied before the sequence is
started:Piston rod of cylinder 1A in retracted end position (proximity switch 1B1
and relay K1 actuated) Piston rod of cylinder 2A in retracted end position (proximity switch
2B1 and relay K3 actuated) START pushbutton (S5) actuated. If all of these conditions are met, relay
coil K6 is energised. Solenoid coil 1Y1 is actuated, and the piston rod of cylinder 1A advances.
2ndstep:When the piston rod of cylinder 1A reaches the forward end position,
sensor 1B2 responds. The second step of the sequence is activated. Solenoid
coil 2Y1 is actuated, and the piston rod of drive 2A advances.
3rdstep:When the piston rod of cylinder 2A reaches the forward end position, sensor 2B2 responds. The third
step of the sequence is activated. Solenoid coil 1Y2 is actuated, and the piston rod of drive 1A retracts.
4thstep:When the piston rod of cylinder 1A reaches the retracted end position,sensor 1B1
responds. The fourth step of the sequence is activated. Solenoid coil 2Y2 is actuated, and
the piston rod of drive 2A retracts.
shows the complete electrical circuit diagram of the feeding device, including contact
element tables and current path designations.
 Principles of pneumatic control

(a) Pneumatic circuit

 Pneumatic control systems can be designed in the form of
pneumatic circuits.
 A pneumatic circuit is formed by various pneumatic components,
such as cylinders, directional control valves , flow control valves, etc.
 Pneumatic circuits have the following functions:
1. To control the injection and release of compressed air in the
cylinders.
2. To use one valve to control another valve.
(b) Pneumatic circuit diagram
 A pneumatic circuit diagram uses pneumatic symbols to describe its
design.
 Some basic rules must be followed when drawing pneumatic
diagrams.
 Basic rules

1. A pneumatic circuit diagram represents the circuit in

static form and assumes there is no supply of pressure.
 The placement of the pneumatic components on the
circuit also follows this assumption.
2. The pneumatic symbol of a directional control valve is
formed by one or more squares.
 The inlet and exhaust are drawn underneath the
square, while the outlet is drawn on the top.
 Each function of the valve (the position of the valve)
shall be represented by a square.
 If there are two or more functions, the squares should
be arranged horizontally
3 3. Arrows "↓↖" are used to indicate the flow direction of air current.
If the external port is not connected to the internal parts, the symbol
“┬” is used. The symbol “⊙” underneath the square represents the air
input, while the symbol “▽” represents the exhaust. Fig. 12 b, shows an
example of a typical pneumatic valve.
4. The pneumatic symbols of operational components should be drawn
on the outside of the squares. They can be divided into two classes:
mechanical and manual
 Cont….

5. Pneumatic operation signal pressure lines should be drawn on one side of the squares,
while triangles are used to represent the direction of air flow
 (ii) Basic principles
`
• Fig. 15 shows some of the basic principles of
drawing pneumatic circuit diagrams, the
numbers in the diagram correspond to the
following points:
 Cont…
1. When the manual switch is not operated, the spring will
restore the valve to its original position.
2. From the position of the spring, one can deduce that the
block is operating. The other block will not operate until the
switch is pushed.
3. Air pressure exists along this line because it is connected to
the source of compressed air.
4. As this cylinder cavity and piston rod are under the
influence of pressure, the piston rod is in its restored
position.
5. The rear cylinder cavity and this line are connected to the
exhaust, where air is released.
 Single acting cylinder control

• Single acting cylinders can be controlled manually. However,

they can also be controlled by two or more valves. This is called
logic control. Examples of logic control include ‘OR’ function,
‘AND’ function, ‘NOT’ function, etc.
(i) Direct control and speed control
 (ii) OR Function

• it can be operated by two different circuits. Examples include manual

operation and relying on automatic circuit signals, that is, when either
control valve1 or control valve 2is operated, the cylinder will work.
Therefore, the circuit in Fig. 17 possesses the OR function. However, if
the output of two 3/2 directional control valves are connected through
the port of a triode, the air current from control valve 1will be released
through the exhaust of control valve 2, and so the cylinder will not work.
This problem can be solved by connecting a shuttle valve to the port of
the triode.
 (iii) AND Function

Circuit diagram of AND function

 Another name for an AND function is interlock control. This means
control is possible only when two conditions are satisfied.
 A classic example is a pneumatic system that works only when its
safety door is closed and its manual control valve is operated.
 The flow passage will open only when both control valves are
operated. shows the circuit diagram of an AND function circuit.
 The cylinder will work only when both valve 1and 2are operated.
 Double acting cylinder

(i) Direct control

• The only difference between a single acting cylinder and a double
acting cylinder is that a double acting cylinder uses a 5/2
directional control valve instead of a 3/2 directional control valve.
• Usually, when a double acting cylinder is not operated, outlet ‘B’
and inlet ‘P’ will be connected. In this circuit, whenever the
operation button is pushed manually, the double acting Cylinder
will move back and forth once.
 Cont..
• Circuit diagram of a double acting cylinder direct
control
• In order to control the speed in both directions, flow
control valves are connected to the inlets on both
sides of the cylinder.
• The direction of the flow control valve is opposite to
that of the release of air by the flow control valve of
the single acting cylinder.
• Compared to the throttle inlet, the flow control valve is
tougher and more stable.
• Connecting the circuit in this way allows the input of
sufficient air pressure and energy to drive the piston.
 (ii) Single control

• A cylinder always has to maintain its position in a lot of

situations, even after the operational signal has disappeared.
• This can be achieved by the use of a circuit that possesses the
memory function.
• The extension path of a double acting cylinder is activated by
control valve 1, while retraction is governed by control valve 2.
• Control valve 3, on the other hand, maintains the position of the
cylinder by maintaining its own position.
• Control valve 3will be changed only when one of the manual
control valves is pushed.
• If both control valves 2and 1are operated at the same time,
control valve 3will be subject to the same pressure and will
remain in its original position.
Control of single and double acting cylinder
The control system is implemented using double-acting
cylinders and 5/2-way double solenoid valves. The pneumatic
circuit diagram .
Lo3 configure and adjust mechatronices devices

 Configuration is the way a system is set up, or the

assortment of components that make up the system.
 It is a Particular arrangement or pattern of a group of
related things. Configuration can refer to either
hardware or software, or the combination of both.
 Systems which consists from many sub-systems or
sub-units such as Mechatronics and control system
needs careful configuring task during installation in
order to the system/device operate its intended task.
 Hard ware configuration:
• Components/elements of instrumentation and
controlling systems should be selected
according to their design specification, arrange,
place and fix them systematically according to
work/signal flow diagram (topology) of the
system, assemble/ install and connect them
according to installation manual, set/select
proper position of: switching devices, jumpers,
timers , valves etc…
 Software configuration:
 assigning addresses for I/O devices, determine communication
ports, define parameters, set/select: jumpers, switches, types of
device used…
 Example look at the configuration of PID controlled closed-loop
process control system in Fig.1 and Fig.2 as block diagram form and
actual process form respectively.
 the process variable to be controlled is temperature of
liquid(process) at a given target set point, temperature sensor
should be installed at the process body(fig.2) and sense( measure)
the actual temperature of the liquid and then transmit the standard
electrical signal to the PID controller module via the temperature
transmitter(TT).
 The PID controller generate control variable or signal (voltage) and
tune continuously the steam valve in order to eliminate the error(E)
and keep the temperature to its target set value.
Fig.1
Fig.2
 Cont…
 PID control is often referred to as three-mode, closed-loop feedback
control.
 Because the PID module receives the process variable in analog
form and computes the error difference between the actual value
and the set point value.
 It then uses this error difference in the algorithm computation to
initiate a three step, simultaneous, corrective action through a
control variable output.
 First, the module formulates a proportional control action based on
an output control variable that is proportional to the instantaneous
error value (KPE).
 Then, it initiates an integral control action (reset action) to provide
additional compensation to the output control variable.